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What is legacy DCS. How it looks?

What is legacy DCS. How it looks?. What is DCS?. Integrates the PLCs and process controllers of a process line. Enables you to manage the process as a complete system. DCS lets you see the “ big picture ” . Improve the overall efficiency and quality of your plant.

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What is legacy DCS. How it looks?

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  1. What is legacy DCS. How it looks?

  2. What is DCS? • Integrates the PLCs and process controllers of a process line. • Enables you to manage the process as a complete system. • DCS lets you see the “big picture”. • Improve the overall efficiency and quality of your plant. • In a process industry, DCS is a for plant activity.

  3. What is DCS? • Instantaneous controlling and monitoring of plant is dominant function for DCS at the control room. • Up to some extent, DCS is performing reporting & analysis job for plant.

  4. Challenges of legacy DCS? Sharing information from DCS - missing

  5. What challenges does legacy DCS have? • Proprietary communication Bus. No access to data without software and /or hardware from the DCS manufacturer. • Data Output from DCS is printed on paper. Analysis of the data becomes cumbersome and many a times impossible task. • Plant information cannot be made available on-line to top executives. • Maintenance of the proprietary spares/peripherals. • Spares from the suppliers are exorbitantly costly.

  6. What challenges does legacy DCS have? • Alarms are printed continuously, leading to wastage of stationary. • Graphic page and the trend page print from the DCS is costly. • Configuration of various reports with calculations and various layouts is a time consuming – manual. • Lack of MIS. • Delay in decision making process. • Operational effectiveness – room for improvement.

  7. What is the way to ease challenges? Indus’ way!

  8. What are the key benefits? Un-structured informationAs - is Structured informationProposed

  9. What is the way to ease challenges? Structure it.

  10. What are ePlant objectives? • Fetch the data from proprietary DCS system and store on commercial PC thru RS232 port. • Make the process data on-line for better monitoring of the plant at various levels of management. • Store the required data in database format for in- depth analysis of the plant performance. • Data is analyzed. • Information is shared thru LAN / Web. • No extra hardware required.

  11. What are the key benefits? Proposed solution

  12. What are the key benefits? • One shot view of the plant on any PC on LAN. • Database of plant parameters can be established for any analysis. • Instant POP-UP for any critical alarm to the concern authority. • Important graphics can be configured for various users. • Multi trends for data comparisons.

  13. What are the key benefits? • Reports of Raw material, utilities, power and finished goods, for specific consumption analysis • Efficiency calculations of Heat exchangers, reactors, distillation columns etc can be configured into Excel sheet from the data captured in structured form.

  14. What are the subsequent benefits? • Freedom from proprietary piracy • Analyzed tag data can shared beyond the DCS • Complements your efforts on information flow • Sharing of DCS info on LAN / Web • Information sharing at minimal cost • Produce & publish trend analysis thru eOffice(Indus tool) • Produce and publish the alerts to the designated • Graphical analysis of plant information • Operational effectiveness –leapfrog

  15. What will make it work? • Dedicated p4 and above PC. • Connectivity to DCS through RS232 port.

  16. What is its credibility? Exit • Bayer ABS, Gujrat – Tata Honeywell DCS • Birla Cellulosic, Gujrat – Tata Honeywell DCS • Godrej industries, Gujrat – Tata Honeywell DCS

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