paper and DIP -DCS ENG-UPDATE

TECHNICA L PA RT OF ITB FOR DISTRIBUTED CONTROL SYSTEM (DCS) FOR HIGH-LEVEL COLOUR OFFSET NEWSPRINT TECHNICA L RENOV A TIONPROJECTOF SHA NDONG HUA TA I PA PER CO. LTD.1 GeneralThe Seller is requested to supply a complete distributed control system (DCS) for the HIGH-LEVEL COLOUR OFFSET NEWSPRINT technical renovation project of Shandong Huatai Paper Co. Ltd. in accordance with the basic design data and the requirements specified in this document. The DCS system will be used for process control of the production lines of stock preparation (DIP, BCTMP and NBKP refining line) and papermaking (one paper machine numbered PM12 manufactured by VOITH PAPER, Approach flow system shall be supplied by VOITH.)of the expansion project. The bids provided shall exclude the quality control system (QCS) and the paper machine control system (MCS).The supplier of the control system (DCS) shall have sufficient experiences in pulp and paper industry and have done pulp & papermaking project(s) with the similar scale to the Huatai PM12 in the last three years. The supplier should also have good experience to cooperate with V oith Paper. A reference list of the last three years in China shall be provided with the bids.The control system (DCS) provided shall be advanced in performance and complete in system, reliable in quality, proven in technology, good in stability, and run economically, safely and reliably in the paper mill. The hardware and software of the control system shall be of reliable and up-to-date technology or version in the market delivered by the supplier.The delivery shall be of "turn-key" type. The delivery shall be a complete system, including all the necessary equipment, hardware, basic software, configuration software, application programs, and all the other necessary software and hardware, as well as advice, technical instructions, application software configuration, technical training, guidance/supervision, testing and start-up assistance in order to make the system run with the specified performances.The configuration of application software shall be included in the scope of supply. The control system shall be running in normal manner after being installed, powered on site and commissioned.The Seller shall be fully responsible for the functions and capacity (incl. software and hardware) of the control system. If the system or the equipment provided fails to meet the specified requirements, the Seller shall supplement the hardware, software and services so as to realize all the specified functions, and all the relative costs shall be solely borne by the Seller.In case there are any upgrading of system software, configuration software and firmware during the warranty period, the relative cost shall be solely bone by the Seller.Changes of the scope of supply might be made on the basis of limiting to the number and functions specified in the contract. The Seller shall be responsible to take into account of the complexity of the application practice.If the Buyer requests to change the quantity of equipment, the price shall be adjusted on the unit prices basis specified in the contract. Therefore, unit-price for each type of equipment, card/element and the concerned software shall be given in the bids.All the instrument functions, logic functions, motors operation, operation of remote on-off valves, interlocking and alarms shall be realized on DCS.The system provided shall be composed of standard products. If products from a third party are included in the bids, they shall be clearly indicated in the bids with the vender and model. The products from any third party shall be deemed by the Seller as an integrated portion of the control system, and the Seller shall provide guarantees for reliable operation of them in this project.The equipment and software versions provided by the Seller shall be compatible with the later higher versions, so that all future developments can be implemented at a minimum cost and downtime. The Seller shall be responsible to keep the Buyer being informed timely of relevant product upgrading during the warranty period.The system shall be of an open system with self-diagnostics and self-protection functions. The system shall conform to the open system standard ISO/OSI.The system shall include the remote-diagnostics and remote-trouble shooting functions, which can communicate with the Seller’s equipment in its service center via Internet. The Seller shall be able to access, from his service center, to the provided system through Internet and carry out the remote diagnostics and assist the end user for trouble shooting.Descriptions of all the hardware, software, configuration software, application software, real-time database arrangement and historical database arrangement shall be provided in the bids.Specification and catalogue/brochure of the related hardware, software and configuration software shall be provided in the bids.Breakdown prices shall be given in the bids. The breakdown prices for hardware shall consist of the breakdown prices for equipment and the breakdown prices for module/card.Should the Bidder prefer other solutions, which are different from what specified, they shall be presented as an optional solution in documents, and mark in a deviation list.Description for the Seller’s technical support organizat