Developing DCS Specifications for Control ABB Users Group

Baton Rouge; 2013

System Modernization

Tim Duffy
DCS Engineer
Solvay - Baton Rouge
9/11/13

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 ABB Users Group
Presentation Agenda Baton Rouge; 2013

1. Presentation Objectives
2. Pros and Cons of a Migration Project
3. Overview of the Project Requirements Process
4. Overview of a DCS Configuration Specification
5. Vendor Quoting Process
6. Functional Specification

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 There are 6 key messages (objectives) in this ABB Users Group
Baton Rouge; 2013
presentation

1. Provide an overview of the requirements process. (Slide 4)

2. Principle Requirements need to be developed with upper management early in the
project (Slide 5)
3. The DCS Configuration Specification is the key document to address the
fundamental challenge in obtaining comparable quotes, while minimize exposure
to scope changes without developing a functional specification (Slide 8-9)
4. Provide a table of contents and content examples for a DCS Configuration
Specification (Slides 10-12)
5. The Vendor quoting process uses summary data, averages & statistics to generate
a proposal. The DCS Configuration & Service Specification compliments this
process (Slide 13)
6. In order to ensure the generation of an effective functional specification, the
document contents and approach needs to be specified (Slide 14-16)

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 A Migration project has advantages over a ABB Users Group
Baton Rouge; 2013
greenfield facility.

Advantages
•Instrumentation is installed and working
•Process Control Methodology and sequences are known, proven and working
•Existing software can be used as process definition
These items contribute the majority of
issues encountered in a new installation

•Disadvantages
•Two Existing technologies must run side by side – gateways must be defined
•IO Migration is the primary concern
•Cutover time must be minimized

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 Developing requirements is an evolutionary ABB Users Group
process that can be separated into two phases. Baton Rouge; 2013

Principle Requirements
Proposal Phase
This presentation focus
is on the proposal phase
DCS Qualification Requirements

Configuration & Service

Feed Study
Specification (CSS)

Generate a Quote

Vendor Selection

Project Execution Phase

Functional Specification

Design Specification Scope Changes

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 Principle Requirements need to be developed ABB Users Group
Baton Rouge; 2013
with upper management early in the project
1. DCS system shall be upgraded to the most advanced technology available on the
market today, maximizing the life cycle for the hardware, system software and
services.
2. The latest advance control and maintenance management technology shall be
deployed to maximize return on the investment.
3. The existing DCS functionality shall be maintained

Support
& Service

Risk Avoidance

Hardware Application/
Operating System

Advance Control/features ROI

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 DCS Qualification Requirements are used to ABB Users Group
Baton Rouge; 2013
qualify and select DCS vendors

Principle Requirements This specifies the “tool box”, ie: temperature

ratings, analog resolution, vibration
requirements communication protocol, auto
DCS Qualification Requirements tune, advance control etc

At Solvay, the DCS selection process had

Configuration & Service already been completed for North America
Specification (CSS) at the corporate level.

Generate a Quote

Vendor Selection

Functional Specification

Design Specification Scope Changes

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 The CSS addresses the challenge of obtaining an ABB Users Group
Baton Rouge; 2013
accurate quote without generating a functional spec

Principle Requirements

DCS Qualification Requirements

This specifies the “house”: the square

Configuration & Service footage, number of rooms, ranch or
Specification (CSS) colonial, lot size, neighborhood

The objective is to:

Generate a Quote • Generate quotes that are comparable
• Minimize Scope Changes

Vendor Selection A feed study is used as the starting point

for this document

Functional Specification

Design Specification Scope Changes

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 The Configuration & Service Specification defines the ABB Users Group
Baton Rouge; 2013
high level requirements

• Work Stations • Project Execution

• History • Documentation Deliverables
• Controller • Factory Acceptance Test
• IO Requirements • Startup
• Gateways • Support Services
• Graphics • Training
• Control &Sequences • Service Labor Rates
• Batch • Customer Deliverables
• Reporting

The CSS is not a functional specifications document and does not specify system
performance parameters or provide functional definition for the application software
development.

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 Document organization and structure are important ABB Users Group
Baton Rouge; 2013
aspects in generating a successful specification

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 Document organization and structure are important aspects ABB
in Users Group
Baton Rouge; 2013
generating a successful specification (continued)

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 The information provided in a CSS should be ABB Users Group
Baton Rouge; 2013
summary information, not functional details.

Summary Information is sufficient for

DCS vendors to generate quotes

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The Vendor quoting process uses summary
data, averages & statistics to generate a proposal
Principle Requirements
DCS Qualification Requirements
Configuration & Service
Specification (CSS)
Generate a Quote
Vendor Selection
Functional Specification
Design Specification
T Duffy
ABB Users Group
Baton Rouge; 2013
The CSS compliments this process
The following should be defined:
• Quantity
• Complexity (simple, medium, Complex)
• Identify areas that are Unit Relative
The CSS is designed for statistic based
quoting
Consider using a Kepner Tregoe decision
matrix (or similar tool)
Scope Changes
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 ABB Users Group
A migration project leverages the existing software Baton Rouge; 2013
as the primary functional specification

Principle Requirements

DCS Qualification Requirements

Configuration & Service

Specification (CSS)

Generate a Quote
Vendor Selection
Functional Specification
This specifies the interior & exterior: land
scape, furniture, carpet, building
materials, etc
The existing application software
provides the starting point of this
specification

Design Specification Scope Changes

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DCS Functional specification is critical in replicating the ABB Users Group
Baton Rouge; 2013
functionality, define your expectations in s specification

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 ABB Users Group
Define what you expect for sequence Baton Rouge; 2013
documentation

Flow Chart OR Psuedo Code

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 Document the functionality, then Replicate the ABB Users Group
Baton Rouge; 2013
requirements and innovate the solution
Document Existing Application
CFD Requirements CFD Requirements

CFD Library Design CFD Requirements

New

CFD Instance Table CFD Instance Table

Loops will change

Number of rows will be the same

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 There are 6 key messages (objectives) in this ABB Users Group
Baton Rouge; 2013
presentation

1. Provide an overview of the requirements process. (Slide 4)

2. Principle Requirements need to be developed with upper management early in the
project (Slide 5)
3. The DCS Configuration Specification is the key document to address the
fundamental challenge in obtaining comparable quotes, while minimize exposure
to scope changes without developing a functional specification (Slide 8-9)
4. Provide a table of contents and content examples for a DCS Configuration
Specification (Slides 10-12)
5. The Vendor quoting process uses summary data, averages & statistics to generate
a proposal. The DCS Configuration & Service Specification compliments this
process (Slide 13)
6. In order to ensure the generation of an effective functional specification, the
document contents and approach needs to be specified (Slide 14-16)

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