internship report

NBPS

CHAPTER-1INTRODUCTION

Yokogawa Electric Corporation is a Japanese electrical engineering and software

company, with businesses based on its measurement, control, and information

technologies. It has a global workforce of over 19,000 employees, 88 subsidiary and

3 affiliated companies operating in 56 countries. The company is listed on the Tokyo

Stock Exchange and is a constituent of the Nikkei 225 stock index.

Yokogawa pioneered the development of distributed control systems and introduced its

Centum series DCS in 1975. Some of Yokogawa's most recognizable products

are production control systems, test and measurement instruments, pressure transmitters,

flow meters, oxygen analyzers, field bus instruments, Manufacturing Execution Systems

and Advanced Process Control.

1.HISTORY

Yokogawa traces its roots back to 1915, when Dr. Tamisuke Yokogawa, a renowned

architect, established an electric meter research institute in Shibuya, Tokyo. After

pioneering the development and production of electric meters in Japan, this enterprise

was incorporated in 1920 as Yokogawa Electric Works Ltd.

In 1933 Yokogawa began the research and manufacture of aircraft instruments and flow,

temperature, and pressure controllers. In the years following the war, Yokogawa went

public, developed its first electronic recorders, signed a technical assistance agreement

for industrial instruments with the U.S. firm Foxboro, and opened its first overseas sales

office (New York).

In the 1960s the company made a full-scale entry into the industrial analyzer market and

launched the development, manufacturing, and sales of vortex flow meters, and in the

decade following established its first manufacturing plant outside Japan (Singapore),

opened a sales office in Europe, and became one of the first companies to bring a

distributed process control system to market.

MECS,EIE-DSCE

NBPS

In 1983 Yokogawa merged with Hokushin Electric Works and, towards the end of the

decade, entered the high-frequency measuring instrument business. In the 1990s,

Yokogawa established an office in Bahrain to oversee its business in the Middle East and

entered the confocal scanner and biotechnology businesses.

In 2002 the firm continued its growth with the acquisition of Ando Electric, and in 2005

set the stage for a new level of globalization in its industrial automation business with the

establishment of Yokogawa Electric International in Singapore. In 2008 the company

entered the drug discovery support market with a new bio test system.

2. BUSINESSES

2.1 Chemical

Being a producer in the chemical industry has become more and more challenging over

the years. Customer needs for products, pricing, and delivery are more demanding and

material requirements have become complex and ever-changing. Additionally,

compliance in environment health, safety and security have always been primary

requirements to do business. Throughout the years, Yokogawa has partnered with many

chemical companies to provide technology solutions that help overcome these challenges.

2.1.1 Bulk & Petrochemical

Whether you produce petrochemicals, in organics or intermediates, chemical companies

are under cost and margin pressures to deliver products in a timely and efficient manner

while maintaining safe and compliant operations. Additionally, chemical companies need

to adjust to fluctuating feedstock and energy prices and to provide the most profitable

product mix to the market.Yokogawa has been serving the automation needs of the bulk

chemical market globally and is the recognized leader in this market.

2.1.2 Ammonia

Ammonia producers are faced with rapid growth combined with many older control

systems. Growth is driven by global demand for fertilizer and supported by cheap and

plentiful shale gas.

MECS,EIE-DSCE

NBPS

Yokogawa is the leading automation supplier to the ammonia and methanol industry. Our

reputation for reliability, along with global install base in ammonia with Main

Automation Contractor capabilities translate to lowest total life-cycle cost to customers.

Yokogawa has unique analytical offerings such as TDLS and a KBR partnership with

process licenses in 54% of North American install base and will use Yokogawa

automation technology as part of the process license.

2.1.3 Specialty & Fine Chemical

Specialty Chemical plants typically rely on batch production processes, which adds a

level of complex procedural requirements to a control system. The emphasis with a batch

process is having a control system that allows great flexibility in making adjustments to

formulas, procedures, and the like. Control systems need to be managed in available

quality history of product, and to be able to execute non-routine operations. With its

extensive product portfolio, experienced systems engineers, and global sales and service

network, Yokogawa has a world class solution for Specialty Chemical Batch

applications.

2.1.4 Lube Oil Blending

In Lubricant and Grease manufacturing there are ever-changing complex formations

whether material is processed in an in-line blending system or in a batch process. This

emphasis, requires a control system that allows great flexibility in making adjustments to

formulas, procedures, and need to be managed in available quality history of product, and

to be able to execute non-routine operations.

With its extensive product portfolio, experienced systems engineers, and global sales and

service network, Yokogawa has world class solutions for lubricant manufacturing

applications in many areas such as:

Recipe Validation

Automatic valve sequencing

Blend Property control

Advanced Monitoring of Emergency Stop Conditions

Property trimming control

MECS,EIE-DSCE

NBPS

Flexible Batch sequencing

Terminal Automation

Tank Farm Inventory measurement and tracking

ERP Workflow and production interfacing

Advanced LIMS interfacing

Path and product transfer line compatibility management

2.2 Oil & Gas Upstream

Upstream automation is focused on the drilling, completion, extraction, and separation

components of the oil and gas ecosystem, leading up to midstream transport and

downstream processing and conversion. The upstream industry includes offshore and

onshore activities including wellhead automation, fractionation, completion, and

separation to recover and prepare underground or underwater crude oil and natural gas.

As petroleum is brought to the surface, it must be separated prior to transport. Primary

and secondary separation stages commonly distribute gas flow, water flow, and oil flow

in three phase separation. Gas movement requires pipeline and can include a fractionation

process in the upstream stage prior to movement. Liquids can be placed into a tanks or

pipelines and sent for processing, requiring accurate level measurements.

2.2.1Onshore

The onshore upstream industry faces ever higher demands and greater challenges with

increasingly difficult and hostile environments in which it must operate. As the

unconventional natural gas resources opportunities, particularly shale gas, are growing in

North America, Yokogawa's total solution plays an important role helping customers

meet the challenges of reducing both CAPEX and OPEX, while enhanced built-in

technologies increase production.

2.2.2Offshore

Offshore exploration and production requires maximum uptime under harsh conditions.

Manned and unmanned facilities need reliable integrated control and safety systems

(ICSS) with advanced remote monitoring capabilities. Yokogawa has state-of-the-art

MECS,EIE-DSCE

NBPS

technology and extensive experience in executing offshore projects of all sizes and

automation levels of complexity.

2.3 Oil & Gas Midstream

Yokogawa's innovative technology platforms and industry leading execution is well

regarded in the global marketplace as a solutions partner pioneering the integration of

technologies for all aspects of the oil & gas ecosystem from reservoir to enterprise.

Proven solutions that include predicative business modeling, plant optimization and

highly reliable automation platforms are assisting midstream operators to run their

businesses at the optimal efficiencies.

2.3.1 Pipeline

Pipelines and Local Distribution Companies (LDCs) provide an essential service by

transporting and delivering natural gas, crude oil and refined petroleum products safely

and efficiently. Pipeline SCADA and automation systems are required for monitoring and

control of pump and compressor stations, meter stations, storage fields, terminals and

other assets.

2.3.2 Gas Processing

The midstream natural gas gathering and processing industry is experiencing incredible

growth driven by the shale play revolution. The industry is challenged with managing

growth and profitability under constantly fluctuating economic and operational

conditions. A comprehensive solution that includes predictive business modeling, plant

optimization, and industrial automation is required. With the recently announced strategic

alliance between Yokogawa and eSimulation, a comprehensive platform is now available

to help manage and optimize economic and operational interactions across the enterprise.

