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Project:

Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 1 of 15

5.1

Conceptual Formulation for Electrical and Instrumentation

5.1.1

General

The electric power distribution is designed to cover the load or consumption conditions of the
process plant during production, start-up or shut-down.
Instrumentation and control of the complete plant is designed to achieve a high standard of
process operations, according to the requirements of quality and safety.
All components fulfill the requirements in accordance to the local regulations and
international standards and regulations (VDE/IEC).
5.1.2

Climatic conditions (inside building)

The climatic conditions inside the building regarding the room for switch cabinets have to be
as follows:
Temperature not more than
35 C
(24-hour average 30C)
Relative air humidity not more than
95 %
(avoidance of sweating)
Regarding the control room the climatic conditions have to be as follows:
Temperature should be less than
30 C
Relative air humidity should be less than 85 %
(avoidance of sweating)
To realise these conditions it is necessary to install an air condition (control room and room
for switch cabinets).
5.1.3
Kind of power supply net
TN-S power supply net is confirmed by all parties as shown in figure 1.
Undervoltage trip signal comes from the Low Voltage Distribution to the DCS-system.

Figure 1: TN-S net will be used

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 2 of 15

5.1.4

Standard for electrical power supply


Voltage
380V / 220V
+10% and -10%.
Signal voltage
24V
Phases
3
Frequency
50 Hz
2% ( 1Hz).

5.1.5

Earthing, neutral and compensation of potential

Figure 2: Equipotential bonding system

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 3 of 15

As shown in the figure 2 generally there will be a connection to the steel construction of the
building also using technological steel constructions. Additional there should be one
connecting point in each room (each structural module) to connect to the building.
Equipotential bonding bands have to be installed inside of each switch cabinet. All shields of
the wire have to be connected there.
The customer give a guarantee to the earthing resistance of less than 1 Ohm using the steel
structure of the building.
5.1.6

Low Voltage Main Distribution

The low voltage main distribution, located adjacent to the transformer station,is fed from the
transformer with 0.4 kV and distributes the power to the MCC inverters, other subdistributions and switchboards. There are two transformers inside one power plant. In case of
any fault in one of the transformers there is an automatically switch over to the other one. The
automatically switch over time has to be confirmed by customer .
This switchgear system consists of input load breakers, with short current, thermal, and
undervoltage release.
The input feeder is equipped with the required power measuring devices, as well as power
consumption metering.
The reactive power compensation system may be integrated into the low voltage main
distribution, for a power factor of at least 0.90.
5.2

Conceptual Formulation for instrumentation

5.2.1

General

The instruments and the components are made for the industrial standards of the chemical
industry. All devices are carefully selected in accordance with the required task, the
environment and the classification of the process function.
Field mounted gauges indicate various process conditions such as pressure, temperature, flow,
concentration or level.
Important operating parameters will be measured by sensing elements and converted by
electronic transmitters into electric signals, which are connected to the local ET 200 control
cabinet in each floor. The local ET 200 control cabinets are connected with the central control
station via redundancy Profibus DP. Final elements, such as control valves or electrically
controlled devices, receive commands from local ET 200 control cabinets or the central
control station.
5.2.2

Signal level of sensors and actuators

The standard signal level of sensors is fixed by using 4 20mA. RTD elements only for
indication of temperature will be directly connected to the ET200.
The standard signal level of actuators is fixed by using 4 20mA.

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 4 of 15

The pneumatic auxiliary power supply will be instrument air with the conditions as follows:
Pressure
6 bar (g)
10%
Temperature
15 30 C
Dew point - 40 C (at normal pressure conditions)
The instrument air must be clean by dust and oil.
In each floor are several auxiliary air distributors.
5.2.3

Principles of measurement and vendor

Using the fluid code numbers there is a classification to the measuring method for the
measured variable as follows:
Fluid code
number
1210, 1220,
1310, 1400,
1410, 1610,
1630, 1640,
1910, 1920

Measured variable

Measuring method

Temperature

PT100 (cover tube)


