Client : WK Asia (Ford-India)

System : RTO Control system

Document : I/O List
Rev : 0
Date : 8-Apr-18

Tag Number

Group reference

Instrument No.
Group No.
P&ID Reference

Full TAG
P&I
#

31 WK-RTO 10.00666 B319_256 Air/Water Heat Exchanger-FGS GO 11 8 GO11.8

53 WK-RTO 10.00666 B326_284 Combustion Air (RTO) M 1 1 M1.1
61 WK-RTO 10.00666 B320_260 Waste Air + Fresh Air M 0 1 M0.1
78 WK-RTO 10.00666 B320_262 Diesel Train (RTO) M 7 2 M7.2
WK-RTO 10.00666 B320_264 Combustion Air (RTO) M 1 2 M1.2
WK-RTO 10.00666 B326_286 Combustion Air (RTO) M 1 2 M1.2
85 WK-RTO 10.00666 B321_266 Combustion Air (RTO) PDIC 1 1 PDIC1.1
86 WK-RTO 10.00666 B322_268 Combustion Air (RTO) PDIC 1 2 PDIC1.2
87 WK-RTO 10.00666 B322_270 Waste Air + Fresh Air PDR 0 1 PDR0.1
88 WK-RTO 10.00666 B323_272 Waste Air + Fresh Air PIC 0 1 PIC0.1
105 WK-RTO 10.00666 B329_298 Air/Water Heat Exchanger-WS TR 5 1 TR5.1
106 WK-RTO 10.00666 B323_274 Waste Air + Fresh Air TSA 0 1 TSA0.1
107 WK-RTO 10.00666 B324_276 Waste Air + Fresh Air TSA 0 2 TSA0.2
128 WK-RTO 10.00666 B324_278 Waste Air + Fresh Air XSA 0 1 XSA0.1
131 WK-RTO 10.00666 B325_280 Diesel Train (RTO) PIR 7 1 PIR7.1
132 WK-RTO 10.00666 B325_282 Diesel Train (RTO) PIR 7 2 PIR7.2
133 WK-RTO 10.00666 B319_258 Purge damper / Clean gas QIR 11 1 QIR11.1
 Prepared by :
Submitted by :
Approved by :

Signal

Device Type

Signal Type
Equipment Description Ext. Tag

Clean Gas Inlet to HE valve POS GO11_8_POS VLV_AO AI

Combustion Air Blower VFD 11kw SFB M1_1_SFB VFD AI
Waste and fresh Air Blower VFD 200kw SFB M0_1_SFB VFD AI
Diesel Line valve POS M7_2_POS VLV_MTR AI
Combustion Air line valve POS M1_2_POS VLV_3 AI
Combustion Air line valve POS M1_2_POS VLV_3 AI
Differential pressure Combustion Air blower DPV PDIC1_1_DPV AI_BLK AI
Differential pressure before burner DPV PDIC1_2_DPV AI_BLK AI
Differential pressure waste air DPV PDR0_1_DPV AI_BLK AI
Negative pressure in waste air duct DPV PIC0_1_DPV AI_BLK AI
Heat Exchanger water out temperature TV TR5_1_TV AI_BLK AI
Waste Air Blower bearing temperature-1 TV TSA0_1_TV AI_BLK AI
Waste Air Blower bearing temperature-2 TV TSA0_2_TV AI_BLK AI
Waste Air Blower Vibration value VV XSA0_1_VV AI_BLK AI
Diesel line pressure sensor-1 PV PIR7_1_PV AI_BLK AI
Diesel line pressure sensor-2 PV PIR7_2_PV AI_BLK AI
Gas sensor GV QIR11_1_GV AI_BLK AI
 Signal 0 0 17 0 0 PLC

Module type

I/O Channel
AI-
Tag Description DI DO AI TC AO

Rack

Card
Clean Gas Inlet to HE valve position feedback AI 1 B 319 256
Combustion Air Blower VFD 11kw Speed feedback AI 1 B 326 284
Waste and fresh Air Blower VFD 200kw Speed feedback AI 1 B 320 260
Clean Gas Inlet to HE valve position feedback AI 1 B 320 262
Position feedback, Poti, Potentiometer AI 1 B 320 264
Position control and position feedback AI 1 B 326 286
Differential pressure Combustion Air blower AI 1 B 321 266
Differential pressure before burner AI 1 B 322 268
Differential pressure waste air AI 1 B 322 270
Differnetial pressure AI 1 B 323 272
Heat Exchanger water out temperature AI 1 B 329 298
Waste Air Blower bearing temperature-1 AI 1 B 323 274
Waste Air Blower bearing temperature-2 AI 1 B 324 276
Waste Air Blower Vibration value AI 1 B 324 278
Diesel line pressure sensor-1 AI 1 B 325 280
Diesel line pressure sensor-2 AI 1 B 325 282
Gas sensor AI 1 B 319 258
 PLC Engg
Engg. range Max