2.4 LNG Supply Chain

For over 30 years, Yokogawa has delivered field proven engineering, automation,

measurement and control solutions to the LNG industry to help reduce project risk and

MECS,EIE-DSCE

NBPS

implementation cost. With availability of 99.99999%+ across more than 20,000 installed

systems, you can depend on Yokogawa as your global LNG Automation Partner.

2.5 Power

In the mid 1970s, Yokogawa entered the power business with the release of the EBS

Electric Control System. Since then, Yokogawa has steadfastly continued with the

development of our technologies and capabilities for providing the best services and

solutions to our customers worldwide. Yokogawa has operated the global power solutions

network to play a more active role in the dynamic global power market. This has allowed

closer teamwork within Yokogawa, bringing together our global resources and industry

know-how. Yokogawa's power industry experts work together to bring each customer the

solution that best suits their sophisticated requirements.

2.5.1 Renewable Energy

The use of renewable energy protects the environment and takes both society and

industry closer to the goal of achieving sustainability. However, compared to

conventional energy sources, there are certain challenges that stand in the way of its rapid

adoption, such as higher production costs and greater instability in the supply of power to

the grid. As a leading company in the control and instrumentation business, Yokogawa

has always striven to help its customers in various industries achieve stable operations

and improve productivity in their plants. Based on our Vigilant Plant concept for

attaining operational excellence, we are providing solutions that pave the way to the use

of renewable energy sources.

2.6 Refining

In the ever changing marketplace, refineries are seen not only as crude processing units

but also as profit centers. At the same time, there is a keen awareness of the need for

safety at such facilities. A total production solution that encompasses planning,

scheduling, management, and control is required to achieve long-term goals for

profitability, efficiency, and environmental protection.

MECS,EIE-DSCE

NBPS

2.7 Water & Wastewater

Yokogawa delivers cost benefit solutions through the water and wastewater plant controls

and instrumentation. This improves the performance of plants and ensures that they can

operate competitively in today's water markets, and also reduces their operation costs.

Yokogawa assists plant owners to identify areas of plant operations that benefit from

modern controls running on the latest digital control system platform, with modern field

instrumentation. Yokogawa supports a wide range of control applications in both

municipal and industry market.

2.8 Pharmaceutical

The pharmaceutical industry currently faces a major challenge in taking full advantage of

the opportunities presented in large emerging markets. And more than ever,

pharmaceutical companies need to introduce lean manufacturing techniques that will

enhance profitability. As one of the world's leading industrial automation suppliers,

Yokogawa is committed to delivering the best possible solutions for your best

manufacturing practices.

2.9 Metal Mining, Cement & Glass

Mining operations produces valuable minerals or geolocial materials from the Earth.

Economical recovery often requires high throughput and high availability of the process

with low operation costs, and stringent safety and environmental regulations. Similarly,

float glass production and automated production of cement in process kilns can benefit

from capital investments in energy efficiency, advanced process control, and

environmental compliance.

Yokogawa provides integrated production control systems (DCS), transmitters, magnetic

flowmeters, pH analyzers and a local area plant network. The fully redundant DCS

enables high process availability at an economical cost. Integration of the motor

protection relay diagnostics into the control system significantly reduces maintenance

times.

MECS,EIE-DSCE

NBPS

2.10 Food & Beverage, Pulp & Paper, Iron & Steel

Industry leaders striving for operational excellence will benefit from a new vigilant

approach to plant automation. Yokogawa helps you see, know and act with greater

confidence and ease with field-proven tools and services.

3. PRODUCTS & PLATFORMS

3.1 Distributed Control System (DCS)

Yokogawa offers multiple automation and control strategies, architectures, and solutions

for every application size and complexity. Our distributed control system (DCS) is

designed for large, complex industrial processes, and geographically distributed

applications. The DCS can employ advanced process/supervisory control applications,

operator-centric, enterprise-integrated information, configuring disparate systems into a

holistic process overview and coordinated control strategy. A DCS utilizes a more

distributed node topology and is often implemented with Yokogawa as a single source of

responsibility. CENTUM VP is the latest generation of the CENTUM DCS series.

CENTUM VP features unrivaled 99.99999% availability along with an intuitive human

machine interface and a versatile field control station suitable for both large and small

scale data processing tasks.

3.2 Safety Instrumented Systems (SIS)

Industrial processes and plants increasingly experience concern about potential incidents

that can affect people, assets and the environment in and outside the plant. A safety

instrumented system (SIS) can dramatically reduce the risk of accidents in your plant.

The ANSI/ISA 84 functional safety standards is widely used to implement safety

instrumented systems and are 'good engineering practices in relation to Process Safety

Management' (OSHA PSM 29 CFR Part 1910).In the continuously evolving process

industry, the need for expansion and upgrades of aging safety platforms and

infrastructures is undeniable. Yokogawa understands your need to implement a safety

system that is compliant with the new safety regulations, such as the ANSI/ISA 84 and

NFPA standards.

MECS,EIE-DSCE

NBPS

Our expertise covers all major applications such as ESD (Emergency Shut Down), F&G

or FGS (Fire and Gas Systems), BMS (Burner or Boiler Management Systems) as well as

HIPPS or HIPS (High Integrity (Pipeline) Protection Systems).

Yokogawa has over 50 years of experience in the development and implementation of

safety systems and is the world's most trusted automation solutions partner for efficient

project execution and safety system solutions.

3.3 SCADA Systems

Supervisory control and data acquisition (SCADA) systems are typically used for

monitoring and control of small or large-scale processes which can span multiple sites

across large distances. Common applications include oil & gas production fields,

pipelines, water and wastewater. Yokogawa's SCADA portfolio includes hardware and

software SCADA technologies.

3.4 Process Controllers (PID/PLC/RTU)

Process controllers maintain an environment based on a set of specific rules by reading

levels, temperatures, pressures and speeds, adjusting them to meet application

requirements.

3.5 Field Instruments

Yokogawa field instrument products includes a complete line of flowmeters, pressure

transmitters, differential pressure transmitters, temperature transmitters, level

transmitters, Fieldbus instruments and safety measurement instrumentation.

3.6 Process Analyzers

Process analyzers are on-line tools for industrial process analytics. They are used to

determine the chemical composition or physical properties of substances involved in

industrial processes. They enable process optimization, asset protection, and compliance

with environmental regulations. With one of the most comprehensive families of sensors

and on-line analyzers for pH, conductivity, dissolved oxygen, combustion oxygen,

humidity, liquid and gas density and process gas chromatography.

MECS,EIE-DSCE

NBPS

Yokogawa is recognized as a world leader in the field of analytical equipment. Accurate,

repeatable measurement is the key to obtaining optimal results in your process, and

Yokogawa's diagnostic-based analytical instrumentation offers the flexibility to meet a

range of individual requirements. Whether for liquid or gas applications, our analyzers

can resolve even the most demanding situations. Yokogawa's leadership in process

analytics helps to protect the environment by reducing energy consumption and

CO2 emissions.

3.7 Data Acquisition

Data acquisition (DAQ) is the measurement, recording, analyzing, and presentation of

real world phenomena. It includes electrical measurements such as voltage, current,

power as well as measurements through sensors and transducers including temperature,

pressure, flow, level, strain, acceleration, pH, humidity, and more.

Selecting the ideal data acquisition components or solution depends on your application.

Typical factors include sample rates, channel scalability, signal conditioning, sensor

types, analysis capability, mobility, and environmental conditions.