Local gas pressure thermometers (cover tube)
Suspended body flow meter
Bypass / float level indicator / switch or
Level switch by tuning fork or
Radar / Microwave level transmitter
Boundary tube gauge (pressure gauge) only local
Pressure transmitter (screwed or flanged)
PT100 (cover tube)
Pressure transmitter with diaphragm or siphon
PT100 (cover tube)
Suspended body flow meter, differential pressure
flow meter
Boundary tube gauge (pressure gauge) only local
or Pressure transmitter (screwed or flanged)
PT100 (cover tube)
Level switch by tuning fork or
Radar / Microwave level transmitter
Pressure transmitter with diaphragm
PT100 (cover tube)
Mass flow meter, flow indicator
Displacer level transmitter or
Radar / Microwave level transmitter
Pressure transmitter with diaphragm
PT100 (cover tube)
Mass flow meter
Radioactive level transmitter or
Radar / Microwave level transmitter
Pressure transmitter with diaphragm, flanged
Ultrasonic transmitter

Flow
Level

Pressure
2310, 2320
3110, 3120,
3910, 5010,
5030

Temperature
Pressure
Temperature
Flow
Pressure

3410, 9120

3420, 3421,
6410, 6420, ,
7010, 9210,
9250, 9211,
9220, 9221
8710, 8720
8730

Temperature
Level
Pressure
Temperature
Flow
Level
Pressure
Temperature
Flow
Level
Pressure
Concentration

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 5 of 15

Fluid code
number
8740, 9110
5610, 5620
8790

8750, 9130

Measured variable

Measuring method

Temperature
Pressure
Temperature
Level

PT100 (cover tube)


Pressure transmitter with diaphragm, flanged
PT100 (cover tube)
Radioactive level transmitter or
Radar / Microwave level transmitter
Polymer melt pressure transmitter
PT100 (cover tube)
Local bimetallic thermometers (cover tube)
Suspended body flow meter or
Ultrasonic flow transmitter
Radar / Microwave level transmitter
Pressure transmitter with diaphragm, flanged
p Pressure transmitter with diaphragm, flanged
Ultrasonic transmitter
PT100 (cover tube)
Bypass magnetic level indicator
Boundary tube gauge (pressure gauge) with
siphon, only local
Pressure transmitter with diaphragm

Pressure
Temperature
Flow
Level
Pressure

9710, 9720,
9730, 9740,
9750, 9760

Concentration
Temperature
Level
Pressure

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Project-No.:
Drawing up:

Thailand 1
605520
5. Electrical, DCS and Measurement

5.1 Conceptual Formulation for electrical, instrumentation and DCS-system

page 6 of 15

List of approved vendors for E&I devices


Instruments for flow measurement
1 flow

Rotameter, gas and fluid

15-100 Krohne

SS H250/ RR/ M9

22

nitrogen and water in:


Lactamstorage
Extraction / Drying

indication only local

http:/ /www.krohnemar.com/Metal_Cone.11106.0.html

2 flow

Rotameter, gas and fluid

10-25

SS H250/ RR/ M9/ K1

12

nitrogen in Lactamstorage

indication only local, switch contact to DCS

http:/ /www.krohnemar.com/Metal_Cone.11106.0.html

3 flow

Rotameter, gas and fluid

15-100 Krohne

SS H250/ RR/ M9/ ESK

60

nitrogen and water in:


Lactamstorage
Extraction / Drying
Poly / Recovery

indication local and DCS

http:/ /www.krohnemar.com/Metal_Cone.11106.0.html

4 flow

coriolis flow meter

10-50

Siemens

SS MASS2100

Polymerisation
Additives

with heated jacket and without heated jacked, http:/ /pia.khe.siemens.com/ index_sitrans_f_c_
indication local and DCS
nobr_mass_2100_di_3-40_nobr_-13907.htm

5 flow

Rotameter, gas

10-25

Krohne

SS DK37M

10

Additives

indication and control only local

6 flow

ultrasonic flowmeter

Panametrics

SS AT 868

Recovery

clamp on mounting
DCS

7 flow

orifice flowmeter

40-300

dosch Messaparate
GmbH

SS BLB 300

Diphyl heating System

indication DCS

8 flow

volumetric flowmeter

10

Bopp & Reuther

SS Miniflow

Additives

indication DCS

9 flow

volumetric flowmeter

10-50

Bopp & Reuther

SS batch OI

Additives

indication local and DCS


indication only local, switch contact to DCS

Krohne

10 flow

flow indicator

G1/ 4"

