DCS System Configuration Requirements - Just Measure it

DCS System Configuration Requirements

1. System Capacity Specifications

a) Redundancy and Reserve Rules

  • I/O Modules

    • Reserve ≥ 10% of each type of I/O points

    • Reserve ≥ 10% of module slots (plug-and-play ready)

  • Controller Processing Capacity

    • ≥ 60% margin under normal conditions

    • ≥ 40% margin under stress conditions

  • Operator/Server Workstations

    • ≥ 60% CPU margin under stress conditions

  • Memory Capacity

    • ≥ 40% margin in RAM

    • ≥ 60% margin in external storage

  • Communication Load Limits

    • Token bus load rate ≤ 40%

    • Ethernet load rate ≤ 20%

b) I/O and Control Loop Capacity

  • I/O point count per cabinet/station must meet operational demands

  • Control loop capacity must satisfy process requirements

c) Power Supply

  • Logic and field power supplies must meet applicable codes

  • Reserve capacity must be considered

d) Database Storage

  • Real-time and historical database capacity must meet operational needs

  • Reserve storage must be ensured

e) Cross-System Data Exchange

  • Data exchange capacity with other systems must match unit-level demand

  • Reserve for expansion must be considered

f) Alarm Information Retention

  • Must store alarm records for ≥ 30 days

  • Support both display and printing

g) System Scalability

  • The system must support sufficient operator stations, field control stations, and function modules, with future expansion capability

2. Compatibility and Integration with External Systems

a) Communication Compatibility

  • Compatible with mainstream interfaces, protocols, and configuration tools

  • Supported Physical Interfaces: RS-232, RS-485

  • Supported Protocols: HART, Modbus, mainstream fieldbus, TCP/IP

b) Supported Transmission Media

  • Coaxial cable

  • Optical fiber

  • Twisted pair

c) Protocol Support

  • HART (for smart instruments)

  • Modbus (for device-level integration)

  • Mainstream fieldbus (e.g. Profibus, Foundation Fieldbus)

  • TCP/IP (for network communication)

d) Device Integration Capability

  • Integrate seamlessly with PLCs and fieldbus systems

  • Support third-party equipment connectivity

e) Software Openness

  • Application software shall be modular and open-architecture

  • Provide development tools and interfaces for secondary development

  • Enable sharing of real-time and historical data

f) Enterprise-Level Integration

  • Fully open protocols, enabling integration with enterprise management systems (e.g. ERP)

  • Direct communication with systems and devices using standard protocols like Modbus

3. Configuration Software Usability & Standardization

a) Compatibility

  • Use standard formats such as IEC 61131-3

  • Enable seamless interoperability with third-party systems

b) Unified Design

  • Consistent interface and logic across plant units

  • Fully aligned with process control specifications to minimize operator training

c) High Efficiency

  • Support modular configuration (e.g. drag-and-drop logic blocks, parameter templates)

  • Accelerate configuration and reduce engineering workload

d) Intuitive Interface

  • Adopt standard industry color codes (e.g. green = run, red = stop)

  • Unified graphics and symbols for clarity

e) System-wide Consistency

  • All interfaces must be clean, intuitive, and free of redundancy

  • Labels, color codes, and alarms must be unified throughout the system

4. System Expandability and Upgradeability

a) Hardware Scalability

  • Support online addition/removal of the following:

    • I/O modules

    • Controllers

    • Switches and relays

  • Must follow modular, plug-and-play architecture

  • Device expansion shall not interrupt ongoing system operation

b) Technology Upgrades & Customization

  • Support integrated power plant automation solutions

  • Capable of tailored function development

  • Compatible with both legacy and emerging technologies

c) Full-Level Functional Coverage

  • Enable control and monitoring from field device to enterprise level

  • Support virtual control simulations (PC-based)

Functional Levels:

  • Device Layer: Direct link to sensors and actuators

  • Control Layer: Logic and real-time control

  • Management Layer: Monitoring and analytics

  • Simulation Layer: Offline testing and verification

d) Openness & Universality

  • Based on open network architecture

  • Operate on widely adopted OS platforms

  • Designed to ensure expansion via standard interfaces and avoid vendor lock-in

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