ions in China shall be attached to the bids, with indication of name and address of the organizations, number of engineers and date of establishment, etc.Description of the Seller’s stocks in China for spares and spare parts support shall be attached to the bids, with indication of the stock location and the date of establishment, etc.Packaging of equipment shall meet the requirements for ocean transportation.and should be seaworthy packed. All necessary measures shall be taken to protect the equipment from moisture, dust, corrosion, shock and damages.The bids shall be prepared in accordance with the specifications in the ITB.The Seller’s bidding document must be made in both Chinese and English (8 sets).The technical part of ITB is written in both Chinese and English versions. In case there is any contradiction between the two versions, the Chinese one shall prevail. The interpretation right is in the hand of the CNTIC Trading Co., Ltd..2 Design criteria, process brief introduction and requirements2.1 Basis conditions for designY early average temperature 12.4︒CMax. temperature 41︒CMin. temperature -22.3︒CY early average humidity (relative) 66%Power supply 380/220 V AC, +10 - -10%, 50 HzEarthquake intensity to be protected against degree 7Attitude <20m2.2 Basis dataPaper grade High-level color offset newsprint /high brightness newsprint furnish DIP 75-90% (75%-90% AONP,15-10%AOMG,5-0% ONP domestic, 5-0%domestic mixed office waste paper);Semi-CMP 10-0%；NBKP 5-8%Untrimmed width 9850mmWorking speed 2000m/minDriving speed 2000m/minStructure speed 2000m/minBasis weight 35 – 60g/m2Moisture 6 – 10%2.3 Process briefing and requirementsProduction lines and main process flows are as the following:BCTMP: Slat conveyor → Hydrapulper → Pulp tower → H.D.cleaner → Deflaker → Refiner No.1 → Refiner No.2 →Refiner No.3NBKP: Slat conveyor → Hydrapulper → Pulp tower → H.D.cleaner → Defibrizer → Refiner No.1 → Refiner No.2→ Refiner No.3BCTMP and NBKP share common slat conveyor and pulperDIP drum pulper Slat conveyor→bale breaker→slat conveyor→drumpulper→HC cleaner→dump towerDIP main process: Slat conveyor → Crusher → Slat conveyor → Drumpulper→H.D. cleaner →Dump tower→coarse screen→ Pulp tower→ L.D. cleaner → preflotation → 4stages screen → Disc filter 1 → MC pump → screwpress → disperger → Bleaching stage 1 → Stock chest→ postflotation → Disc filter 2 → MC pump →Bleaching stage 2 → to paper machineSludge handling: Gravity table→Sludge press→DAFAdditives preparation and dosing for above stock preparation lines are included.Paper machine line: Mixing chest →Thick stock screening→Machine chest→ Cleaner → Deaerator → Screening → Headbox →Wire section → Press section → Dryer section → 2stacks of soft roll calender → Reeling → Winder→Wrapping. The systems such as Additives preparation,Broke handling, Vacuum system, Steam andcondensate, Fibre recovery system etc. are included inpaper machine line. Except the paper machine controlsystem (MCS), all the other processes are to becontrolled by DCS.Requirements on control room installation arrangement are as the following according to the requirements of process and operation:DIP production line to be installed with one (1) control room; Drum pulper to be installed additionally with one (1) control room; Chemical preparation to be installed with two (2) control rooms.At the front side of paper machine line to be installed with one (1) control room respectively, i.e. control room wet end control room dryer end;And one (1) separate control room for PM wet end chemical preparation.The above mentioned control rooms can be, based on the needs, divided into control cabinet rooms and operator rooms. The control cabinet rooms shall be installed with I/O cabinets and control cabinets. The operator rooms shall be installed with operator stations and printers.The about distance and location for them of control room see Appendix 2.3 Seller’s Scope of supplyThe delivery shall be of "turn-key" type. The delivery shall be of a complete system, including all the necessary equipment, hardware, basic software, configuration software, application programs, and all the other necessary software and hardware, as well as advice, technical instructions, application software configuration, technical training, guidance/supervision, testing and start-up assistance in order to make the system running with the specified performances. The configuration of application software shall be included in the scope of supply. The control system shall be running in normal manner after being installed, powered on site and commissioned.The equipment supplied by the Seller shall be imported products with high quality in the same kind of equipment and fabricated with up-to-date technology.The Seller shall provide suitable CUP, I/O modules and accessories, accordingto the properties and requirements of the production line, and provide practical and state of the art net work configuration which is sufficient to meet the control requirements of the production line.The Seller is allowed to provide the bids with different I/O solutions (plans) as options if necessary.3.1 Scope of supply for DCS equipment3.1.1 Control room for DIP drum pulperOperator station 1 set s(double monitor)DCS and process I/O cabinet to be provided according to the number of I/O 3.1.2 Main control room for DIP, BCTMP & NBKPOperator