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Tunnel Ventilation Systems & Environmental Control Systems

Dammam, KSA Sept 9th, 2014


Avanceon - TVS & ECS Solutions

Agenda
Avanceon

Global Capacity
GCC Flagship
Partners & Clients
Engineering Process
Rail Industry & TVS
Safety Design
Considerations

Selection of Control
System Platform)

Project
Scope
TVS &
SCADA
Solution

Project
Scope
TVS
ECS

Dubai
Metro
TVS & ECS

Avanceon - TVS & ECS Solutions

Lusail
City
TVS &
SCADA

COMPANYS SNAPSHOT
Global Capabilities & MENA Presence
Avanceon - TVS & ECS Solutions

Corporate Capabilities & Global Presence


Ranked amongst the top 10 System Integrators worldwide, Avanceon is a global engineering firm specializing in
Sustainable Automation and Control Turnkey Solutions since 1984.

Worldwide Headquarters
North America
Regional Operations Center
Exton, PA, USA

+25 years of commitment


+10 key partners worldwide
+1,000 medium & large scale projects
+150 government & blue chip customers

+200 employees
9 offices, 3 operating centers
+10 industrial segments served
+70% Control System Engineers
Middle East and Africa
Regional Operations Center
Dubai, UAE

Southeast Asia
Regional Operations Center
Lahore, Pakistan

Tomorrows Solutions, Today.


Avanceon - TVS & ECS Solutions

GCC Snapshot & Flagship Projects


Scada Systems for Lusail
Utility Tunnels +17k I/Os

Lusail City
Projects

Tunnel Ventilations Systems


for the red and the green
line +24k I/Os

Dubai Metro
Systems

Offshore Oil & Gas FPSO,


MOPU, WHP Automation,
ESD, F&G, DCS, PLC based
SCADA Systems

OMV, Shell,
FO, Santos,
Safer

Islanding & Load-sharing


project system RTR, SGP,
UGP

Saudi
Aramco
Projects

Dammam, KSA
Doha, Qatar
Dubai, UAE
Abu Dhabi, UAE

4 locations in 3 Countries
8 MEA Countries served including GCC, Yemen, Nigeria
+4 industrial segments served
+100 mid to large sized projects
+10 years presence

Avanceon - TVS & ECS Solutions

Partnership & Clientele


Partnership

Rockwell Certified System Integrator


International Experience / Local support
Alliance with Rockwell of 16 years
+20 years of successful history
Instrumentation & Control [I&C] Projects
Process Automation Experience
PLC, ESD, F&G
PIMS and Business KPI Dashboards
SCADA Systems and ERP Connectivity
Maintenance Support Contracts
Energy Optimization Solutions

Avanceon - TVS & ECS Solutions

Credentials & Customer Segments


Customer Segments

Oil & Gas

Pharma &
Life
sciences

Printing &
Packaging

Metals &
Mining

Food &
Beverages

Chemicals
& PetroChemicals

Transport
& Infra
Projects

Power &
District
Cooling

Water &
Waste
Water

Cement

Public
Utilities

Fertilizers

6/18/2014

Avanceon - TVS & ECS Solutions

Engineering Life Cycle / V-Life Cycle & Unique Best Practices


Left side: Development activities
Proposal process

Right side: Verification activities


Support Services

Real-time Traceability
URS to SAT

Site Acceptance
Tests (SAT)

User
Requirements
Review (URS)
FRS to FAT

System Design Process


Preliminary Design
Review (PDR)

Factory Acceptance Tests


(FAT)

Traceability and Seamlessness are at the core of our


success

DDS to FAT
Detailed Design Review (CDRs)
DDS

Unit / Module Tests

Technical Execution Model V-Life Cycle


Programming Practices & Standards
Proprietary Auto Gen Tool
Proprietary Project Execution Model ABACUS
Support Services Program
Project Monitoring Standards [WBS, Project Server &
SharePoint Portals]
Cloud computing

Buy / Build / Reuse / Code


Configuration Items (CI)

6/18/2014

Avanceon - TVS & ECS Solutions

METRO/ TUNNELS INFRASTRUCTURES


DESIGN CONSIDERATION

Avanceon - TVS & ECS Solutions

MENA Rail Industry at a Glance [Source: MEED]


Mena rail industry projects value
USD 556 billions
GCC rail industry project value
USD 125 billions

Avanceon - TVS & ECS Solutions

Life Safety & Mission Critical


Avanceon
A mission-critical & Life Safety System ;
Protect People [fire and related hazards]

V-Life Cycle, Abacus PM,


AutoGEN, CSIA

Filling
the GAP

Contractor
Standards

3rd Party

OEM Standards

Integrators, PEs,
Consultants . . .