EGE-Elektronik GmbH

SS SC 440/ 5-A4-GSP

10

Additives
Extraction

11 flow

Pitot Tube Flow Measurement

500

INTRA-Automation
GmbH

SS ITABAR IBF-25-ID323

Drying

indication DCS

12 flow

vortex flowmeter

300

Krohne

SS OPTISWIRL 4070C

Drying

indication local and DCS

indication local and

http:/ /www.krohnemar.com/DK_37__Variable_Area_Flowmeter__
en.784.0.html
http:/ /www.gesensing.com/ products/ at868.ht
m
http:/ /www.doschgmbh.de/ products04_e/ products/ dpflowmeter
/ blborificeplatewithsingleborepressuretaps/
http:/ /www.burmt.de/ BURMTWWW/ prod.php
?lang=us&prod=Miniflow#Anzeige1
http:/ /www.burmt.de/ BURMTWWW/ prod.php
?lang=us&prod=OI#Anzeige1
http:/ /www.egeelektronik.com/en/products/search.php?Typ=S
C+440%2F5-A4-GSP
http:/ /www.intraautomation.com/pdf/ products/ introduction/en
/ introduction_itabar_en.pdf
http:/ /www.krohnemar.com/OPTISWIRL_4070C__Vortex_Durchflu
ssmessgeraet__en.11250.0.html

Instruments for level measurement


1 level

level switch

15-80

KSR Kuebler

SS Float switches

Diphyl heating System

switch contact to DCS

2 level

magnetic fold down level

15-50

KSR Kuebler

SS batch BNA

16

Diphyl heating System


Extraction / Drying

indication only local, switch contact to DCS

3 level
4 level

vibration level switch


radimetric level transmitter

15-80

VEGA
Endress & Hauser

SS VEGAVIB VB 63
Gammapilot M FMG 60

26
10

5 level

Displacer (buoyancy) level transmitter

80

Foxboro Eckardt

SS 144 LD

15

6 level

Guided level radar measurement

50-100 VEGA

SS Levelflex 66

18

7 level

Guided level radar measurement

50-100 VEGA

SS Levelflex 61

Rev.: 0

Extraction / Drying
Polymerisation
Additives
Extraction / Drying
Lactamstorage
Additives
Recovery
Extraction
Extraction

switch contact to DCS


indication DCS
indication local and DCS

http:/ /www.ksrkuebler.com/ website/ index.php?lang=en&load


=123
http:/ /www.ksrkuebler.com/ website/ index.php?lang=en&load
=236
http:/ /www.vega.com/en/849.htm
http:/ /www.endress.com/ corporate
http:/ /www.foxboroeckardt.com/products/144ld_en.html

indication local and DCS

http:/ /www.vega.com/en/633.htm

indication local and DCS

http:/ /www.vega.com/en/633.htm

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Project-No.:
Drawing up:

Thailand 1
605520
5. Electrical, DCS and Measurement

5.1 Conceptual Formulation for electrical, instrumentation and DCS-system

page 7 of 15

Instruments for pressure measurement


Lactamstorage, Additives,
Recovery, Extraction, Diphyl indication only local
heating System

1 pressure

pressure gauge

G1/ 2"

Manotherm

SS RCh 100-3

55

2 pressure

pressure switch

G1/ 2"

Manotherm

SS RCh 100-3 with limit switch

15

3 pressure

membrane pressure gauge

G1/ 2"

Manotherm

SS RCh 100-3 with MDM 7210

4 pressure

membrane pressure transmitter

50

VEGA

SS VEGABAR 61

5 pressure

differential pressure transmitter

50

VEGA

SS VEGADIF 55

6 pressure

melt pressure transmitter

M18

Dynisco

SS MDT 462F-M18-50-15

10

Polymerisation

indication DCS

melt pressure transmitter with temperature sensor

M18

Dynisco

SS TDT 463F-M18-50-15

Polymerisation

indication DCS

110

7 pressure

Lactamstorage
Additives
Recovery
Lactamstorage
Additives
48
Recovery
Extraction / Drying
Lactamstorage
Additives, Polym.
100
Recovery
Extraction / Drying
Recovery
14
Extraction / Drying

http:/ /armaturenbau.com/ Datenblaetterpdf/ 1201-eng.pdf

indication only local, switch contact to DCS

http:/ /armaturenbau.com/ Datenblaetterpdf/ 1291-eng.pdf

gauge with Diaphragm Seal, indication only


local

http:/ /armaturenbau.com/ Datenblaetterpdf/ 7210-eng.pdf

indication DCS

http:/ /www.vega.com/en/654.htm

indication DCS

http:/ /www.vega.com/en/186.htm
http:/ /www.dynisco.com/products.aspx?FID=7
6&MID=468&lang=en
http:/ /www.dynisco.com/products.aspx?FID=7
6&MID=474&lang=en

