Hi,

I am involved in Detail Engineering works and under my scope is to evaluate which is the most reliable DCS system as of today.

We have already some vendors to select from; like as follows:
1. Honeywell
2. Yokogawa
3. Foxboro
4. ABB
5. Emerson

I want to know if anybody from the group could suggest which is the best DCS system for a Polypropylene Plant.
Thanks a lot and urgently waiting for any reply.

With best regards,
Jonathan Opina
Snr. Instrument Eng'r.
[email protected]

 

When you make a decision, it is important to remember that implementation is as important as the product. The best DCS that is poorly implemented is no better than a lesser DCS that is well implemented.
Normally people are using Emerson / Honeywell systems for this type of applications.

 

We report, you decide(DCS for PP plant):

1. Honeywell > ease of programming, advanced graphics. Uses VB-based programming. I/O hardware is "easily" damaged resulting in need to replace entire cards. Can do APC(Advanced Process Control).

2. Yokogawa > bullet-proof(hard to damage) and most flexible I/O on the market(any channel can be any type of I/O). Can do APC. Excellent batch software(SEBOL) for your catalyst area(?). Maintenance will love you for the hardware.

3. Foxboro > their I/A system? No experience with this one.

4. ABB > the OLD MOD 300 had the most flexible I/O. The newer platforms are less flexible I/O-wise but have much better software tools. Fairly "open" system. Get a Historian with LOTS of capacity and the link to your plant PI or data network if you get this one.

5. Emerson >Fisher/Delta V the best for incorporating various levels of safety shutdown systems "into" the same/but separate system(s). Integrates the old separate PLC/relay rack nightmare into the system yet maintains APPROVED separation.

Make the Vendors thoroughly explain their system and give verifiable references in PP plants running a process similar to yours. Then YOU actually call and talk to the "people in the trenches" running these systems daily. Here there are 2 PP plants: 1 on ABB, 1 on Honeywell.

 

We have Honeywell and ABB systems in our plant.. (Though not a polypropelene plant.. But for that matter a DCS need not show different characteristics for a different process, i suppose...!!).. Our experience says, that go for honeywell, blindly and you shall rejoice your choice later on... Our ABB system has been exceptionally bad... Card failures are too frequent... Except for the Grounding problems, which are readily solvable, Honeywell systems are known to be stable... So much so that we have instances of plants running on Honeywell PLC and maintenece people say that in so many years of operation they never even faced a situation when the PLC change over would take place from Primary to redundant PLC..!!! Such is the stability of the system...

Rahul

 

One of my friend Kishor Lad is working on Foxboro IA series DCS in PP Plant at Reliance, Jamnagar, India.
You may contact him for the performance of Foxboro DCS.
His E mail id is [email protected]

Thanks
Ashish

 

ABB India DCS is the best available today.

 

M/S Selectron is one of the best as far I know. The most reliable Open CAN with features packed.We have hands on experience.

regards

Balaji

 

The best system for a plant may depend on how large you I/O count might be.

Honeywell TDC300 and Foxboro I/A are expensive systems ment for high I/O count (more than 1000 points).

Delta V (or Rosemount System 3, going out) are less expensive and more suitable for low to mid I/O count (less than 1000 points).

We can perform an independent analysis for your plant if you want.

Tony Cantu
Control Works, Inc.
www.cwinc.us
[email protected]
281-493-1212

 

I don't think that I/O count is a good way to choose a DCS.

I have GSE D3, Westinghouse WDPF, Foxboro I/A, Intellution FIX, and for a mechanical process, AB SLC500 with over 1000 I/O points.

The most important attributes of any control system in a chemical plant application are:

(1) Integrity, i.e. the ability to keep running.

(2) Change tracking, security, and ease of modification.

(3) Flexibility, i.e. able to perform many methods of control. From Model based to ladder logic

Attribute #1 is paramount. Based on this alone, the Westinghouse Ovation is the winner. Price prohibits installing these cast-iron systems everywhere in my plants. Standardization elimates them from all plants.

Going to attributes 2 & 3 brings up a contest between the Delta-V and the Foxboro I/A. The Honeywell is eliminated because of poor long-term survival prospects.

Our experience with processes that demand integrity from their control systems because of high risk elements have led to the choice of Foxboro I/A even with I/O counts of 500.

Delta-V is being introduced in some plants for cost reasons. It is too early to judge these efforts.

However, the Foxboro I/A has proven to be robust, versitile, moderately expensive, and the right choice for critical processes. With the introduction of the IACC configuration tool, management of change and standardization will, we hope, become routine.

 

Better use DeltaV from Emerson Process Management. It's a reliable systems & has a lot of installations just like your application.

 

I will switch the industry to the power plants.

Does any one have a comparative experience with the same suppliers?

Regards,
Vas