Yokogawa data acquisition solutions are recognized for industry leading measurement

accuracy, noise tolerance, and build quality. These include most industrial networking

protocols, all-in-one architectures, and typically require no programming.

3.8 Industrial Networking

Getting measurement and control signals to and from your instruments is central to your

automation strategy. Yokogawa supports a wide variety of Fieldbus technologies,

including conventional 4-20mA, wired digital networks, and wireless ISA100.11a. These

technologies are employed at the device, host, and solution level, depending on your

needs.

MECS,EIE-DSCE

NBPS

3.9 Test & Measurement Instruments

Yokogawa has been developing measurement solutions for nearly 100 years, consistently

finding new ways to give R&D teams the tools they need to gain the best insights from

their measurement strategies. As well as offering a wide ranging product lineup and an

extensive range of calibration and other services, the company has pioneered accurate

power measurement throughout its history, and is the market leader in digital power

analyzers.

Yokogawa instruments are renowned for maintaining high levels of precision and for

continuing to deliver value for far longer than the typical shelf-life of such equipment.

Yokogawa believes that precise and effective measurement lies at the heart of successful

innovation – and has focused its own R&D on providing the tools that researchers and

engineers need to address challenges great and small.

Yokogawa takes pride in its reputation for quality, both in the products it delivers – often

adding new features in response to specific client requests – and the level of service and

advice provided to clients, helping to devise measurement strategies for even the most

challenging environments.

4. SOLUTIONS

4.1 Production Management

Production Management consists of systems and methods that are used to control and

optimize the manufacturing of products and materials in industrial plants and facilities.

Software solutions used in the role range from advanced multi-variable process control to

Manufacturing Operations Management (MOM) solutions or Manufacturing Execution

Systems (MES). Yokogawa provides many solutions in this area including Process

Information Management Systems (PIMS) and Operations Management through to real-

time model based process control and optimization.

4.2 Alarm Management

A widespread issue in manufacturing plants is alarm overload. As formerly independent

systems are integrated for more effective operation by fewer operators, each operator has

to monitor an increasingly wider area and consequently deal with more alarms. Without

MECS,EIE-DSCE

NBPS

rigorous alarm rationalization efforts, alarm flooding becomes a serious problem and

increases the risk of safety and environmental incidents.There are a number of documents

such as EEMUA #191 and ISA 18.2 that help customers reduce alarms, but practical

tools that can be implemented are still in short supply. Yokogawa proposes a smart

approach to alarm management that helps customers achieve safe and agile plant

operations based on the concept of combining practical bottom-up solutions with

fundamental top-down improvements.

Yokogawa urges customers facing alarm flooding situations in their plants to introduce

CAMS for HIS. It also benefits those who are looking for alarm management capabilities

that go beyond the current generation of DCS alarm systems. Customers planning to

consolidate their control rooms and design their alarm system to be in compliance with

the ISA 18.2 standard will benefit from this product's practical and immediate solutions.

4.3 Process Safety Management

Process safety management (PSM) is a regulation from the US. Occupational Safety and

Health and Administration (OSHA) applicable to all processes that engage in the

production, movement, storage or use of any Highly Hazardous Chemicals as defined in

OSHA (29 CFE 1910.119). The intent of the regulation is to reduce the severity and

frequency of incidents resulting from the release of chemicals and other energy sources.

OSHA's standard emphasizes s a comprehensive management program that integrates

technologies, procedures, and management practices. Yokogawa has dedicated services

and solutions to help our customers meet these regulations and protect their employees

and assets.

4.4 Operator Effectiveness

Recognizing that an operational error in process plants is one of the major reasons for

significant financial losses, Yokogawa has introduced Advanced Decision Support (ADS)

to assist operators in making the right decisions at times of increased stress such as

during the initial stages of operation or during abnormal conditions. The ADS concept is

MECS,EIE-DSCE

NBPS

designed to use best practices to assist operators in semi-structured or unstructured

decision-making processes to support their judgment.

ADS consists of three key functions, alarm management, HMI management, and

procedure management implemented in the Process Control System. ADS is a consulting

methodology based on Yokogawa consultants specializing in fields such as knowledge

engineering and ergonomic design. This combination can help customers effectively

integrate, engineer and operate the above mentioned functions based upon ISA18.2,

ISA101 and ISA106 standardized approaches.

4.5 Operator Training Simulators

Make every operator your best operator. Operator Training Simulators simulate your

process. Operators can practice startup and shutdown procedures in a safe environment,

before the actual event. Induce problems so if they are encountered during the startup

and shutdown (or normal running) the operator already knows the solution. Simulation

fidelity can be low, medium or high depending on your needs.

4.6 Vertical Market Solutions

Yokogawa offers a myriad of focused solutions that address customer's operational issues

and improve accounting accuracy, asset and energy management, and optimize

production and inventory management.

5.SERVICES

5.1 Engineering Services

Yokogawa delivers a total automation solution, covering the entire lifecycle of projects,

as your automation partner. This proven method brings experience, engineering,

technology, safety, and lifecycle support. It reduces risk and lowers overall costs.

5.2 Instrumentation Services

Yokogawa offers a variety of instrumentation services including:

Calibration and Certification

Installation / Loop Check / Startup

MECS,EIE-DSCE

NBPS

Preventative and Corrective Maintenance Services

Emergency Repair

Programming and Troubleshooting

Factory Repair / Flow Testing.

5.3 Calibration and Certification

On-site calibrations are performed in accordance with agreed to schedules to ensure

specific industry regulatory standards are fully met. All equipment used is certified and

fully traceable according to the National Institute of Standards and Technology (NIST).

All work is fully documented and calibration stickers are included for individual devices.

5.4 Installation / Loop Check / Startup

Yokogawa will provide cost effective installation, loop check and startup solutions that

can be ordered with your initial product purchase. Installation will be performed to

manufacturer's specifications. Loop check will be performed to verify that the expected

output to the final control element is produced. Startup will include functional tests and

on-site configuration of instruments and analytical products. This ensures dependable and

timely startup and continued operation.

5.5 Preventative and Corrective Maintenance Services

When telephone support cannot solve an immediate problem, emergency on- site

assistance may be necessary. An experienced field Service Specialist will be dispatched

to your plant. Yokogawa can provide programming, optimization, repair or replacement

for all manufacturers' equipment.

5.6 Emergency Repair

Testing Yokogawa can perform repair and calibration on the full line of Yokogawa

instrumentation. Preventative maintenance services help maximize the performance of

instrumentation and control equipment. It ensures proper operation by utilizing advanced

predictive maintenance diagnostics, cleaning and periodic maintenance including

consumable replacements. Corrective maintenance service contracts are available for

MECS,EIE-DSCE

NBPS

customers requiring specific response times for crucial processes. Yokogawa utilizes

advanced diagnostic and repair practices to resolve issues quickly.

MECS,EIE-DSCE

NBPS

CHAPTER 2ABOUT THE DEPARTMENT

The department is called as Engineering Centre. The projects taken up will follow the

below steps:

1.Major activities in project engineering:

1.1 IKOM(internal kick-off meeting)

1.2 Sale order updation

1.3 CKOM (customer kick-off meeting)

1.4 Basic engineering

1.5 Detailed engineering

1.6 SDM(system definition meeting)

1.7 Design review

1.8 Transfer of documents to panel department for manufacturing

1.9 Staging

1.10 Pre FAT

1.11 FAT

1.12 Dispatch advice

1.13 Dispatch of system to site

1.14 Final documentation

1.15 Job transfer to FES

1.1 IKOM(Internal Kick-Off Meeting)

1.1.1 Sales and Projects

The following points to be discussed and documents to be collected from sales.