Instruments for temperature measurement


1 temperature

bimetal thermometers

M18

Manotherm

SS TBiCh GEL 100mm

2 temperature

thermometer switch

M18

Manotherm

SS TSCh GEL 100mm with contact

3 temperature

PT 100 temperature

M18

Electrotherm

SS PT 100, Typ 348, Typ 357

4 temperature

safety temperature limiter

Jumo

STB

Lactamstorage
Additives, Polym.
Recovery
Extraction / Drying
Polymerisation
14
Diphyl heating System
Lactamstorage
Additives, Polym.
190
Recovery
Extraction / Drying

indication only local

http:/ /armaturenbau.com/ Datenblaetterpdf/ 8101-eng.pdf

indication only local, switch contact to DCS

http:/ /armaturenbau.com/ Datenblaetterpdf/ 8210-eng.pdf

indication DCS

http:/ /www.electrotherm.de/catalog/ chapter3.


pdf
http:/ /www3.jumo.de/ pio/ JUMO/en_DE/ prd/7
0.1130/ temperature-monitor-limiter-andsafety-temperature-monitor-limiter-formounting-on-din-rail.html

Diphyl heating System

indication local and DCS

Instruments for field analysis measurement


1 analysis

oxygen analyzer

G1/ 2"

AMSGmbH

SS AMS3160

Drying

indication local and DCS

2 analysis

dew point measurement

G 1/2"

DKSDresden

SS NP330 G

Drying

indication local and DCS

3 analysis

concentration analyzer

50

SensoTech GmbH

SS LiquiSonic

Recovery

indication local and DCS

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

http:/ /www.amsdielheim.com/english/ pat.html


http:/ /www.dksdresden.de/ html/ dewpoint.html
http:/ /www.sensotech.com/ cms/produkte0.ht
ml?&L=1

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 8 of 15

5.2.4

MCC and operation philosophy for electrical drives

The MCC are used for the power supply of all electrical consumers. They contain all required
outlets to consumers e.g. motors, heaters or compact units.
The MCC contain all required motor protection switches, circuit breakers, contactors,
transformers, frequency inverters etc. as well as the corresponding control loops.
The MCC room should be direct beside the central control room. There located also the fuse
switches for all electrical drives.
Motors with a rated power of up to 15 kW will be started directly on line. Above 15 kW are
used star/delta starters or electrical soft start devices.
Electrical drives with frequency inverter are direct connected by the Profibus DP via Y-Link
and communicate via Profibus DP with the central control station.
There are automatically and manually operation mode (see figure 3). Switching is possible
from the OS/ES stations. Additional it is necessary to check all technological and technical
conditions before starting electrical drives.

Figure 3: Face plates for operating the electrical drives

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605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 9 of 15

Manually operation for the electrical drives is possible as follows:


There will be local panels for electrical drives in the field. On this local panels there are 3
(three) push buttons and 1 (one) light (see figure 4).
-

STOP means one can switch off the drive and the button is always active
to switch on (START) it is necessary to select LOCAL Operation Mode on the
DCS face plate
only if the LIGHT is off one can switch on the drive
if the LIGHT is on there is an error or an interlock is active
QUIT is to reset all errors regarding this drive

Selected drives are as follows:


- all melt pumps
- all pumps for liquid Caprolactam and recovered Caprolactam
- pumps for extract water in the extraction and recovery
- selected pumps in the heating system

Figure 4: Local panel for selected electrical drives in the field

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 10 of 15

5.3

Conceptual Formulation for DCS-system

5.3.1

General

The central control room is located preferably close to the process plant. For the plant control,
a Distributed Control System (DCS), with a redundant main structure from a well known
expert manufacturer like Siemens (SIMATIC PCS7), is used. This is an advanced system, to
provide coordinated solutions of industrial automation.
The central control room is the operator area, a functional and representative room, the
operator workstations will be arranged, each for the control of the production line. The
operators will manage sequence control and plant interaction from these places.

