Design Qualification

Dynamic engineers Ltd.

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Document name : Design Qualification Effective Date : TITLE: CTO-6 Clean Room Safety Interlocks and Alarms

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Table of Contents

Table of Contents

1.0 INTRODUCTION……………………………………………………………………………..3 2.0 PURPOSE……………………………………………………………………………...............3 3.0 SCOPE…………………………………………………………………………….....................3 4.0 PROCEDURE……………………………………………………………………………......... 4 5.0 REFERENCES……………………………………………………………………………........ 8 6.0SAFETY REQUIREMENT…………………………………………………………………….8

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1.0 INTRODUCTION Dynamic Engineers Pvt. Ltd. have produced this document in co-operation with M/s.Dr. Reddy’s Laboratory Ltd., at Vizag (Andhrapradesh).This document briefly describes the design basis for the automation of CTC-6 clean room safety interlock & alarms. 2.0 PURPOSE The purpose of this document is to provide Hardware & software Qualifications to introduce Oxygen, and LEL sensors and warning mechanism in line with CSHE guidelines in all the clean rooms in CTO 6 to detect nitrogen leaks / build up of solvent vapors / other gases that emanate from the process and warn the concerned of for evacuation and necessary action. This document provides guidelines to be tested used in testing in IQ stage. 3.0 SCOPE This document covers the Hardware specification for CTO-6 clean room safety interlocks & alarms facility. List of the instruments as per below: Oxygen Analyzers • LEL Analyzers • Hooters • PLC System • SCADA(Software specification) • Flameproof Cum Intrinsically Safe Indicator Cum Buzzer. • Media convertor • Optic fiber cable • Zener barrier • 3Lamps with Hooter • 1 Lamp with Hooter • Acknowledge Push Buttons •



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4.0 PROCEDURE 4.1General Guidelines It is recommended that design specification is illustrated by the use of diagram.If such diagrams are produced elsewhere then these shall be cross-referenced by hardware design specifications. 4.2 Hardware specification: 1.0 Oxygen Analyzer : Honeywell Oxygen Sensor with transmitter Part No.: SPXCDALMO1 ATEX/IECEX & AP approved SP XCD Oxygen 25.0%/Vol with LM25, M20 Entry With 2 programmable alarm relays,1 programmable fault relay as well as an industry standard 4-20mA output (sink or source selectable). Qty: 90nos. 2.0 LEL Analyzer Honeywell LEL Sensor with Transmitter Part No.: SPXCDALMFX ATEX/IECEX & AP approved SP XCD Honeywell XCD Fixed LEL Gas Detectors 0-100%LEL With 2 programmable alarm relays,1 programmable fault relay as well as an industry standard 4-20mA output (sink or source selectable). Qty: 40 nos. 3.0 Flameproof Cum Intrinsically Safe Indicator Cum Buzzer. Range: 20 – 25 meters With Flame Proof and Intrinsically Safe Audio Acceptor . 4.0 Single Lamp With Hooter Lamp-Red colour Intrinsically safe Make:Stahl Qty: 121 nos. Authorized by (Sign & Date) QA


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5.0 Tri Lamp With Hooter Lamp-Red,Green,Yellow colour Intrinsically safe Make:Stahl Qty: 50 nos. 6.0 PLC: Allen Bradely make Compact Logix L1 series processor with Point I/O’s is used for this project. Compact logix L1 series is powerful processor, which can handle six no. of point IO modules in it’s base. Apart from this, it can interface with distributed IO’s through Ethernet with four such nodes. In its base it also has 16 no. of Inputs and 16 no. of Output channels. With respect to communication facilities, it comes with two inbuilt Ethernet ports and one USB port for programming. Ethernet ports facilitates Device Level Ring (DLR) topology, which provides redundancy in communication. Catalogue no. of PLC used in this project is 1769-L18ER-BB1B. QTY: 9 nos.

