SPECIFICATIONS FOR REPLACEMENT OF 115U WASTE GAS

PLC WITH NEW PLC.

Present system

Siemens Germany make 115U PLC (S5 series) installed in 1988 at Waste
gas area at D.R. Plant is used for automation and control of complete Waste
gas system including ID fan, DPG, Recycle group, Dedusting group etc.
This is connected with S7-400 PLC, 155 H PLC and WinCC HMI through
Profibus network.

The 115U PLC consist of following cards.

Power Supply Card

TYPE : 6ES5-951-7LD12,
CAPACITY : 7 AMPS / 15 AMPS,
5VOLT/15 AMPS, 5.2VOLT/2.5AMPS, 24VOLT/0.35AMPS,
MAKE : SIEMENS

CPU Module
TYPE : 6ES5-942-7UA12,
CYCLE SCAN TIME: 300 MILLI SECONDS
MAKE : SIEMENS

Profibus Communication Card

COMMUNICATION PROCESSOR CP 5431 FMS (A1),
TYPE: SINEC 6GK1543-1AA01
VERSION: V 3.0X,
MAKE: SIEMENS

Digital Input Card

SIMATIC S5 16 BIT DIGITAL INPUT CARD,
TYPE: 6ES5 431-7LA11,
SUPPLY VOLTAGE : 48 VOLT DC,
NUMBER OF CARDS : 18
TOTAL NUMBER OF INPUTS : 288
MAKE: SIEMENS.

Digital Output Card

SIMATIC S5 32 BIT OUTPUT CARD,
TYPE : 6ES5 451- 7LA11,
SUPPLY VOLTAGE : 24 VOLT DC,
NUMBER OF CARDS : 4
TOTAL NUMBER OF OUTPUTS : 128
MAKE : SIEMENS

OLM Module
OPTIC LINK MODULE,
SIMATIC NET PROFIBUS OLM/P12,
TYPE : 6GK1 502-3CA10,
MAKE : SIEMENS

Rack to Rack Communication Card

INTERFACE MODULE IM 306,
TYPE : 6ES5 306 – 7LA11,
MAKE :SIEMENS

Existing Network
Profibus network of 115 U PLC, 155 H PLC, S7-400 PLC and WinCC HMI
(OS1 and OS2 consoles) is shown in attached annexure PLC_Network.
Baud rate of Profibus is 187.5 kbps.

Existing Siemens Panel:

1. Siemens make two panels (1800x1100x800) each.
2. Each panel opening Front and Back , with relay mounted on back.
3. Space on which all electronic cards/CPU has been accommodated:
length : 470 mm, height :300 mm, depth : 195 mm

REQUIRED SYSTEM

The new system should be PLC (Programmable Logic Controller). The input
and output requirements are as follows.

1. Digital Inputs: :
Type : 48 Volt DC, 8/16/32 channels per card
Quantity : 288 numbers

Positive wire of 48 Volt DC is to be routed to field devices and taken in

Digital input card as INPUT. Bulk power supply rated at 48 Volt DC at 40
Amps is to be used from existing PLC.

2. Digital Outputs:
Type : 24 Volt DC, 8/16/32 channels per card
 Quantity : 128 numbers

Interfacing to field to be done via 1 NO (Normally Open) contact

interposing relay. M/S. Murr make interposing relays rated at 24 Volt DC,
1A and Bulk power supply rated at 24 Volt DC at 25 Amps is to be used
from existing PLC.

Communication:

Supplied PLC to be interfaced with existing WinCC HMI on both consoles

OS1 and OS2 on Profibus network having S7-400 and 155 H PLCs on
network.
Real time functions, normal operator interface, engineering function, time
stamped event logging, alarm management, ON and OFF commands of
individual drives and group of drives, status of supplied PLC like CPU in
RUN/Stop/Fault mode, fault type, Reset are to be interfaced with WinCC
HMI.

SOFTWARE:

User friendly software system should be easily configurable by the user.

Apart from normal function like logical, timers, counters, flags, software
should have Mathematical and Engineering functions.
Buyer will provide details of interlocks required and drive ON/OFF
sequence for logic and software development by the supplier.

SPARES:

List and unit price of two years maintenance spares should be indicated. At
least one card/electronic item of each type should be included in spares.

ENVIRONMENTAL CONDITIONS

A) Dusty atmosphere containing conductive dust .

B) Ambient temperature : 10 to 50 Degree Celsius.
Following is the seller’s scope of work in detail:

1. Design of PLC system architecture, Supply of PLC hardware

and software, Testing of PLC & Commissioning of PLC
system.
2. Development of Functional Description and sign off the same
from M/s Sunflag Process owner. Development, Testing and
fine Tuning of Application software.
3. Supply of one card/electronic item of each type as spares.
4. The system will perform, but not limited to, the following
functions.
4.1 Diagram /screen (representing total hardware system) showing
healthiness up to individual card level. It will report the fault in
system /card with prompting the remedial action.
4.2 PLC program logic to perform all the digital control.
4.3 Development of application logic in Ladder / CSF /STL for
digital control and for mathematical calculations.
4.4 Interlocking of the existing system.
4.5 Program retention during power loss through battery backed
RAM and EEPROM.
4.6 Clock synchronization once or twice in a day.
4.7 Output should stay where it was/become zero, in case of card
failure. This should be configurable.
4.8 Supplied PLC should be housed by seller in existing Siemens
panel in available space (length : 470 mm, height :300 mm,
depth : 195 mm).
4.9 Seller to provide heat exchanger/cooling system in existing
panel, if required.
4.9 Any other function to make Waste gas system automation
complete and effective, will in the scope of seller.
4.10 Design and development should be in such a way that all
software shall run concurrently without loss of performances
or hanging of the hardware.
5. Seller to supply necessary hardware/software (Programming
kit) for carrying out modifications in the program or viewing
the status as and when required by the user.

6. Documentation
 a) As commissioned wiring diagram, 02 sets hardcopy and one set of
CD-ROM.
b) As commissioned software schematic, 02 sets hardcopy and one set
of CD-ROM.
c) Operation and maintenance manuals 02 sets
d) Schematic diagram of the cards and power supplies.
e) Bill of material
f) List of bought-out items with source and specification

7. Commissioning:

a. For commissioning, Party will depute a person who is well

experienced.
b. Drawing of PLC software should be well prepared before starting of
Commissioning and it should be sent to M/s Sun flag well ahead of
Commissioning.
c. Any other outside help/materials/software/tools required for
successful completion of automation/project should be considered
in scope of supply.
d. Number of days required for commissioning should be indicated.
e. Installation and commissioning should be carried out and
completed during DRP shutdown. Pre-intimation of DRP shutdown
will be given by buyer one day in advance.

8. Diagnostic:
With self diagnostic to report failure up to card / component level.
Diagnostic features to report the exact cause of failure and the revival from
failure.

9. Power Supply :
System should be tolerant to 220/110 Volt AC +/- 15%, 50 Hz +/- 5% single
phase power supply variation.

10. Guarantee:

Seller will guarantee the complete system for performance to work best and
well within the norms, for 24 months from the date of successful
commissioning.
11. Support:

Seller will service and support for the developed software and hardware for
a period of 24 months from the date of commissioning.

12. Training:
Training to buyer’s 02 Engineers during execution of the project at buyer’s
site. Advanced training at factory center for 03 engineers.

13. Any other material/software required for the successful

working of the system mentioned above, is in the scope of
supply by the seller.