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 11 of 15

5.3.2

Overall DCS Configuration

Figure 5: Schematic overview of DCS-configuration


There are 3 (three) Operation Stations (OS) and 1 (one) Engineering Station (ES) which are
located in the control room. Each station is able to act all functions. The OS/ES stations have
single CPU inside and accomplished in industrial standard. The system software for the
OS/ES stations should be Windows XP and for the server stations Windows 2003 Server.

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 12 of 15

There is a redundant Ethernet connection between each PLC and each OS/ES-station. This
Ethernet-Bus-system is arranged as a circle and if there is a cut of this circle the Ethernet
works as a line with all functions. This means redundancy of the Ethernet-Bus-system is
realised also.
There is a redundant Profibus system between ET200 and PLC.
There is failsafe PLC (S7-400F) where the safety-related signals (measuring point with Zfunction) are connected.
The customer provides the software for Siemens PCS 7 or PCS7 Asia, and application
software for OS/ES and the PLCs.
5.3.3

Redundancy concept

The DCS is provided by the control processor station in a redundant configuration (see
figure 5). In the redundant operation, both controllers execute identical programs. Output
results are compared and, if identical, the result is transmitted to the input/output modules. In
the case of a mismatch, both controllers go through diagnostic test routines to determine
which one has failed. Both controllers read the same messages from the local network, but
output messages are transmitted by only one of them.
5.3.4

Operating and monitoring philosophy of DCS

All informations from the process and the multifunctional controllers are concentrated at the
operator stations, arranged in the central control room.
An OS/ES workstation is a console, from which the operator can monitor and manage the
process. The Siemens system Simatic PCS7 offer the user (process engineer, operator,
manager, or maintenance engineer) menu-based and pictorial
guidance for all interactions with the system or the process. This makes the system easy to
learn and easy to operate. Menu bars provide fast access to informations.
Description of some attributes of operation on the monitor:
Inside each picture there are buttons to reach the next picture.
All monitor pictures can be print out using screen-shot function (see figure 6). All events can
be printed out by line printer. Default list can also be print out.
Using right side mouse click on measuring points opens a face plate. There is shown the trend
of the historical values (see figure 7).

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 13 of 15

Figure 6: Example for monitor layout

Figure 7: Example for face plate Trend

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 14 of 15

Using left side mouse click on measuring points opens another face plate. There is shown the
parameters of the control loop and the actual state of the control loop (AUTO or MAN) (see
figure 8) or only switch and alarm parameters for an indication measuring point (see figure 9).

Figure 8: Example for face plate Control loop

Figure 9: Example for face plate Indication


It is necessary to arrange a user structure with different rights. For an example ordinary
operators should not be able to change special parameters of control loops (parameters for
PID-controller).

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc

Project:
Thailand 1
Project-No.:
605520
Drawing up:
5. Electrical, DCS and Measurement
5.1 Conceptual Formulation for electrical, instrumentation and DCS-system
page 15 of 15

5.4

Emerency Power Supply

An Uninterruptible Power Supply (UPS) covered unexpected supply failure.


UPS has to be installed for DCS-system only including Operating Stations, Engineering
Stations and PLC. There is no UPS for the power of the field instrumentation and drives. The
time for buffering has to be 30 minutes, the capacity 30 KVA and the nominal voltage 380 V.
The time to hold the signals from the PLC can be only in maximum 2 seconds. After the
duration of 2 seconds the drives will be switched off by PLC and has to be restarted manually.
5.5

Remote maintenance

To realise the remote maintenance for the PLC a internet connection is necessary. The
customer must ensure that the ES-station is connected with an Internet connection.
5.6

Measurement Point Lists

All measuring points will be provide in separate lists.


5.7

Alarm and Set Point Lists

All interlocks, alarms and set points will be provide in separate lists.
5.8

Electrical Power Consumer Lists

All electrical power consumers will be provide in separate lists.

Rev.: 0

605520_5_1_Electrical_DCS_and_Measurement_20120531.doc