Survive failures of Equipment, Process,


Procedure, Software

Standards

Never corrupt or lose critical data [data


integrity]

Tier 2
Standards

National Standards

Very critical to the organizations Mission

Base Line
Standards

Global Standards

Rockwell, Cisco..

Industry Standards

General Best Practices

Avanceon - TVS & ECS Solutions

IEC 61508, IEC 61850,


IEC 24702
EN 50174-1, IEC
14763
CSIA, ISO, ISA,
IEEE, PMI . . .

Tunnel & U/G Stations (Level of Safety)


Its a relative level of risk-reduction provided by a Safety Function
SIL-2 Control Systems are the selected combination
Safety Standards:
1- Hardware Safety Integrity IEC 61508
2- Systematic Safety Integrity IEC 61850
A device or system must meet the requirements for both categories to achieve a given SIL.
It has Verified programming standards to meets IEC SIL-2 requirements
Required Redundancy in Servers, Communications, Power, Controllers, Chassis, Processors
Feedback Signals of I/Os
SIL

Probability of Failure Per Hour

PFH (power)

0.00001-0.000001

105 - 106

100,000-1,000,000

0.000001-0.0000001

106 - 107

1,000,000-10,000,000

0.0000001-0.00000001

107 - 108

10,000,000-100,000,000

0.00000001-0.000000001

108 - 109

100,000,0001,000,000,000

Avanceon - TVS & ECS Solutions

Risk Reduction Factor

Why Tunnel Ventilation System?


Purpose is to produce conditions in the underground stations & running tunnels;
The comfort of the passengers and personnel during normal operations
The comfort of passengers / maintenance personnel on the stalled trains
The control and capture of smoke, in the event of an incident in

either a running tunnel or at an underground station


Emergency Evacuation & Signage for the evacuation of passengers / personnel.
To implement Ventilation, cooling, Smoke controls strategy

Implement Risk mitigation strategies for Life Safety and for Mission Criticality
Implement Redundant Modbus TCP/IP Links with Main Train SCADA

6/18/2014

Avanceon - TVS & ECS Solutions

DUBAI METRO PROJECT DUBAI, UAE


TVS & ECS PROJECT
Red Line & Green Lines
(Over Ground & Underground Works)
Avanceon - TVS & ECS Solutions

Project Background
End-User RTA
1. Guinness World Record longest driverless rail
2. 75 km with 49 stations
3. Red and Green Lines / First in the GCC
In Numbers
1. 72 redundant PLC systems (cabinets)

2. 204 remote I/O panels (cabinet)


3. Backup Control Panels
4. Total number of I/Os is 24,000

Avanceon - TVS & ECS Solutions

Environmental Control System


Deployments - Red Line & Green Line
Jaddaf 2

Health
Care

Abu Baker

Palm
Deira

Al
Ghubaiba

Abu Hail

Stadium

Airport
Freezone

Al Qusais
2

Dubai Metro Greenline

Jaddaf 1

Oud
Metha

Saeediya

Al Ras

Beniyas

Salah Al
Din

Avanceon - TVS & ECS Solutions

Al
Qiyadah

Al Nahda

Al Qusais
1

Environmental Control System & Operations Overview


Environment Control System for Dubai Metro is designed for Monitoring & Control functions of following systems;

Avanceon has successfully met ETA and


RTAs requirements by procuring,
building and completing the testing
procedures for the panels in 4 weeks,
and testing the system at site in a
timely manner. System Integrator by
meeting deadlines.
This was a challenging task and
Avanceon has proven its capability as
an established
Project Director at JV

Air Conditioning System


Smoke Extraction System (Safety System Requirement)
Station Doors, Lift And Escalators
Low Voltage Distribution System / Genset Controls & Sync.
Chilled Water System
Lighting System
Room Temperature Monitoring
Uninterruptible Power Supply Monitoring

Avanceon - TVS & ECS Solutions

Tunnel Ventilation Systems Deployments at Red & Green Lines


Burjuman

Annex-1

Al-Rigga

City Centre

Dubai Metro Redline

Union Square

Burjuman

Saeediya

Annex-2

Annex-4

Al-Ghubaiba
Al-Ghubaiba

Annex-3

Al-Ras

Dubai Metro Greenline

Annex-6

Palm Deira

Annex-7

Baniyas

Avanceon - TVS & ECS Solutions

Union Square

Salah Al Din

Tunnel Ventilation Systems - Life Safety Controls


TVS & SCADA Monitors & Controls the following systems;;
Tunnel Ventilation Fan System [In Normal & Emergency
Modes]
TVS & SCADA are also Life Safety
Systems. It also provides direction to
the people through signage system in
case of fire, and it also controls the
spread of fire through ventilation
modes.
Engineering Manager