Project Overview, background, customer and Project Significant

Clarify the Project Requirements

Scope of work

Project Schedule and plan

Discuss project deliverable

Project Risk Identification and Analysis.

Distribute contact list

MECS,EIE-DSCE

NBPS

Issue list

Minutes of Meeting with sales

1.1.2 Documents from Sales:

Customer Enquiry

Final Sales Offer

Deviation List

MOM & other Correspondences

LOI/PO/PR

Special Requirement

Delivery Date

Scope of work

Agreed T&C

Man-hour estimate by Sales

Project costing by sales

Project Schedule by Sales

1.1.3 IKOM output documents:

Output documents from projects department:

New Job Intimation to all concerned

Project charter

Man Hour Estimation

Project Costing by Projects

Risk Register

1.2 Sale Order Up-Dation: Sale Order Updation (SAP) for Factory Material , Product

and Bought-Outs based on IKOM.

1.3 CKOM(Customer Kick-Off Meeting)

Objective of the Customer Kick off Meeting is to collect the Engineering Input

documents from Customer(i.e., IO list, functional Specification & Operation Philosophy

etc.). If required site survey also to be done.The following document to get approval from

customer during CKOM meeting.

MECS,EIE-DSCE

NBPS

Document Index & Schedule

Customer Document Index & Schedule

Communication Protocol

Project Team Orgainzation

1.4 Basic Engineering Documents

SCD(System Configuration Drawing)

BOM(Bill of Material)

Channel Base Drawing

Power Consumption & Heat Dissipation

Power Distribution Drawing

Grounding Scheme

Control Room Layout

Cabinet General Specification

1.5 Detailed Engineering Documents

Typical GA & IA Drawing

Typical Console Drawing

Typical Loops

Typical Channel base Drawing

Grounding Scheme

Functional Design Specification(FDS)

Nest Loading & Front Loading

Interconnection cable Schedule

FAT Procedure

1.6 SDM(System Definition Meeting)

System Definition meeting is to finalize all the typical engineering documents.

Project philosophy to be finalized.

MECS,EIE-DSCE

NBPS

1.7 Design Review Meeting

Design review meeting is to get all engineering document approval.

1.8 Transfer of documents to MFG/ panel department for manufaturing

The following document to be transfer to Manufacturing department to start

manufacturing activities.

GA & IA of System/PDB Cabinet

GA & IA of Marshaling Cabinet

GA & IA of consoles

Manufacturing Specification

Printer table drawing

1.9 Staging

All the material collected from stores and stage it in factory for testing.

1.10 Pre-FAT: PRE-FAT will be conducted as per FAT Procedure

1.11 FAT FAT will be conducted as per Approved FAT Procedure document.

1.12 DISPATCH ADVISE

Dispatch Advise issued to Logistic department for dispatching the materials.

After dispatch the material Logistic department will issue Packing list to Project

department.

1.13 DISPATCH OF SYSTEM TO SITE: Material will be dispatched to concern from

Logistic department.

1.14 FINAL DOCUMENTATION: Final Documentation shall be done based FAT

changes and same shall be transmitted to customer.

1.15 JOB TRANSFER TO FES: Documents will be transfer to FES as per Job transfer

to FES check list(QMSE format).

MECS,EIE-DSCE

NBPS

2. Tools & Techniques Used

2.1 Distributed Control Systems - CENTUM VP

CENTUM VP is Yokogawa's latest integrated production control system, also known as a

distributed control system (DCS). Nearly 40 years of knowledge and experience with

DCSs has gone into its development.

CENTUM VP has a more intuitive human machine interface and power field control

stations capable of processing data faster and more reliably. Thanks to features such as a

pair & spare CPU configuration, CENTUM VP achieves 99.99999% (seven-9s)

availability.

CENTUM VP is the core platform of Yokogawa's Vigilant Plant solutions, that are

designed to achieve the ideal plant. CENTUM VP also is a highly reliable platform that

provides system operators integrated access to intelligent instrumentation diagnostics and

subsystem data.

CENTUM VP complies with the rules and requirements of the VGB R170C guidelines

developed by VGB PowerTech which represents the interests of power plant operators as

well as power industry related manufacturers and institutions.

CENTUM VP consists of four components which are operation and monitoring

functions, engineering functions, control functions, and a network communication

system. It can be flexibly configured to suit the requirements of plants both large and

small in a wide variety of industries.

In addition, integration with ProSafe-RS safety instrumented systems, STARDOM

network-based control systems, and different generations of CENTUM systems extends

its scope of operations.CENTUM VP also manages plant assets with Plant Resource

Manager.

MECS,EIE-DSCE

NBPS

Yokogawa has sold over 25,000 CENTUM projects in all kinds of industrial plants

worldwide such as oil and gas, petrochemicals, chemicals, power, pulp and paper,

pharmaceuticals, food, iron and steel, waste, and water and sewage treatment. The

majority of the customers are from oil and gas, and petrochemical industries. It means

that once the CENTUM system is delivered and start its operation, it has to be in

operation non-stop.

In the past 40 years of experience, Yokogawa is reputed with the high reliability of the

CENTUM system winning customer satisfactions. Yokogawa is engaged in the global

purchase agreements with world major customers as their sole instrumentation supplier.

Yokogawa needs only one project to convince customers of our capability and win trust.

Once Yokogawa system is delivered, customers stay with Yokogawa.

CENTUM VP is designed based on the concept to keep the plant operation availability

high. Customers expect Yokogawa products to perform its functions without failure so

that the plant operations shall not stop. Yokogawa developed our own FCSs so that we

can meet up with the customers’ expectations. Quite a number of FCSs are still in

operation even after 20 or more years passed since those are originally installed. It is

owing to the high quality of the products themselves that has been supported by the total

serviceability such as skilled manufacturing, quality control, after sales service and

appropriate training.

2.2 Batch Automation

Batch automation processes have sequential processing steps each with unique failure

recovery routines. Every project presents unique requirements to achieve safe, flexible,

and expandable solution. CENTUM VP Batch is the ISA-88 (IEC-61512) batch control

package, which provides recipe management and process management functions

interfaced to the CENTUM VP standard unit supervision function.

MECS,EIE-DSCE

NBPS

2.3 Progressive Compatibility

The upgrade path for every CENTUM system is carefully considered as new versions are

developed. Yokogawa's exclusive ownership of CENTUM development throughout the

history of its DCS platform translates into customer benefit during system

upgrades. Since 1975, CENTUM users enjoy the industry's lowest total cost of ownership

over the plant lifecycle with a progressively compatible upgrade path and rock-solid

reliability.

2.4 Agile Project Execution

Agile Project Execution provides new engineering possibilities and changes the way

projects can be planned and executed, reducing risk and adding flexibility to the

schedule.

2.5 Process Safety System ProSafe-RS - World's First Truly Integrated Safety

Controller

Achieving absolute integrity between distributed control systems (DCS) and safety

instrumented systems (SIS) for plant automation has traditionally raised complex design

and integration issues. Conventionally, two separate monitoring and operating

environments were required for a DCS and SIS. Different communications and

distinctive hardware architectures had to be set up. Plant managers striving to optimize

process operations have taken it as a given that project time and expenses would escalate.

Now Yokogawa puts an end to DCS-SIS incompatibility with the new ProSafe-RS, the

world's first truly integrated "safety PLC" for the process industries.