7.0 IO Modules: IO modules are part of the hardware which interfaces field signals to PLC. Allen Bradley make Point IO modules are used for this project. Point IO modules are low cost, low space occupying modules. They can be put in remote panels and can be interfaced with PLC with help of communication interface like Ethernet, Devicenet or Controlnet. They also support, Remove and Insertion Upon Power (RIUP), which facilitates replacement of any IO module during powered condition. These modules provide diagnostic information regarding status of module or channel. Catalogue no. of IO Modules used in this project is 1734-IB8, 1734-OB8. These modules will be mounted on terminal base with part no. 1734-TB, interfaced with communication adapter 1734-AENTR which facilitates redundant communication. 1734-IB8 – 8 Channel Digital Input Module Qty:56 nos. 1734-OB8 – 8 Channel Digital Output Module Qty:64nos. 8.0 Zener Barriers: Zener barriers isolate field signals which comes from non-safe area to safe area where PLC system is located.Make of zener barrier shall be MTL.Barriers are used to interface signals from Push buttons and signals going to lamps and hooters. These barriers isolate signal between safe zone and unsafe zone. Part no. of barriers used in this project is MTL7741 and MTL7728 with some accessories as mentioned below. MTL7741 – Digital Input Barrier Qty:173 nos. MTL7728 – Digital Output Barrier Qty:444 nos. Authorized by (Sign & Date) QA


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9.0 SCADA (Software specification) FactoryTalk View SE: FactoryTalk View SE is Rockwell Automation software, which interface with PLC device and act as front end. FactoryTalk View® Site Edition (SE) is a supervisory HMI software package for enterprise solutions. It has a distributed and scalable architecture that supports distributed-server/multi-user applications, giving maximum control over information where you want it. Also this software compliance to 21 CFR Part 11. System Requirements Hardware requirements for running FactoryTalk View SE The hardware (or software) used to run FactoryTalk View SE components depends on the demands of application places on the system. The greater the demand, the more powerful a system is needed. To develop applications with FactoryTalk View Studio, or to host large or complex applications, computers with faster CPUs and more RAM are used. In any application, faster CPUs and more RAM will result in better performance. It is also recommended that enough disk space is available to provide virtual memory that is at least twice the size of the physical RAM. Hardware requirements for operator workstations For computers hosting FactoryTalk View SE Clients in a network application or for a FactoryTalk View SE Client running a local application: Recommended: Intel Core 2 Duo, 2.66 GHz or higher and 2 GB RAM or more. Minimum: Intel Pentium 4, 2GHz or higher and 1 GB RAM or more. Hardware requirements for engineering workstations For computers hosting FactoryTalk View Studio or FactoryTalk View SE Administration Console in a network application: Recommended: Intel Core 2 Duo, 2.66 GHz or higher and 2 GB RAM or more. Minimum: Intel Pentium 4, 2GHz or higher and 1 GB RAM or more.

Hardware requirements for application servers To support any number of clients (FactoryTalk View SE Client, FactoryTalk View Studio, the FactoryTalk View SE Administration Console, a FactoryTalk Transaction Manager connector, or a FactoryTalk View SE Server), for computers hosting application servers: Recommended: Quad Core Intel Xeon, 2.33 GHz or higher and 4 GB RAM. Minimum: Intel Pentium 4, Dual CPU, 3GHz or higher and 2 GB RAM or more.



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10.0 Optic fiber cable: Optic Fibre cables are of 6 Core Multi mode Armoured Finolex make. 11.0 Media convertor: Appendix Specification General Standard IEEE 802.3 10Base-T IEEE 802.3u 100Base-TX/100Base-FX Topology Star Protocol CDMA/CD Data Transfer Rate Ethernet: 10Mbps(Half Duplex); 20Mbps(Full Duplex) Fast Ethernet: 100Mbps(Half Duplex); 200Mbps(Full Duplex) Ports 2 10/100Mbps RJ-45 ports 2 SC Fiber ports ( F1: 1310/1550 nm Single- mode single Fiber F2: 1550/1310 nm Single-mode single Fiber) LED indicator POWER Power on Each port RJ45 port:10/100Mbps Link/Act Fiber port: 100Mbps Link/Act RJ45 port: Cat. 5 Twist-pair SC Fiber port: single-mode fiber cable Max. Distance Twisted pair (Cat.5): 100m Single-mode fiber cable: 20km Environmental and Physical Power Power Adapter (9V, 0.8A) Dimension(LxWxH) 122mmx76mmx24mm Environment Operating temperature: 0ºC ~ 40ºC Storage temperature: -20ºC ~ 70ºC Humidity: 5% ~ 90% RH



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5.0 REFERENCES

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1.User requirement Specifications 2. Control Philosophy 3.I/O list 6.0 SAFETY REQUIREMENT

Zone Classification: - Care should be taken while specifying the zone of installation for measuring instrument (Provision available in the specification sheets, CTO –ENGG- SYS- 027). In case there is any Zone-1 instrument then EEXia code shall be specified.



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Design Qualification

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