Air conditioning system [AHUs]


Tunnel Lighting System
Emergency Signage / Evacuation System
Monitoring of Battery Room & Power System
Smoke Extraction system [SEFs]
Tunnel Drainage System
Fire Protection system

TV Damper & TV Fan Controls

Avanceon - TVS & ECS Solutions

TVS Emergency, Safety & Maintenance Procedures


Emergency Situations
TVS PLC - SCADA OCS Communication Failure while Mode is active from SCADA OCS
TVS PLC - BCP Communication Failure while Mode is active from BCP
BCP Power Failure while Mode is active from BCP
Safety Procedures
Selecting Remote to Local Mode Control Shifting SCADA OCS to BCP
Selecting Local to Remote Mode Mode Control Shifting BCP to SCADA OCS
TVS PLC- SCADA OCS Communication Failures Mode will continue Running from SCADA OCS
BCP Power Failures Mode will continue running from BCP
Maintenance Procedures
Preventive
Corrective
ECS METHADOLOGY IS ALSO ON THE SAME GROUNDS HOWEVER IT SHOULD HAVE BCP AND PANEL BASED HMI
Avanceon - TVS & ECS Solutions

SQAP & TVS Design


ControlNet
Network
Tunnel I/O Panel Inside
Tunnel

2 Core Signal
Cable with
single wire
Drain LSF for
Field
Instruments
Supplied by Others
Temperature
Sump Pit
Transmitter
Level
for Tunnel
Sensors

Differential
Pressure Switch
across Ventilation
Fan
Air Flow
Meter for
Cross
Tunnels

Motorized Smoke
Fire Dampers
Lighting Control
Inside Tunnel

Implementation of SQAP Compliance


SQAP consists of SIL-2 IEC61508 Guidelines
Compliance of the system & Design Verification
Tables
Documentation & System is audited by leading 3rd
party Agency nominated by the client
Integrated FAT & Timely Seamless Commissioning
with SCADA
Service Level Agreement with the client
Redundant PLC (SIL-2 hardware) Panels for each
station and Annexes
Redundant Control Net communication between
controller and I/Os
Redundant Modbus TCP/IP communication
interface with SCADA
IP55 rated Panels

Avanceon - TVS & ECS Solutions

RL-GL Interface Modes


Interface modes for Burjuman and Union Square Station

Hardware added for RL-GL integration includes ControlNET communication modules in the existing Redline and
Greenline Hardware
1. These module act as communication bridge between the two lines.
2. In normal condition both Redline and Greenline operate normally as per their respective mode tables
3. In emergency condition we can have two scenarios
Emergency in Greenline,

40 Modes

Emergency in Redline,

30 Modes

4. When emergency condition is removed both the lines return to their previous state (Normal Mode)

Avanceon - TVS & ECS Solutions

Control Priorities & ECS Control Schematic


ECS equipment for each station is controlled from four locations
Equipment priority 1 Smoke MFAP SEF (FMOP)
Equipment Priority 2 FAS [Fire Alarm System]
Equipment Priority 3 Operator Control Center Manual Override, Local OCS
Equipment Priority 4 Supervisory OCS SCADA
System

Avanceon - TVS & ECS Solutions

LUSAIL UTILITIES TUNNEL PROJECT


DOHA, QATAR
A TVS & SCADA PROJECT
Utilities Tunnel BMS & SCADA Project
Avanceon - TVS & ECS Solutions

Project Background
Marina District Utilities Tunnel
Accommodating utilities for Misc. 400 Buildings

Satellite View

Most ambitious ground development in the World

Dry & Wet Tunnels with 20 Zones each


1. Zones separated through fire-rated walls
2. Utility Tunnel with 07 number 11 kV Substations
In Numbers
1. +17k hardwired I/O.s, +100k soft wired I/Os
2. +200k SCADA Points
3. +70k terminations, 16k Fibre splicing
4. 47 Redundant pair of SIL-2 PLC Systems
5. +100k Engineering / Site Man Hours

Avanceon - TVS & ECS Solutions

Sky Map

Scope of Work
Design, engineering, supply, configuration, installation, field and panels side termination, testing and commissioning of
below scope
SCADA HMI
Ethernet Network,
including switches and cabling

PLC Control Systems


Field Instrumentation
Installation & Cabling Works
Works including detailed
engineering and shop drawings
Installation material supply
Installation work for 47 zones