2.6 Process Safety System ProSafe-SLS

Yokogawa is the world's most experienced safety and control firm. Our commitment to

providing reliable, state of the art safety instrumented systems is rooted in a wealth of

installations since 1962.The solid-state, hard-wired ProSafe-SLS covers all requirements

in process industries. The product line covers specific requirements for individual safety

instrumented systems and offers all safety integrity levels (SIL 3-4) for the oil & gas,

MECS,EIE-DSCE

NBPS

petrochemical, chemical industries. ProSafe-SLS safety instrumented system is also fully

integrated with Yokogawa's CENTUM VP/CS 3000 process control system.

2.7 SCADA Systems: SCADA Hardware - STARDOM FCN

2.7.1 Never Interrupts Your Process

High reliability is essential for the systems that control your critical processes. The dual

redundant capability of the field control node (FCN) autonomous controller ensures that

these processes continue without interruption even when a damaged module is replaced.

CPU unit, power supply unit, fieldbus module, and control network can all be

dual redundant.

Automatic switchover to stand-by CPU.

Automatic data transfer from control side to replaced stand-by CPU.

Hot-swappable modules including CPU.

Fault-tolerant design.

2.7.2 Automatic switchover without interrupting your process

If the control-side CPU fails, the stand-by CPU automatically detects this and takes over

control. To maintain consistency, all process data is synchronized on the stand-by and

control-side CPUs. When a hot-swappable CPU module is replaced, the module

automatically functions as the stand-by CPU by synchronizing both application and

database without interrupting the process. No PC tools are required to perform this

synchronization.

2.7.3 Easy Engineering for Redundant Applications

No special engineering work or dedicated CPU modules are required for redundant

applications. The stand-by and control CPUs also use the same spare parts, allowing

users to keep fewer parts in stock.

2.7.4 Minimize TCO by Minimizing Replacements

Power failure during disc access is a major cause of file corruption in the CPU module.

Without having to replace the entire CPU module, it is possible to recover a damaged file

system by replacing just the FCN system card.

MECS,EIE-DSCE

NBPS

2.8 HMI & SCADA Software FAST/TOOLS

HMI and SCADA software allows operating personnel to graphically view, control, and

analyze industrial processes. FAST/TOOLs is scalable from small HMI to enterprise

systems with over a million tags. FAST/TOOLS is a powerful, state-of-the-art, flexible,

distributed operations information and supervisory control system. It is a leading package

utilizing the latest best in class IT technology for these applications and is available on a

wide range of industry-standard computer systems.

FAST/TOOLS provide solutions for a wide range of control and supervisory applications

where, for example one or more of the following requirements apply:

• Multiple Process Site environments

• Integration of third party systems

• Wide Area (Media independent) communication

• Robustness for intermitted communication

• Security against unauthorized access

• Disaster recovery and high availability architecture

• Alarm & Event management, Trending & Reporting

These characteristics are often seen in for instance:

• Oil & Gas production and transport, infrastructure, utilities and energy management

• Critical manufacturing applications It also allows the flexibility of combining different

types of systems to provide hybrid solutions, both on new and existing sites (green and

brown field development).Many global industrial companies and utilities rely on

Yokogawa’s SCADA System FAST/TOOLS. The system is used to manage production

processes while guarding availability and efficiency in a way that maximizes return on

investment and minimizes cost of ownership. FAST/TOOLS success, in many of these

critical applications, is based on its highly reliable open architecture design, support of

quadruple redundancy and its on-line configuration possibilities. These properties

contribute to high efficiency and high quality production processes.

MECS,EIE-DSCE

NBPS

FAST/TOOLS has been developed with a number of key issues in mind, one of which is

the provision of a system that can start small and which can easily grow with short and

long term application needs. This guarantees your investment against premature

obsolescence. Furthermore as a hardware and operating system independent supplier

Yokogawa is committed to the support of standard operating systems, standard network

protocols, standard user interfaces and standard software development tools.

FAST/TOOLS has been developed with over 35 years of experience by combining our

expertise in Supervisory Control And Data Acquisition (SCADA) with requirements

from users and industry leaders. The FAST/TOOLS package is a powerful, modern,

flexible, distributed operations information and control software package. It implements a

Web-based supervisory control human machine interface, OPC server/client functions,

data acquisition from a variety of controllers and devices, alarm management and

historical data management. Furthermore it is a leading system package for operations

control and information integration with business systems and is available on a wide

range of industry standard operating platforms. Many industries and utility companies

with a need for data integration and data integrity use FAST/TOOLS from Yokogawa in

their applications.

FAST/TOOLS is also successful in critical applications due to its very reliable design,

support of redundant and nonstop systems and its on-line configuration capabilities.

These properties contribute to high efficiency and high quality production processes.

FAST/TOOLS has been developed with a number of key issues in mind, one of which is

to provide a system that can start small and which can easily grow with client needs, both

in the short and long term. This philosophy protects against premature obsolescence. The

consequence of being a hardware independent supplier means support of standard

operating systems, standard network protocols, standard user interfaces and standard

software development tools.

FAST/TOOLS provides solution possibilities in a wide range of control execution

applications with the following characteristics:

MECS,EIE-DSCE

NBPS

• Multiple Process Site environments

• PLC/RTU based control systems

• Wide area communication

• Intensive (mission critical) control performed by subsystems

• Relatively high content sequential (logic) control.

These characteristics are often seen in for example Oil & Gas production and transport,

infrastructure, utilities monitoring and control and high performance manufacturing

applications. It also allows the flexibility of combining different types of systems to

provide hybrid solutions, both on new and existing sites (green and brown field

development).

FAST/TOOLS has a truly User Environment. All the workflow processes, business logic,

and database links were designed after careful studies both technical and ergonomically.

It’s built to work autonomously in a web-based user environment and can be extended

with new applications. Web-based applications can easily access legacy data on other

platforms. Typically interactive, the application accepts input from the web user,

processes the input, and displays the results. Information is stored on BuildLinks’ servers

and the access is obtained via secure logins.

Applications and process information can be rapidly deployed and is easily maintained

centrally on the server. This so called “zero deployment” means that client applications

can be run from any web-browser and the users always get the most recent version of an

application. There is no need to manage licenses and software installations on the client

side and no application files need to be copied over and no communication configurations

need to be setup. Benefits include faster application deliverys increased IT productivity,

and widely accepted technology.

Other benefits of a user environment are:

• Information can be accessed anywhere an Internet connection is available.

• The information is ‘real-time’ (no waiting time for critical information).

MECS,EIE-DSCE

NBPS

• The information is more secure than it would be on a personal computer.

• Upgrades containing new functions and enhancements are free and automatically

deployed there is no need to manually install software or license keys.

The FAST/TOOLS Web HMI consists of a Web HMI Server and a Web HMI Client

component that can either run separate from the FAST/TOOLS Server or be installed

altogether with the FAST/TOOLS Server environment on a standalone node. Installing

the Web HMI Server on a separate node has the advantage that load can be shared

between the FAST/TOOLS Server and Web HMI Server.