Engg. range Min

Terminal Strip
Source supply

Conn. details

Terminal No.
PLC Address

Engg unit

Location
Signal
PIW 256
PIW 284
PIW 260
PIW 262
PIW264 0 1000 Ώ POTI
PIW 286
PIW 266 -5 125 mbar 3W 4-20mA
PIW 268 -5 65 mbar 3W 4-20mA
PIW 270 -5 65 mbar 3W 4-20mA
PIW 272 -5 65 mbar 3W 4-20mA
PIW 298 -50 400 °C 1x PT100 three-wire circuit
PIW 274 PT100PT100 °C PT100
PIW 276 PT100PT100 °C PT100
PIW 278
PIW 280 0 40 bar 4-20mA
PIW 282 0 40 bar 4-20mA
PIW 258
 Controlled by: Fox Remarks

PLC
PLC
PID
PLC Kindly Confirm for the signals. Because we have not considered vol
Valve open and close movement test and position feedback controlPurpose of 2 position feedback AI's?

PLC/PID
Confirm if 4-20mA signal or TC device?
not sure if 2,3 or 4 wire circuit PT100, TBC
not sure if 2,3 or 4 wire circuit PT100, TBC
DI or AI TBC

measuring range unknown and power supply unknown, customer supply, TBC
Because we have not considered voltage modules
 DIGITAL INPUT
0 B101_0 I0.0 CP0_0_LOC
1 B101_1 I0.1 CP0_0_REM
2 B101_2 I0.2 CP0_0_STR
3 B101_3 I0.3 CP0_0_STP
B101 I0
4 B101_4 I0.4 CP0_0_RST
5 B101_5 I0.5 RMT0_0_RSS
6 B101_6 I0.6 CP0_0_BON
7 B101_7 I0.7 CP0_0_CON
0 B102_0 I1.0 CP0_0_SUP
1 B102_1 I1.1 CP0_0_EM
2 B102_2 I1.2 CP0_0_SFTY
3 B102_3 I1.3 M1_1_OPR
B102 I1
4 B102_4 I1.4 M1_1_FLT
5 B102_5 I1.5 CP0_0_GAS
6 B102_6 I1.6 BR0_0_OPR
7 B102_7 I1.7 BR0_0_FLT
0 B103_0 I2.0 PZA2_1_PS
1 B103_1 I2.1 PZA1_3_PS
2 B103_2 I2.2 PZA1_1_PS
3 B103_3 I2.3 PZA1_2_PS
B103 I2
4 B103_4 I2.4 TZA3_1_TS
5 B103_5 I2.5 RMT0_0_DRY
6 B103_6 I2.6 RMT0_0_PRO
7 B103_7 I2.7 RMT0_0_EXR
0 B104_0 I3.0 GO15_1_OPN
1 B104_1 I3.1 GO15_1_CLS
2 B104_2 I3.2 GO15_3_OPN
3 B104_3 I3.3 GO15_3_CLS
B104 I3
4 B104_4 I3.4 GO11_8_CLS
5 B104_5 I3.5 GO11_8_OPN
6 B104_6 I3.6 GO16_1_OPN
7 B104_7 I3.7 GO16_1_CLS
0 B105_0 I4.0 GO16_3_OPN
1 B105_1 I4.1 GO16_3_CLS
2 B105_2 I4.2 LSA7_1_LS
3 B105_3 I4.3 PZA5_1_PS
B105 I4
4 B105_4 I4.4 FZA5_1_FS
5 B105_5 I4.5 PZA7_1_PS
6 B105_6 I4.6 PZA7_2_PS
7 B105_7 I4.7 CP0_0_DIE
0 B106_0 I5.0 PZA7_3_PS
1 B106_1 I5.1 TZA5_1_TS
2 B106_2 I5.2 BR0_0_ONF
3 B106_3 I5.3 XSA0_1_VS
B106 I5
4 B106_4 I5.4 M0_1_OPR
5 B106_5 I5.5 M0_1_FLT
6 B106_6 I5.6 XZA3_1_US
7 B106_7 I5.7 RMT0_0_BYP
0 B107_0 I6.0 PZA1_4_PS
1 B107_1 I6.1 GO11_7_OPN