Avanceon - TVS & ECS Solutions

Interfacing & Conceptual Network Diagram


MEP systems are installed in each zone of the dry and wet, controlled and monitored by utility tunnel SCADA

Avanceon - TVS & ECS Solutions

Turnkey Design & Build Project

INTEGRATED FACTORY ACCEPTANCE TESTING LUSAIL CP1 SCADA PROJECT NOV 2012

FACTORY ACCEPTANCE TESTING MAY 2014

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Tunnel Facilities / Ventilation System HMI Snapshot


FOC Connectivity with Media Convertor to Access Switch

Mod Bus R485


Daisy Chain
Network Cable

ION 6300 Energy


Meters (Supplied
by others)

Generator
Fuel Oil
System

FM 200

CCT V
System
Status
Direct Expansion Split Unit
Foam Fire Suppression System Operated By Fire
Indicator Panel

H2S Sensor &


Temperature Transmitter
for Battery Room

Avanceon - TVS & ECS Solutions

Supplied By Others

Dry Tunnel Side View


Showing Ventilation Arrangement
Sand Traps

Fans
[04 for Dry]

Fans at each end


coordinate in pushpull mode to get fresh
air from one side and
expel it from the other

Avanceon - TVS & ECS Solutions

Fans
[04 for Dry]

TVS Normal Mode


No Fire

Fans
[04 for Dry]

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Fans
[04 for Dry]

TVS Smoke Mode


Push - Pull

Fans
[04 for Dry]

Fans
[04 for Dry]

Avanceon - TVS & ECS Solutions

BASIS OF CONTROL SYSTEM


PLATFORM SELECTION
AN INSIGHT
Mission Critical & Life Safety
Avanceon - TVS & ECS Solutions

Hardware Selection
Exact Application Fit

Choose the right controllers for control, not data Management

Add or remove devices without impacting other


devices in the system (RIUP)

System can be installed piecemeal & bump less

Avanceon - TVS & ECS Solutions

Programming & Development Tools / HMI


Use of the shelf HMI

Choose an HMI that meets your company requirements


(multiple vendor selection is possible)

Electricians language - Major


flexibility

Standard programming languages (VB, C++, Java)

Timers, counters, last state or as you decide.

Commercial software in your language

No re-programming for old nodes when you add new nodes

Structured data tables make it easy to replicate the program.


Online de-bugging capabilities

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Communication & Speed on the Basis of Scan Rate


Measured in milliseconds

Open Networking Standards


Communication among multiple vendors using industry standard protocols

Utilize next generation communication protocols (producer / consumer)

Speed important
Precise control
React to system upsets

Open connectivity to the enterprise


Structured data tables make it easy to replicate the program.
Online de-bugging capabilities

Permits running on the edge huge savings

Online de-bugging capabilities

Avanceon - TVS & ECS Solutions

Process Control & Factory Acceptance Testing


PID Control
Range Limits

Integral part of development process


All I/Os checked at factory

Set point ranges


100% software exercised
Buffering
Digital & Analog I/Os simulated
Scaling
Sequence of Operations checked fully.
Cascading
Anti-windup

Avanceon - TVS & ECS Solutions

Diagnostic & Evasive Actions in Case of Mechanical Failures


Monitor the performance of the system
Back-up modes Preprogrammed
Alarm when beyond preset Limits
Industry standard Alerts and Alarms time stamped at the I/O
level

Predictive maintenance when mechanical performance begins to


degrade

Redundant components mean zero downtime for the facility

Enhanced as soft spots become known

Avanceon - TVS & ECS Solutions

System Ownership & Documentation


If it is not documented, its life is limited
Owned by Owner
P&I Diagrams Your facility
Multiple support sources

Documentation allows independence

CAD Drawings Your facility

Easy of as builts and future changes


Commented software your program

Avanceon - TVS & ECS Solutions

Training / Goal Sufficiency & Support


Factory Acceptance Testing The operator takes part in the
FAT

Hardware is a commodity So no issues for the client

Software is documented can be maintained by anyone


Training is part of the install, formal class room trainings.
Training is available from multiple sources
Customized user guide for system
Service is available from multiple sources

Avanceon - TVS & ECS Solutions

About Philosophy & Contact Information


Candor
Agility
Sarmad Mahmood Qureshi

To passionately grow to
become the leader of
automation solutions
through the inspired
development of our teams
whilst building value to our
customers

Creativity

General Manager - Middle East

Quality
Teamwork
Integrity
Sustainability

TVS & ECS Solutions

Thank You
Avanceon

MEA Headquarters
Office FZS1BD04
Jebel Ali Free Zone
PO Box 18590
Dubai, UAE
+974 (0)4 408 5213
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