FAST/TOOLS has a true client/server architecture, which is not limited to stand-alone

stations, and allows for distributed functionality. Front-end Servers give the possibility to

reduce the load on the SCADA Server by preprocessing data on remote locations and

passing through only relevant data. Configuration of these stations is stored on the

SCADA Server and is automatically deployed to the Front-end Servers. There is no need

for the engineer to visit the remote locations. SCADA and Front-end Servers can run one

or more I/O-drivers per node, e.g. a configuration could be an application running up to

70 I/O-drivers at the same time on one node, using for example only three network

connections available to connect to the 70 remote PLC/RTU devices. Where system

availability is a prime issue FAST/TOOLS can be configured to run in a redundant

configuration. Several redundancy concepts are available as a standard, illustrating the

flexibility of FAST/TOOLS. Examples are dual or triple server configurations, redundant

networks between the SCADA system servers and clients and/ or between SCADA

system servers and PLC’s, RTU’s, etc. With the exception that Front-end servers can

only be configured as a single server entry.

2.9 STARDOM

The STARDOM is the first system rolled out as a Yokogawa network-based control

system (NCS). An NCS proposes an architecture designed for the e-business era. The

increasingly common business practice of E-commerce provides an environment for

swiftly responding to changes in market demand in many industries. However, these

MECS,EIE-DSCE

NBPS

industries have now come to require a new system architecture for industrial control

systems. An NCS meets these emerging new requirements and offers high flexibility to

build a superior control system, i.e., a system befitting each user’s purpose.

The STARDOM is an NCS that embodies Yokogawa’s expertise in the industrial

automation market. Reliability, operability, flexibility, scalability, and other keys for

implementing functionality in an industrial control system are all featured in the

STARDOM. The STARDOM allows users to enjoy the merits of important information

technologies such as, Web, Java, and security as part of the system. The use of a variety

of these ITs allows an open system to be configured more flexibly to suit each user’s

intended application e-commerce, supply chain management without having knowledge

of particular systems.

Besides, the STARDOM is a Commercial Off-The Shelf (COTS) system, thus slashing

the total costs of ownership. Also offered by the STARDOM is a new way of operation

and monitoring using a VDS Viewer as the human interface. This means that whatever

the operation and monitoring task, it can be performed anytime, anywhere with a thin

client as a COTS platform. Its control network can be any TCP/IP-based network such as

an Ethernet, fiber distributed data interface, or wireless satellite communication network,

and a variety of communication protocols in the control layer can be combined with the

system.

The STARDOM consists of the following highly independent components:

FCN (an acronym of Field Control Node) is a modulus controller assembled with CPU,

I/O, and other modules as necessary. It supports a variety of I/O modules, has superb

expandability, and can build a highly reliable system with its power supply, CPU, and

control network duplexed.

FCN-RTU (Low power Autonomous controller) is a modulus controller assembled with

a CPU module with built-in analog,digital I/O,communication ports. Up to eight arbitrary

I/O module can be installed (with long base module). FCN-RTU can be used wide

temperature range and high altitude place.

MECS,EIE-DSCE

NBPS

FCJ (an acronym of Field Control Junction) is an allin-one controller with a built-in I/O

interface, ideal for installing inside machine equipment as well as configuring a

distributed system. Besides, its control network can be duplexed.

2.10 VDS Versatile Data Server Software: VDS is a software package that runs under a

Windows operating system and implements a Web-based human machine interface, OPC

server functions, data acquisition from a variety of controllers and devices, and historical

data management.

Other features include:

• Graphic windows for operation and monitoring, are enabled by HMI server and HMI

client (VDS Viewer) mechanism.

• Object-oriented, COM/DCOM-enabled data sever

• Optionally duplexed network that links autonomous controllers with readily available

Ethernet devices.

• Link with not merely autonomous controllers of the STARDOM but also Yokogawa

FA-M3 controllers and other manufacturers’ controllers

• A wealth of optional packages such as Report Package and Trend Package

• Components practically usable on Visual Studio, including graphic components and

multi-task application development supporting components

2.11 Application Portfolios

Application Portfolios are packages in which many years of Yokogawa’s expertise in

control system configuration are packed, and provide application libraries of broad ranges

of software parts from small parts to those covering an entire plant control application.

Application Portfolios increase efficiency of all engineering stages from designing,

coding, debugging, to startup. In addition to portfolios containing elementary software

parts for control and communication functions, collections of control functions tailored to

a specific process or equipment are offered as Application-specialized Portfolios.

MECS,EIE-DSCE

NBPS

CHAPTER-3

TASKS PERFORMED

As an intern I was appointed as a Project Trainee in a project named “Design, Supply,

Installation, Testing & Commissioning of SCADA & APPS System, PLC System,

Telecommunication System for Naharkatiya - Barauni Pipeline.

The objective of the project is to design the system functionality in all respect to full-fill

the requirement of contractual specification of the project. The functional capabilities of

the system, Hardware and Software used for communication and data flow, flow

relationships among the various components and interfacing with HMI, sub-systems and

instrumentation interfaces are described in the document. The document also includes

communication protocols, system redundancies, General arrangement of various

equipment system configuration diagrams, and interface with the OIL supplied

communication system and technical literature of all equipment. This report describes

how the functional requirements for this new OIL-NBPL SCADA system, as specified in

the OIL documentation, are implemented by Yokogawa.

This Design Specification covers the conceptual design of:

SCADA Application For Pipeline Monitoring, Control And HMI, Namely,

Fast/Tools

Engineering Tool For Logic Development.

Overall System Architecture And Network Drawings

Overall System Hardware Design.

Communication Between Stations.

External Interface Descriptions.

Design, supply, installation and commissioning of SCADA and Station Control Centre

facilities & associated Instrumentation system of the proposed pipeline from Naharkatia

to Barauni along with branch pipelines from intermediate points at various locations as

described:

Noonmati and Jorhat will be the Master and Emergency Control Stations (SMCS

& ECS) of SCADA system for the Naharkatiya-Barauni Crude Oil Pipeline.

MECS,EIE-DSCE

NBPS

Noonmati is designated as SCADA Master Control Station(SMCS) while Jorhat is

configured as Emergency Control Station (ECS).

The entire data of NBPL stations including RS / RT / PS will be controlled from

Local PS / SMCS / ECS.

SMCS at Noonmati will be interfaced with the ECS at Jorhat for synchronization

of the data between Server to Server.

To ensure effective and reliable control, management and supervision of the pipeline, the

entire pipeline network is envisaged to be monitored and controlled from SMCS

consisting of SCADA & APPS system located at Noonmati (PS-5) and ECS at Jorhat(PS-

3).To enhance the availability of SCADA system, redundant data connectivity through

RTU’s & Local Server (PS-1, PS-2, PS-3, PS-4, PS-5, PS-8, PS-10 and TPS) and RWS

(PS-6,PS-7,PS-9 & NRL RT) distributed along the pipeline is envisaged between SMCS

and ECS over the following paths:

100 Mbps Redundant Ethernet LAN provided for SCADA servers over SDH

system.

100 Mbps Ethernet LAN NJ provided for database and events synchronisation

Between SMCS and ECS over SDH system.

6 Mbps Backup communication link over Leased Line (LL-2) between PS-1 &

PS- 10{back up link required in case OFC link failure}.

4 Mbps Backup communication link over Leased Line (LL-1) between SMCS

(PS-5) and ECS (PS-3) {back up link required in case OFC link failure}.

40 Mbps Redundant Ethernet LAN provided by Fiber optic communication for

RTU communication.

40 Mbps Redundant Ethernet LAN provided by Fiber optic communication for

RWS communication.

For intermediate monitoring and control two nos. of Dual redundant Local Server and

Station PLC Workstations will be provided under password control for the following

identified locations :

MECS,EIE-DSCE

NBPS

Naharkatiya Pumping Station (PS-1)

Tengaghat Pumping station (PS-11).

Moran Pumping Station (PS-2).

Jorhat Pumping station (PS-3)(ECS).

