SIEWIRE - Tool To Create DCS Wiring Diagrams

SIEWIRE Tool to create DCS Wiring Diagrams

Trainee Engineer Seminar III05/02/2023 1Energy Sector

05/02/2023 Energy Sector 2

Overview

•Technical Introduction

•Initial Situation

•Goals and Objectives

•Methodology

•Key Milestones

•Tool Implementation and Statistics

•Results and Future Work

What are Wiring Diagrams?• Representation of measurement schemes

or signal acquisition schemes being followed in a Project.

What is C2 Loading table?• Contains wiring details of every signal

acquired in a DCS panel.• Required to create Wiring diagrams.

Introduction

05/02/2023 3Energy Sector


Applications of Wiring Diagrams

For wiring in the DCS panels at vendor’s place

For continuity checks of wire connections in DCS panels

For IO testing at the time of FAT

For Commissioning of panels

For maintenance after commissioning of panels

Introduction

Initial Situation

Methods used currently to create wiring diagrams: •Developed by Siemens AG

for Hardware engineering of DCS panels

Tec4fde

•Diagramming and vector graphics application developed by Microsoft

MS Visio


Case Study

CLP CCPP Stage2 (PAGUTHAN)

• DCS commissioned in 2012• 650 IOs • Tec4fde used to create

wiring diagrams• It took 2 months to create

the c2loading table and the wiring diagrams.

TATA CCPP Stage1 (TROMBAY)

• DCS commissioned in 2012• 714 IOs • MS Visio used to create

wiring diagrams• It took 2 and half month to

create the c2 loading table and the wiring diagrams.



Challenges In Current Approach

Tec4fde

• Complex procedure• Trained engineers

required to use this tool• Additional server

required to run this tool, thus cannot be used outside office

Visio

• Every diagram needs to be drawn individually

• Consumes lot of time and cost

• Prone to engineering errors

• Cost of MS Visio license

Basic Idea


SIEWIREsaves

• Requirement of a simplified tool that could create all wiring diagrams at once.

Time

Cost

Complexity

Goals and Objectives


To save time and human effort

To develop a user friendly and efficient tool

To minimize engineering errors

To produce numerous hardware engineering documents

• Scope to edit diagrams, add text and graphics• Data checks in input database• Produce other hardware engineering documents(eg.

Loop chart, Power supply diagram, earthing concept etc)

Scope of the Project


3 Ways to create Wiring Diagrams

New diagrams from scratch

All diagrams at once

One by One (2 clicks/diagram)

Executed Project

documents

Manuals from the internet

EFIE InfobaseSiemens IE Infobase

SILK

Sources Used


HTML and Javascript

Simple code, No software installation required, Runs over Internet Explorer

VB Scripting in Microsoft Studio

Microsoft Studio installation, License cost, Microsoft Studio training required

VB Scripting in MS Visio

MS visio installation, License cost, Implementation with Macros, Complicated Code


Multiple Approach Evaluation


Methodology

Implementation

Verification and Review (From Seniors)

Code Development and User Interface

Collection (Data sheets, executed Projects)

Key Milestones


Code for Wiring Diagrams without FIM

Derive on aMethod to Develop

Finalization of Templates

Prepare the User Interface

Search Similar tools, Study

Survey Preparation & Analysis

Jot down Requirements

Status Review

Milestone 1 Milestone 2 Milestone 3 Milestone 4

Tool Implemented in TATA Trombay

Stage 2

Cost Analysis andTool Statistics

TES 3

Code for Wiring Diagrams with FIM

Status Review Status Review

Data Checks andError Handling

Code to OtherHardware Engineering

Diagrams

Open the tool in Internet Explorer

Type location of the tool in your system

Browse and select your access

database

Input the required table in this

database

Change your print settings as per

requirement of tool

Click to generate the wiring diagram

in pdf format

How SIEWIRE Works?


DEMO

• SIEWIRE was first implemented in TATA Trombay Unit 7, Stage 2

• Output Wiring Diagrams were used for IO testing in FAT

Tool Trial


Combined Cycle Power Plant

20 cabinets, Approximately

8000 IOs

Scope: BOP and Electrical

TATA Trombay Stage 2 • Number of I/Os in the project: 8000.

C2 Loading T

able

Wiring D

iagrams

Loop Chart

Training Hours

Total0

500

1000

1500

2000

2500

3000

1620

2671 60

1948

1240

13 1 1

12551333

43 1

2597 TEC4FDEMS VISIOTOOL

1220Hour

s


Engineering hours saved vis-à-vis Tec4fde=693. (36% time saved)Engineering hours saved vis-à-vis MS Visio=1342. (52% time saved)

Cost Benefit

Engineering Cost

Additional Cost

Total Cost 0

500000

1000000

1500000

2000000

2500000

1.85

0.06

1.91

2.47

0.02

2.49

1.19

0

1.19 TEC4FDEMS VISIOTOOL


Cost saved vis-à-vis Tec4fde = INR 0.72 million.Cost saved vis-à-vis MS Visio = INR 1.3 million.

Why our approach is a better one?

Advantages overTec4fde

Saves time and cost

Less training hours

Simplified and user friendly

Can be used in any computer

Advantages overMS Visio

Saves time and cost

No supporting software needs to be installed

Avoids manual errors

Error handling and Input data checks


Since SIEWIRE produces wiring drawings in very low time and cost, it becomes possible to produce wiring diagrams in all, big and small projects.


Additional Advantages

• Tec4fde is beyond

the budget of the project

• No wiring diagram

document used

• Using tabular data instead of graphical wiring

details for panel wiring, FAT panel checks and commissioning becomes difficult.

• Tec4fde used to

produce drawings

In Big Projects In Small Projects

Feedbacks from: • Siemens Employees who have created wiring diagrams before.• Siemens employees working in TATA Trombay stage 2.• Project manager of the TATA project.

Feedback


Average Rating

(1 to 10)Ease of use 9.2

Accuracy 8.6

Output quality 8.8

Managed to save time 9.6

Variety of templates 7

• Can be used in Industries Sector to create wiring diagrams for DCS panels used to control Cement plant, Steel plant etc which contains approximately 10,000 IO’s.

Scope in Other Sectors


Next Steps


• Code to produce wiring diagrams at one click

• Wiring Diagrams for projects with FIM• Data checks & Error Handling.• Create other Hardware Engineering

Documents• User to upload his own diagram

templates.