station 44 sets（double monitors screen 2 sets）Operator station 1 set (single monitor)Laser printer 1 pcHardcopy Ink-jet color printer 1 pcAlarm printer 1 pcEngineering station 1 set (single monitor)DCS and process I/O cabinet to be provided according to the number of I/O 3.1.3 Control rooms for stock preparation plant chemicals addition3.1.4 Control room for dryer end paper machineOperator station 2 sets（single monitor）3.2 CableCables in the system and communication cable with sufficient length according to the actual needs.3.3 Software of control systemThe delivery shall include all the necessary software, basic software, database, configuration software, application program and all the other necessary software. The software can be delivered in carrier media of tape, floppy disc orCD. The software shall be delivered with relative written (literal) description. All configurations shall be completed for the control system before delivery.4 Number of I/ODivided into instrumentation and electrification.ElectricalNote: AIP is supplied 24VDC from the system, AIA is supplied with 220VAC or 24VDC out of the system.“*”means dry contact signal.“**” means 220VAC input/ output separated by relays.220VAC DI/DO is to be separated with relays, and all the relays will be in a centralized arrangement according to different control rooms.Total I/O count: 4650 ?, among which 2704 4036counts for instruments,1708? counts for low voltage motors (connected by soft wire, i.e. onlyprogramming configuration is needed instead of I/O modules), and 238168 forhigh voltage motors (connected by hard wire).Total low voltage motors: 388 553pcs (PM323pcs, DIP 230pcs).Total high voltage motors: 2221 pcs (PM18 pcs, DIP 3 pcs).For this project, Smart MCC will be used, and the communications between DCS and MCC(high voltage motor excluded) will be realized by means of buses. The working load of processor generated from motor data handlingshould be fully considered when controllers are going to be selected forquotation.20% margin is requested for end u ser’s use in addition to the above listed number of I/O, including terminals.Additionally, 20 pcs signal isolator should be included.Including 20% spare, the number of I/O for each I/O cabinet shall not be morethan 230.Optical switch must be installed in control cabinet or alone control box.All the of DI DO AI should be use fuse with indicial lamp for every loop.5 T echnical requirement to control system5.1 General requirementsThe control system’s design, specification, structure and test should conform to the following standards of the latest version:ISA StandardISO StandardIEC StandardANSI StandardNEMA Standard5.1.1 The BCTMP, NBKP, DIP on one side and paper machine on the other side aretwo production units. The equipment of the production lines shall be installed in their production buildings respectively. The DCS system shall connect the control equipment of the two departments via. bus.*5.1.2 The DCS system shall be equipped with the function of self-diagnostics, the function of localizing errors of modules and failures of the bus data transmission system, the function for checking multifunction of hardware and software and other necessary functions of self-diagnostic. The DCS should have special displays to indicate errors and failures for troubleshooting.*5.1.3 Failure of one module or one input/output channel shall not lead to failure of the whole system.5.1.4 The system shall be totally functional over a short-period power break. In case ofa longer power break, the system shall still be capable of shutting itself down toa safe status predefined and the system shall keep the latest set points, tuningparameters and configurations, etc. After return of the power supply, the system shall start automatically and go to the operator pre-specified, logical starting state within about 30s.Back-up battery shall be installed in the RAM module, so that the system can be easily re-started with the latest set points, tuning parameters and configurations, several hours after the power break.5.1.5 Security system shall be provided in the offered system, with which associateduser log-in name and password can be checked. DIP, BCTMP and NBKP stockpreparation workshop and PM workshop can share the displays, but can not operate each other.5.1.6 All the DCS parts delivered by the Supplier shall have nameplates.5.1.7 The control room equipment shall be the low noise type.*5.1.8 While the system is in operation, it shall allow the operator to remove or install any modules from or to any station without interrupting the system and damaging any modules or units.5.1.9 Redundancy shall be established for control bus.5.1.10 Operator stations in one control room should be spares for each other.5.1.11 V entilation and other auxiliary devices shall be installed in the operation cabinetsand process control panels.*5.1.12 Reserves∙There shall be 10% empty rack and 10% terminal strips reserves (installed spare), and there shall be sufficient reserves for the related software. Theterminal strips shall be of the single layer structure.∙All cabinets and panels shall be with 10% empty space for future expansion.∙In the cases with the worst operation load, the actual data transmission of all the operator stations and system buses should be less than 50% of thebuses load.