Sekoni Pumping station (PS-4).

Noonmati Pumping station (PS-5) (SMCS).

Sonapur pumping station(PS-8).

Barauni pumping station ( PS-10).

For intermediate monitoring and control, SCADA - HMI & APPS Remote Workstations

will be provided (under password control) at the following identified locations :

Bongaigaon pumping station ( PS-6)

Madarihaat (PS-7)

Dumar (PS-9)

Numaligarh Refinery terminal (NRT)

To monitor various process, electrical equipment status, Cathodic Protection and

control, SCADA, PLC and RTUs are considered at following locations: -

Naharkatiya Pumping Station (PS-1)

Tengakhat Pumping station (PS-11)

Moran Pumping Station (PS-2)

Jorhat Pumping station (PS-3) (ECS)

Sekoni Pumping station (PS-4)

Noonmati Pumping station (PS-5) (SMCS)

Sonapurpumpingstation(PS-8)

Barauni pumping station ( PS-10)

To monitor various process, electrical equipment status, cathodic protection and

remote control from SCADA, RTU based system are considered at following

locations: -

MECS,EIE-DSCE

NBPS

Bongaigaon Pumping station( PS-6)

Madarihat Pumping station ( PS-7)

Dumar pumping station ( PS-9)

Unmanned Repeater station (Sectionalising valves) stations - 16 Nos.

Refinery terminals- 4 nos. (Digboi, NRL, Bongaigaon and Barauni)

For reliable and efficient operation of pipeline, APPS system has been considered

long with Leak Detection & location at all conditions through APPS for the complete

NBPL pipeline project, supplementary APPS modules for enhancing the pipeline

operational aspects has also been considered.

My Section of work:

1.Trace P&ID’s.

2. Functional Schematics.

3. Trace System Configuration.

4. Interconnection Cable Schedule.

5.Front loading & Nest loading.

6.POKEYOKE.

7.Project Documentation.

1.P&ID(Piping and Instrumentation Diagram)

MECS,EIE-DSCE

NBPS

Piping and Instrumentation Diagrams or simply P&IDs are the “schematics” used in the

field of instrumentation and control (Automation) The P&ID is used to by field techs,

engineers, and operators to better understand the process and how the instrumentation is

inter connected.Most industries have standardized the symbols according to the ISA

Standard S5.1 Instrumentation Symbol Specification.

A piping and instrumentation diagram/drawing (P&ID) is defined by the Institute of

Instrumentation and Control as follows: A diagram which shows the interconnection of

process equipment and the instrumentation used to control the process. In the process

industry, a standard set of symbols is used to prepare drawings of processes. The

instrument symbols used in these drawings are generally based on International Society

of Automation (ISA) Standard S5.

The primary schematic drawing used for laying out a process control installation.

P&IDs play a significant role in the maintenance and modification of the process that it

describes. It is critical to demonstrate the physical sequence of equipment and systems, as

well as how these systems connect. During the design stage, the diagram also provides

the basis for the development of system control schemes, allowing for further safety and

operational investigations, such as a Hazard and operability study commonly pronounced

as HAZOP.

For processing facilities, it is a pictorial representation of

Key piping and instrument details

Control and shutdown schemes

Safety and regulatory requirements

Basic start up and operational information

MECS,EIE-DSCE

NBPS

Figure.1- Legends

MECS,EIE-DSCE

NBPS

Fig.2- P&ID for PS-6

MECS,EIE-DSCE

NBPS

Fig.3- P&ID for PS-6

Fig.4- Surge tank and

Transfer pumps at PS-6

MECS,EIE-DSCE

NBPS

2.FUNCTIONAL SCHEMATICS: A carefully planned schematic diagram will

simplify the study and servicing of the equipment. Whereas a conventional schematic

merely shows the electrical components and how they are connected, a functional

schematic will place these parts on the drawing in such a way as to delineate the circuits

they build. It is expanded by considering major equipments as electrical structures built

of circuits, and by treating components as having functions to perform in their circuits.

These points are illustrated with functional drawings. Ideas and techniques are suggested

which can make schematic diagrams more lucid. Below is the P&ID and Functional

Schematics for one pump station.

Fig.5- Functional Schematic for Analog input with IS barrier without interlock

MECS,EIE-DSCE

NBPS

Fig.6- Functional Schematic for Differential Pressure Transmitter

MECS,EIE-DSCE

NBPS

Fig.7 Functional Schematics for Voting System

MECS,EIE-DSCE

NBPS

Fig.8 Functional Schematics for Electric Heater

MECS,EIE-DSCE

NBPS

Fig.8- Functional Schematic for Electric Heater

Fig.9 - Functional Schematic for Motor Operated Valve

MECS,EIE-DSCE

NBPS

3. SYSTEM CONFIGURATION

Fig.10- System configuration-PS3-Jorhat

4.ETHERNET CABLE SCHEDULE:

Below Figure.11 shows the Ethernet Cable Tags for pump station 3 named Jorhat. In this

schedule all the Ethernet cables are traced between all servers, switches, HMI’S,

Controllers etc.,

MECS,EIE-DSCE

NBPS

Fig.11- Ethernet Cable Schedule for PS3

MECS,EIE-DSCE

NBPS

Ethernet Cable Schedule for PS3

MECS,EIE-DSCE

NBPS

5.FRONT LOADING AND NEST LOADING

The Yokogawa System consists of a minimum of one field control station and a human

interface system.

In an FCS( Field control station) there are different nodes consisting of different cards to

which the inputs are connected and outputs are taken out after processing. The selection

of cards and the number of cards in each node depends on various parameters.

The selection of these cards and the loading of them in each node taken into account of

all the parameters is called NEST LOADING. It depends on whether the input or output

is digital or analog, voltage or current, coming from a RTD or thermocouple or whether

its a field-bus input etc and the CPU loading.

MECS,EIE-DSCE

NBPS

Fig.12 Front loading for PS-6

MECS,EIE-DSCE

NBPS

6. POKEYOKE- An Efficient tool designed by Yokogawa to produce Nest-Loading Reports.

Fig.13- IO list Dashboard

MECS,EIE-DSCE

NBPS

Fig.14- Station Table

MECS,EIE-DSCE

NBPS

Fig.15- Nest Loading Wizard.

MECS,EIE-DSCE

NBPS

Fig.16- Wiring Details

MECS,EIE-DSCE

NBPS

Fig.17- Document Map

POKEYOKE follows below steps to produce Nest Loading reports:

As shown in Fig.13- IO list Dashboard is the first step in which the IO list is imported as

an input. Gamma IO list is produced. Spare estimation is also done in this step along with

Junction Box Schedule.

In Station Table all details about each pumping station is entered as shown in Fig.14

which is the second step.

In the third step the front loading which was designed for the Analog and Digital Cards is

placed along with all its specifications as shown in Fig.15 named Nest Loading Wizard.

Fig.16 gives us the Wiring details which is the last step of this tool. This step also

includes importing the Wiring Table and Bill of Material.

Fig.17- Document Map gives the details of all the documents prepared, its revision

number, revision date and about its approval status.

MECS,EIE-DSCE

NBPS

CHAPTER-4

REFLECTION NOTES

Specific technical outcomes:1.Learnt how to trace the wiring of cabinets of all pump stations. Below is the

General Arrangement for RTU system cabinet at Pump Station-6.

Types of Cabinets:

System Cabinet.

