Practical No:

AIM: - To study and prepare cost estimation for DCS

OBJECTIVE:

To study preparation of cost estimation document of hardware, software and other non
hardware components.
To study various specifications of DCS.

THEORY:DCS can be classified into following components:

HARDWARE COMPONENTS:
1. Items related to Operator Console and Related Items
A) Operator Console
a) Size of Data Base (type and number of control/monitoring data, quantified using file or
record size)
i)
Batch Recipes
ii)
Standard Operating Procedures
iii)
Operational Data
iv)
Maintenance Data
b) Basic Features
i)
Redundancy Consideration
ii)
Software backup Procedure
iii)
Data base security and integrity
iv)
Access Security
c) Processing Power and Memory
i)
Type and number of microprocessors and needed to guarantee processing power
and response time
ii)
Size of main and cache memory needed to store real time data base, trends,
recipes and reports
iii)
Bulk memory devices to store recipes, operating procedures, maintenance data
etc.
d) Displays
i)
Preformatted color graphic displays (overview, group, point, number)
ii)
Custom graphic color displays (type, number)
iii)
DCS status displays (type, number)
iv)
Alarm summary Displays (Sequence and number variables)
v)
Real Time Trend Displays (Trending interval and number)
vi)
Historical trend displays (type, number)
vii)
Report type displays (number)
viii) Statistical process control displays (type, number)
e) CRT and Keyboard
i)
Video Monitors (type, size, number and requirement for special housing)
ii)
Keyboards (type such as operational or engineering, number and requirements for
special packaging to meet environmental safety needs)

B) Archiving Units
i)
Type, size and number of bulk memory devices (hard disks drives, diskette
drivers, tape drives, optical disk drives)
ii)
Report archiving time interval
iii)
Type and number variables (each with archiving times)
iv)
Trend archiving
v)
Trend and report generation (researching criteria)
C) Printers, Hardcopy Devices
i)
Terminals for logging, reporting, graphics, trends, alarms
D) Engineering Station
i)
Type of processor
ii)
Type, size and number of bulk memory devices (hard disks drives, diskette drives,
tape drives, optical disk drives)
iii)
Type of monitor, keyboard and printer
iv)
Supporting Software
v)
Application libraries cover: spreadsheets, programming languages, statistical
process control analysis, physical properties libraries, reporting, device
monitoring, local area network monitoring and data base packages
2. Items related to Data Highway
A) Traffic Communications Director
i)
Redundancy Requirements
ii)
Network Topology (Star, Multidrop, ring)
iii)
Transmission Type (Twisted pairs, Coaxial, fiber optic)
iv)
Communication Controllers (Type and number of transponders)
B) Interface Units
List manufacturer, model, number, data base structure, configuration and programming
requirements for all microprocessor based equipments including:
i)
PLC interfaces
ii)
MIS or other computer interfaces
iii)
Engineering Workstations
iv)
Smart Transmitters or analyzers of other suppliers
v)
Digital controllers of other suppliers
vi)
Smart Laboratory Equipment
vii)
Product identification or inventory equipment
viii) Smart control valves
ix)
Stacker cranes or automated guided vehicles
3. Field Mounted Devices
A) Control Units (CUs)
a) The type and number of microprocessors should be specified to guarantee the required
processing power within the allowable response time.
b) The physical specifications should state power consumption, heat dissipation, floor
space requirements and equipment weight.
c) The type and size of the memory specified must be able to store all the data and
programs associated with the CU.
d) Power supplies should be sized to meet the load and distribution needs
e) Power supply redundancy should be considered.
f) Fault tolerant architecture should be specified when necessary
g) Control Requirements should be specified including:
i) Type, number and scan time of all PID, cascade or other more complex loop.

ii) Type, number and scan times for all devices associated with interlock control
iii) Type, number of operations, steps per operations, and scan times for all
instruments associated with sequential control
h) Inter-processor communications should be specified
i) Mathematical calculations should be listed
j) Monitoring and alarm requirements associated with all motors, valves and other
digital or analog devices should be specified
k) Type and number of data to be uploaded and downloaded via communications
networks should be specified
l) Specifications for fault tolerant operations should be included
m) I/O specifications should be listed, including:
i)
Built in or remote I/O
ii)
Power supply voltage and power loading requirements
iii)
Type and number of I/O (specified to include 20% spares)
Analog (single ended or isolated 4 to 20mA, thermocouple, RTD,
millivolts, weight scales etc.)
Discrete (Momentary or latching 120V AC, relay NO or NC)
Time proportioned
Pulse Count
Binary coded decimal (BCD)
Serial Port
n) Packaging requirements for the particular environment should be specified
o) Internal and external wiring requirements should be specified
B) Multiplexer, Data Acquisition Units
The same requirements apply as for CUs, except for control.
NON - HARDWARE COMPONENTS
Non Hardware components may include following items:
1. Software development costs for configuration, batch sequencing, special displays, etc.
2. System integration, factory acceptance testing (FAT), field installation and checkout, site
acceptance testing (SAT), documentation, and support services including project
management, training and maintenance.

Assignment: Prepare cost justification sheet for any one of the make and model of the DCS
available in the market.