∙The reserves for memory in each operation station and in each process station shall be 50% of the memory capacity respectively after start up.∙The load of CPU for operation station and process station shall be less than60 50% of the full load of CPU in all running conditions after start up.5.2 Screen display Operation5.2.1 Dynamic process displays and group displaysProduction processes are monitored and operated by using dynamic process displays. Dynamic process displays shall be with different color coding for on-off valve and motor states, graphical indication and figure indication of tank levels, etc. For normal motors (constant speed, single direction), three operating states (run, stop, fault) shall be indicated with different color.∙Standard loop display of measurements, controls, control switches and etc.shall be used in dynamic process displays for setting of parameters andcontrolling of field equipment.∙Setting of parameters, setting of parameter set points, adjusting of control parameters, setting of alarm limits, integrating of alarm signals shall beeasily made from operator terminals.∙For sequence control, group control, and other similar control systems, there shall be screen displays to indicate the actuation, steps, procedure ofoperations, the state of interlock and starting permissive conditions as wellas other necessary information.5.2.2 Trend∙All variables shall be stored for later trend presentation and they shall be possible for operators to select and create trends accordingly. It shall bepossible for operators to display dynamic trends operation individually or ingroups. It shall be possible for operators to define the parameters included inthe trend displays. It shall be also possible for operators to modify the timecoordinate of tread.∙There shall be control loop tuning displays for each operator terminal for operators to trim the control loop and tuning the control loop. The controlloop tuning displays shall provide trend graphic with suitable time scale forcontrol loop tuning. The trend shall include the measuring variables, setpoints, outputs, etc. The operator shall be able to use the displays for tuningthe PID parameters and other necessary data.∙The memory capacity shall be defined as the system being able to store fifteen thirty days6080%of analog I/Os, and the data-samplingtime shall be 2 seconds. The system shall have on-line capacity to store andretrieve seven days of trends for all analog and discrete inputs, outputs, setpoints and calculated values. Floppy diskette and CD storage for on-linestorage of trend data is not allowed.∙It shall be possible to expand or compress the time base of the displayed trends on-line. It shall be also possible to change sampling rate and retentionrate on-line5.2.3 Operation recordAll the important operation at each operator station (for instance motor on/off, valve on/off) shall be recorded in details by the system. Detailed data to be recorded will be determined in project liaison meeting.5.3 Data Historian∙Historian application shall be available to collect real-time process data and store them for use by other applications such as logging, trending, dataArchiving and open data export.∙Data collection and storage rate, retention span and collection options (average, minimum and instantaneous) shall be able to be set and modifiedon-line.∙The Seller shall describe the maximum tag capacity of data collection and available means for open data export.5.4 Alarms∙Process variables in the alarm state shall be shown in the related dynamic operating displays with colors different to those of normal values.∙All the displays of operator terminals in the same production department shall provide an alarm strip area to display all the existing current alarming ofthis department.∙All operator terminals shall provide alarm summary display of the related department. The alarms shall be arranged chronologically. The initial andterminal time of the alarm and the acknowledgement shall be shown in thisdisplay.∙Alarms shall be able to be:-divided into DCS system alarms and process alarms-Masked, when they are irrelevant (e.g. during a start-up or shutdown)-Arranged chronologically according to time of appearance-Prioritize-*Grouped and first alarm function. The first alarm recognition time should be at least within 20ms.5.5 Reporting and logging∙Summary logs shall be available to examine the status of system database and create lists of all points, which match certain criteria.∙Operator shall be able to schedule printing for both logs and spreadsheet type reports, either on time or event basis.∙Any printer on network shall be capable for printing of these logs and reports. It shall be possible for operator to assign a printer as the backupprinter for all logs and reports.5.5.1 Production Report∙The production report shall be including-Shift report-Day report-Month report-Other necessary reports (such as batch report, reel report, etc.)5.5.2 Event Printing∙The event printing shall be performed on the alarm printer and chronologically arranged in the same printing report.