Server Cabinet

Analog Marshalling Cabinet

Digital Marshalling Cabinet

PDB Cabinet

MECS,EIE-DSCE

NBPS

Fig.18 – General Arrangement

Fig.19 – Internal Arrangement

MECS,EIE-DSCE

NBPS

Fig.20 – Internal Power Wiring 24V DC

MECS,EIE-DSCE

NBPS

Fig.21 – Internal Power Wiring 230V AC UPS

Fig.22 – Internal Power Wiring 230V NON-AC UPS

MECS,EIE-DSCE

NBPS

Fig.23 – Panel Bill of Material

Outline :

Panel / Console wiring for this project is subjected to client’s visual Inspection to confirm

that wiring done is in accordance with terminal Arrangement and Panel/Console

drawings.

Objective : The purpose of this test is to verify that the following are in accordance with

the approved wiring drawings.

Reference :

1. GA/IA Drawings of Panel/Console.

2. Panel Wiring Drawings.

3. Typical Loop Drawings

MECS,EIE-DSCE

NBPS

Procedure : Visually check that each Panel/Console wiring based on above objectives

and verify that each Panel wiring is in order.

Criteria : Each I/O configuration should confirm in accordance with the Nest loading.

2.Participated in ordering of materials for the project i.e., raised MPR(material

purchase requisition).

Fig.24- MPR for Network Devices

MECS,EIE-DSCE

NBPS

Fig.24- MPR for Network Devices

MECS,EIE-DSCE

NBPS

3.Loop Check of Cabinets at all pump stations during Pre-FAT and FAT.

The Factory Acceptance Test (FAT) will be conducted in accordance with the test

procedures detailed in this document. The scope of this FAT at YIL, BANGALORE

would include hardware check, visual checks on workmanship and functional tests in

accordance with the FAT documents and to clear the equipment for delivery to site.

The Factory Acceptance Test consists of 4 main parts namely, inspection of: -

Hardware.

System Software.

SCADA System Application.

Loop Checking.

The system shall be energized at least 30 days before FAT. The loop checking of all I/Os

shall be carried out as per the procedure elaborately explained in this document. This

ensures the hardware loop integrity from the marshalling cabinets to the graphics. This

also takes care of proper functioning of Terminal Boards, Relays, pre-fabricated cables,

nest loading and configuration of software blocks in the system. The controllers shall not

be put in to simulation (test function) mode while these checks are carried out.

Subsequent to the successful completion of above activity, the controllers shall be put in

test mode for testing of loops and logics.

Outline :

I/O configured for this project is subjected to client’s inspection to confirm that Hardware

& Software configurations are in accordance with the Nest loading.

Objective : The purpose of this test is to verify that the I/O configuration is done as

per nest loading.

Reference :

1. Front Loading and Nest Loading

2. Typical Loop Drawings – RTU

3. Functional Schematics

Procedure :

1. For Analog input 4-20mA shall be injected with the help of calibrator across the rack

terminals. The Value of the input on the Face plate shall be noted (5 Point Check

0%,25%, 50%, 75%, 100%).

MECS,EIE-DSCE

NBPS

2. For Analog outputs tag value shall be forced from the face plate. The current is

measured using a calibrator. The analog signals shall be increased / decreased and

different readings to be noted.

3. For testing Digital Input loops, the signal will be simulated from the marshalling

terminals & the status change is observed in face plate.

4. For testing Digital Output loops, the tag shall be forced from the faceplate and the

voltage/Continuity across the marshalling terminals shall be checked by using the Multi-

meter.

5. 50% of the loops per card will be tested, however 100% loops will be tested during Pre

FAT.

Criteria : Each I/O configuration should confirm in accordance with the Nest loading.

Test Record Ref : Loop Check sheet.

4.System configuration Check

Outline : The various systems and the components of the project are connected as per the

client specification which forms part of the system configuration.

Objective : the purpose of this test is to verify that all the systems are connected in line

with the overall system configuration.

Procedure :

1. Ensure that all the RTU controllers are connected as per the configuration

2. Ensure that all the HMI stations are connected as per the configuration

3. Ensure that all the network components are connected as per the configuration

4. Ensure that all the printers are connected as per the configuration

5. Ensure that the network connectivity between various systems is in order.

Criteria : the system connectivity is in line with the approved system configuration.

MECS,EIE-DSCE

NBPS

5.BOM(BILL OF MATERIAL) check

Outline: All hardware & software for this project is subjected to client’s visual

inspection to confirm that all components & accessories model no. And quantities are in

accordance with the BOM.

Objective : the purpose of this test is to verify the model no. And quantity of all

hardware, software and accessories.

References:

1. Bill of material

2. Commissioning & warranty spares

3. Hardware FDS

Procedure:

1. Visually inspect each component based on the above objectives and verify that each

component is in order.

2. Verify whether the required software is loaded in the respective Stations.

3. Verify spares and spare space as per the approved project philosophy.

4. Verify the hardware specifications of servers, workstations, laptops as per the

approved datasheets.

Criteria : All component & accessories model no. & quantity should as per the BOM.

6. Front loading check

Outline :

All Remote Terminal Unit (FCN), I/O Nodes and Modules are defined during

engineering and the position & quantity of each item installed in the respective cabinets

are of utmost importance.

Objective :

The purpose of this test is to verify that all RTU, I/O Nodes and modules are correct in

quantity and that each item is installed in the right position.

References : Front/Nest Loading-RTU

Procedure :

1. Visually check that each Node Interface Unit (NIU) is installed in the right position

and correct in quantity.

MECS,EIE-DSCE

NBPS

2. Visually check that each I/O Nest is installed in the right position and correct in

quantity.

3. Visually check that each I/O Module is installed in the right slot and correct in

quantity.

4. Visually check that all labeling is in order.

Criteria : The locations of the RTU, I/O Nodes & Modules are in accordance with

the Front / Nest Loading.

Specific Non-Technical outcomes

Personally Experienced the following while working at YOKOGAWA.

A resourceful, creative, internationally-oriented work environment.

Independence and considerable personal responsibility.

A flat organization with short lines of communication.

A continuous process for learning, development and growth.

A talented team of professional, highly-motivated colleagues.

Making the Most of my Experience.

Internship is an opportunity to achieve personal and professional goals, and learn new

ideas and skills. In addition, this experience is a great way to network.

Being positive, enthusiastic, and a problem-solver.

Be realistic and be willing to take on less-than-glamorous tasks.

Not every assignment will lead to glory, but the task may be important to the employer.

Being attentive and giving 100% will be strong indicators of your work ethic and will

lead to greater responsibility.

Project comes along that interests you

Demonstrate organizational skills and initiative. Begin to develop new levels of

responsibility by noticing the tasks around the office that need to be done, and asking the

supervisor if you can take on the challenge.

Asking questions, but know when to listen and observe.

In the beginning, noticed processes or procedures that do not seem to make sense.

MECS,EIE-DSCE

NBPS

Be willing to accept feedback and criticism.

This is one of the hallmarks of a true professional.

Keeping the supervisor informed.

If you need more time on a project, ask for it. Keep the lines of communication open.

Seeking out mentors and learning from colleagues.

Make a point to learn business etiquette.

REFERENCES AND ANNEXURES

MECS,EIE-DSCE

NBPS

1. http://www.yokogawa.com/in/technical-library/2. https://en.wikipedia.org/wiki/Yokogawa_Electric

MECS,EIE-DSCE

NBPS

MECS,EIE-DSCE

internship report

Documents

yokogawa electric works

tamisuke yokogawa

production of electric

industrial instruments

chemical companies

hokushin electric works

measurement instruments

acquisition of ando