Levels of Integration Specification

Our specification defines X6 Levels of integration for packages

- Level 1 Integration - No Package PLC

- Level 2 Integration - Package PLC in a safe area
- Level 3 Integration - Package PLC in the field
- Level 4 Integration - Package OSBL/ in the field
- Level 5 Integration - Discrete/ analogue signal interchange
- Level 6 Integration - OPC UA
- Level 7 Integration – OPC DA OSBL – TBD (more IT > OT)

It should be noted that there may be hybrids of the levels of integration above.
Levels of Integration – Integrated Level #1 = Easy
Pros
- less hardware than a ‘package’
no switches, cables
- UPS power as no field PLC etc
- Reduced footprint in LER/ Field
- Control of Cyber Security (back door)
- Seamless HART diagnostics
- Seamless Time Synch
- $$ savings construction,
commissioning and construction.

Equitables
- Remote IO enclosures and cards
- Interface engagement different

Cons
- More work upfront- Advanced ‘freeze
design’ dates for Emerson config
- Emerson config $$ costs v Vendor
Levels of Integration – PLC Level #2 – complex
Pros
- Less work upfront- No reqirement of
an Advanced ‘freeze design’ date for
Emerson config

Equitables
- Emerson v Vendor Config negligible
- Interface engagement ‘traditional’
read that as you will!
Cons
- More hardware ‘package’ switches,
cables
- Additional UPS power loading and
cables etc
- A x2 + footprint in LER/ Field
- Control of Cyber Security (back door)
- Interface and cost HART diagnostics
- Interface and cost Time Synch
- Added interfaces - construction,
commissioning and construction.
Levels of Integration – PLC – Level #3 – complex Pros
Level 3 Integration - Less work upfront- No reqirement of
Suppliers Package (skid / module) LER / MCC Building PCA Building an Advanced ‘freeze design’ date for
(East / West) (Rack Room)
Emerson config
LCP
DCS Field Note 2
Field HART / MUX iDMS CLOCK
Devices
Devices-- Note 1
4-20mAHART
4-20mA HART Package HMI
AV-Encoder Note 2

Equitables
Av-Decoder
FieldField
DCS Devices -
DevicesIO-
Digital Note 2 ICSS DCS
Digital IO
Package PLC
Controller
- Emerson v Vendor Config negligible
Bespoke
package
- Interface engagement ‘traditional’
Note 3 Note 3 Note 5 Alarm & Events
controller
e.g. Anti-
Note 2
Cons
surge, CEMS

Historian
Electrical
Electrical
e.g. motors
Note 1
Switch gear/
MCC's Note 4
- Class 1, Div 2
- HVAC and cabinet cooling
Vibration,
- More hardware ‘package’ switches,
Orbit 60 MMS Note 2 Supervisory
thrust, bearing (Note 6) MMS e.g. S1
sensors

(trip) Note 1 Note 1

cables
SIL/
FGSFGS
Devices -
Devices -HART
4-20mA
Note 1
(trip) (trip)
- Additional UPS power loading and
cables etc
4-20mA HART PLC
SIS/ FGS Engineering
ICSS SI/ FGS
SMART
SIS/ FGS ICSS SI/ FGS Workstation
- A x2 + footprint in LER/ Field
FGS FGS
SIL/ FieldField Controller
JBs
SMART Controller
Devices -
Digital IO Operator
Workstation - Control of Cyber Security (back door)
Notes
1 - Hardwired copper connection
- Interface and cost HART diagnostics
2 - Redundant Fibre Optic connection
3 - Can be datalink or hardwired
- Interface and cost Time Synch
4 - Redundant FO or CAT connection
5 - CEMS/ Analyser link to Analyser Maintenance Management System - Added interfaces - construction,
6 - Orbit 60 rack to be mounted in local control panel, in field or LER
commissioning and construction.
 Project and ongoing
5 13 13
Level of effort / engineering/ labour CAPEX & OPEX (total) 38.5% 92.9% 92.9%
Item Level 1 2 3 Discussion trigger
ICSS Process control, alarms, setpoints and status information configured within the ICSS and used for YES - - Control Narratives, logic diagrams and data for software configuration. Vendor
display, acknowledgement and historizing. and MAV interface and management
Design Package Suppliier detailed FDS, I/O and Alarm List YES YES YES Required for mapping lists
Design First Out Alarm/ Trip Annunciation (both Analogue and Digital strings) - YES YES Digital alarm/ trip tags in the PLC transferred to the ICSS
Design UPS Power (battery back up of PLC Cabinet) - YES YES UPS back up of Remote IO incorporated in the design of CTO enclosures
Hardware Instrument to field JB/ and or Controller YES YES YES Negligible
Hardware Cabinet with PLC automation Controller Comms, Network Switch, Fibre converters etc - YES YES IO included in the DeltaV CHARMS infrastructure
Hardware Additonal support cables wrt to infrastruture - FO, Time Synch, HART - YES YES DeltaV CHARMS CTO enclosures within design. Some growth but no big impact
Time Sync Time synchronization with the ICSS Master Time Server - YES YES Not required if incorporated in DeltaV ICSS
Diagnostics Instrument HART diagnostics via HART Multiplexers - YES YES Not required if incorporated in DeltaV ICSS
SIL Safety Integrity Level implemented within IEC61511 certified PLC - YES YES Not required if incorporated in DeltaV ICSS
FAT The Package Supplier FAT and attend Integration Testing to confirm correct configuration. YES YES YES Similar requirements
SAT The Package Supplier SAT to compete system commissioning and Site Acceptance Testing. YES YES YES Similar requirements
Maintenace Hotfix, upgrades - YES YES Hotfixes under DeltaV covered anyway. Vendor PLC's would be additional
Maintenace Obsolescence - YES YES Supported through DeltaV frame agreement. Vendor PLC's based on PLC model
 On the Net
https://www.thefreelibrary.com/DCS+vs.+PLC.-a057641056
Life cycle management costs for a component-based system [PLC/HMI] vs. an integrated
system [DCS] through its maintenance, evolution, changes, updates and additions can be
substantially more