Bactee comments on Automation front :

 
Raspberry network cable: 
This cable does not have a substitute for this project and it is very susceptible to damage.
When installing this cable, any kink, stretch or stress on the jacket such as around a corner
will cause the raspberry color to turn white indicating cable integrity has been damaged and
replacement will be required.  Our team recommends that this cable be secured from and
installed by the BacTee team during the next site visit. 
 
Shielded sensor cable: 
This is just a 22 gauge 2 and 4 conductor totally shielded with drain wire.
This can be substituted with any like cable in the event of damage.
 
Shrink caps: 
The caps should be procured in the US and shipped with the BacTee team   The caps have an
adhesive inner liner to keep gases/moisture from attacking the copper conductors they are
protecting. This is a heat sensitive product and it very likely the original units are no longer
usable.
 Sikaflex:
This is a heavy concrete polyurethane caulk to prevent gas and
moisture leakage into the sensors and panels.  This product can
be substituted but be aware the equipment will not survive the
environment of the compost hall should this gas/moisture seal
be broken at any time.
 

 
Duct Seal: 
This product is a clay type sealer that does not get hard over time allowing for a long-term
gas and moisture seal.  Wabag can use any product available that will provide the same
performance.
 
UPS:  
The UPS should be large enough to handle the server and the BCM (ACM) controller.  The
BCM (ACM) should remained powered all the time.  The logic and software is designed to
notify personnel of a power outage at any location in the process. This can only be
accomplished if the server and the BCM (ACM) are powered and fully functional.
 
Air Hose: 
If the air hose in the photos is still pliable and without cracks causing leakage, it can be
reused.  If the hose has gotten dry and brittle it will fail when installed.

 
BCM/Envision Software: 
The version of the BCM/Envision software installed on the equipment is no longer
supported by the original vendor and any problem requiring vendor support during
commissioning or any subsequent use by the Pappankalan operators will result in a non-
functioning system.  Thus, if this occurs with the existing system during commissioning, an
upgrade will need to take place resulting in delays due to procurement time and likely a
second trip by BacTee personnel.  At this time, the lead time is more than a month to
receive the hardware.  BacTee highly recommends this upgrade (now referred to as
Compass) be secured immediately as there is a very high probability that, after this long a
time, the old system will fail and a second trip would be required to finish the project
creating further delays.
 
Existing computer and software status:
The hardware shipped in the control package goes back to the initial commitments for this
project which included hardware available nominally 8 or more years ago.   This equipment
is now obsolete with respect to running software that is presently supported by the
software vendor (as above).    The lead time to secure the new hardware before BacTee
personnel can secure the equipment and conduct a site visit is at least two months.
 
An upgrade for the above global controller and HMI software to make it reliable and
supported for the benefit of the Pappankalan operation involves the following:
       Replace the Envision software for a licensed copy of the new Compass
software
       Replace the Envision server with a Lenovo server with Win10 Pro and i5
processor.
       Replace the BCM global controller with an ACM global controller.
       Convert the existing project program, configuration and graphics from
Envision format to Compass format.
       Repurpose existing Envision server into another client HMI terminal
 
This is a web-based software system and the Lenovo web-server needs to have internet
access:

•       10 static IP addresses will be needed for this project. If this system is to be part of the
facilities LAN the BacTee team will require IP, Subnet-mask, Default Gateway IP and DNS
server(s) information two (2) weeks before departing the US.

•       A high-speed internet service needs to be accessible and operational before

departing the US. All equipment functionality is dependent on the BacTee team having
access to complete final setup before startup.

New Bacnet VFD Drive Requirement:

The VFD drive equipment originally provided for the Pappankalan project has a Bacnet card
that was part of the Bacnet Gen-4 chipsets.  Since then, the entire Bacnet industry has
developed new chipsets to speed up the networks and data transfer.  The ACM global
controller is the next generation upgrade and the existing VFD drives have older Bacnet
communications modules. Unfortunately, the existing Bacnet cards on the drives cannot be
upgraded as the vendor replaced the prior P-series drives with new X-Drives.  That being the
case, the system will not be able to communicate to the VFD’s once the software is
upgraded. 

 
The solution is to provide a larger Global Control panel and add two more controllers that
can send and receive I/O points to each drive without a network connection.  This will allow
Pappankalan operations to replace the drives with any drive on the market. With these
controllers, the network option will be removed.
 
BacTee, therefore, recommends the following solution:

Two (2) VLC-1188 controllers in a Type-4 enclosure with panel trim and power supplies.

 
Currently, the hardware for the above is on a 6-week delivery schedule with the precaution
of limited chipset availability.  Immediate ordering is necessary to avoid further supply chain
delays.  At least one (1) week from time of hardware arrival to BacTee personnel in the US is
required before departure from US to India.
 
Cost:
The cost for providing the 1) raspberry network cable, 2) heat shrink caps, 3) upgrade of the
global controller and HMI software, and 4) two VLC-1188 controllers in a Type-4 panel,
is US$22,500 plus freight and any taxes or duties.
 
The BDP Agitator operation does not depend on the DDC control system (BCM) for
operations.  The feedback of the agitator location and distance helps the operators start and
stop other process.  Please note:  If the distance from the dolly panel to the closest BCM
panel is greater than 100 meters then fiber will be required between the panels.  The
current setup is for a cable connection.  If fiber is required, Wabag will have to supply the
additional hardware to support it.
 
Photos:
BacTee personnel would like to see photos of the following:
 The present global controller panel installation, inside and out.
 The MCC room with drives and starters installed and conduit piped.
 The inside of all the zone control panels as installed with conduit connections
completed.
 The inside of the Bio-filter control panel as it is installed with conduit connections
completed.
 All panels hanging on the walls to allow a view of the outside surroundings of these
enclosures.
 All the sensors – temperature and pressure.
 
COVID travel restrictions:  We have been tracking the COVID travel
requirements/restrictions from the Indian and US Embassies.  We understand vaccination is
not required for entry; only a negative COVID test 72 hours before departure and
temperature scans, as required by airlines/airports.  Are there any additional local
travel/lodging restrictions and requirements that may apply?   A letter of invitation from
Wabag declaring members of our team as essential service travelers would be requested
before travel.  This same/similar letter would be required for the update of business visas. 
 
Please review the above in preparation for a conference call later next week.