∙Event logs shall be capable to examine historical database and create lists of all events, which occurred within a specific time span. Events filtering andselection shall be available.5.6 T echnical requirements to operator station monitorColor LCD for operator station shall be supplied. The screen diagonal dimension shall not be less than 1921”. The screen r esolution shall not be less than 1280 x 1024 (horizontal x vertical), The spot distance shall be 0.24mm. Contrast less than 700:1, average lightness (cd/m2) less than 700. Keyboard, mouse or track ball shall be included in the operation station.5.7 Printers and DVD rewriter5.7.1 The printers shall be-Prints shall be of network connectedReport printers shall be of laser printersEvent printers shall be of matrix printer-Designed for continuous operation (24 hours, 0 …100 % printing rate)-Remote input control, automatic on-off control-Manual/automatic shift-132 characters per line-With device failure signal-Low noise operation-Max. distance between printer and the CPU shall be 200m.5.7.2 The DVD rewriters shall bePortable, USB interface5.8 Colored Hardcopy deviceIt shall be possible to copy any screen display with the hardcopy unit in full color.The Hardcopy device shall be-in A4 format-colored-1200dpi resolution-remote input control-length of cable running to the central processing unit max. 200m5.9 Operation station5.9.1 The operation station is used to support operation of the operator terminal; tocarry out calculations and control functions which are not suitable to be realized on the process station; to communicate with process station, the system network and to perform other communications. The operation station shall have the function of database.The operation station display should be able to be switched between Chinese and English, and the display should be refreshed within at least 1 second.The operator station shall be provided with the functions of log-in permission, necessary double log-in authorization for important machine, and operation record for further investigation for the operating of important machine.The operation display shall be easy to understand, friendly interface, and Windows and Internet as well based technology.With sufficient on-line help function.The operator display shall provide full screen window operation, and monitor all analog circuit and digital devices of the system. Displaying of part of the system, detailed system, trends, help functions shall able to be performed with functions of pop-up windows. Operator can choose either full screen display or pop-up display.The display shall be fully functionalized in operation through menus. Operator can directly select window and / or display, control mode, and operation function with mouse and / or track ball. Any window or display can be accessed / activated through menu and tool bar in the window through mouse. The window shall be able to be activated by less than double clicks.5.9.2 CPU shall be of 32 bit at least.5.9.3 The operator station has to be state of the art, special for industry applicationwith high performance and the brand of the operator stations are not allowed to be no-name.5.10 Process station5.10.1 The process stations shall perform all the functions which are necessary tocontrol the process, including process continuous control, motor control, remote valve control, interlocking, group control, sequence control and other controls.The process stations shall also have the functions of calculation, small-scale advanced control, self-tuning control and etc. The process stations shall connect to and communicate with the operation stations via communication bus. The controller applied in the system by the tenderer shall perform the function of self-adapt PID data setting, repeat application, and shall meet the requirements of IEC-6113-3 standard control.5.10.2 Calculation of the capacity for system hardware, CPU and memory shall bemade by the Seller based on the scope of supply specified in this document and its experiences in paper mill applications. Calculation of the capacity shall be made based on the following scanning cycle:Analog loop: 500msStandard motor control: 1sOn/Off valve: 500ms*5.10.3 The loop scanning cycle shall be variable and selectable. The min. scanning time for certain loops should be possible to set 40ms.*5.10.4 CPU shall be of 32 bit at least. The loadability of analog output should be at least 700Ω.5.10.5 The delivery shall include:∙Cabinets with mounting racks∙CPU, memory, A/D, D/A, processing units, interface and other necessary electronic units, etc.∙I/O cards and terminal strips for external connections∙Main power supply incoming, internal power supply, earthing, ventilation, etc.∙Internal wiring and cabling5.10.6 Connections of field instruments and motor controls∙The standard signals are:AO 4 - 20mA, 24VDCAIA 4 –20mA, 220V AC or 24VDC(external power)AIP 4 - 20mA, 24VDCDI 24VDCDO 24VDC or 220V AC∙The power supply for analog output and for analog input signal from passive mode (2-wire) transmitter shall be from AO card or AI card respectively.Loop wise fuses or other means of protection for over voltage, over currentand short circuit as well as failure indication shall be provided on the cards.Power supply for active mode (4-wire) transmitters shall be provided by theBuyer.∙DI and DO shall be powered from the power supply in DCS. 220V AC DI/DO will be separated by relays, and all the relays will be in centralizedarrangements according to different control rooms.∙The DO signals interlocking with other systems (if hardwire connected) must be dry contact signals.。