B107 I6
 2 B107_2 I6.2 GO11_7_CLS
3 B107_3 I6.3 V7_1_OPN
B107 I6
4 B107_4 I6.4 V7_2_OPN
5 B107_5 I6.5 SPR_DI3
6 B107_6 I6.6 PZA1_5_PS
7 B107_7 I6.7 BR0_0_RLS
0 B108_0 I7.0 V1_1_OPN
1 B108_1 I7.1 V1_3_OPN
2 B108_2 I7.2 V1_2_OPN
3 B108_3 I7.3 GO0_10a_OPN
B108 I7
4 B108_4 I7.4 GO0_10a_CLS
5 B108_5 I7.5 GO0_10b_OPN
6 B108_6 I7.6 GO0_10b_CLS
7 B108_7 I7.7 GO0_11a_OPN
0 B109_0 I8.0 GO0_11a_CLS
1 B109_1 I8.1 GO0_11b_OPN
2 B109_2 I8.2 GO0_11b_CLS
3 B109_3 I8.3 GO0_2_OPN
B109 I8
4 B109_4 I8.4 GO0_2_CLS
5 B109_5 I8.5 GO0_8a_OPN
6 B109_6 I8.6 GO0_8a_CLS
7 B109_7 I8.7 GO0_8b_OPN
0 B110_0 I9.0 GO0_8b_CLS
1 B110_1 I9.1 GO0_9a_OPN
2 B110_2 I9.2 GO0_9a_CLS
3 B110_3 I9.3 GO0_9b_OPN
B110 I9
4 B110_4 I9.4 GO0_9b_CLS
5 B110_5 I9.5 M7_2_OPN
6 B110_6 I9.6 M7_2_CLS
7 B110_7 I9.7 M5_1_HLT
0 B111_0 I10.0 M5_1_RUN
1 B111_1 I10.1 M5_1_TH
2 B111_2 I10.2 M6_1_HLT
3 B111_3 I10.3 M6_1_RUN
B111 I10
4 B111_4 I10.4 M6_1_TH
5 B111_5 I10.5 M7_1_HLT
6 B111_6 I10.6 M7_1_RUN
7 B111_7 I10.7 M7_1_TH

DIGITAL OUTPUT
0 B212_0 Q0.0 RMT0_0_SYS
1 B212_1 Q0.1 M1_1_STR_CMD
2 B212_2 Q0.2 BR0_0_ONC
3 B212_3 Q0.3 CP0_0_RSC
B212 Q0
4 B212_4 Q0.4 BR0_0_RSC
5 B212_5 Q0.5 M0_1_STR_CMD
6 B212_6 Q0.6 M0_1_JOG_CMD
7 B212_7 Q0.7 M11_2_CMD
0 B213_0 Q1.0 RMT0_0_ROT
1 B213_1 Q1.1 RMT0_0_WOP
2 B213_2 Q1.2 M15_1_CMD
3 B213_3 Q1.3 M15_3_CMD
B213 Q1
B213 Q1
4 B213_4 Q1.4 M11_8_CMD
5 B213_5 Q1.5 M16_1_CMD
6 B213_6 Q1.6 M16_3_CMD
7 B213_7 Q1.7 M11_7_CMD
0 B214_0 Q2.0 M0_2_CMD
1 B214_1 Q2.1 M0_8_CMD
2 B214_2 Q2.2 M0_9_CMD
3 B214_3 Q2.3 M0_11_CMD
B214 Q2
4 B214_4 Q2.4 M0_1_RST_CMD
5 B214_5 Q2.5 M1_2_CMD
6 B214_6 Q2.6 RMT0_0_CBD
7 B214_7 Q2.7 M1_2_CMD
0 B215_0 Q3.0 M1_1_JOG_CMD
1 B215_1 Q3.1 M1_1_RST_CMD
2 B215_2 Q3.2 BR0_0_ONFC
3 B215_3 Q3.3 BR0_0_TBH_CMD
B215 Q3
4 B215_4 Q3.4 BR0_0_TBC_CMD
5 B215_5 Q3.5 M7_1_CMD
6 B215_6 Q3.6 M6_1_CMD
7 B215_7 Q3.7 CP0_0_HRN
0 B216_0 Q4.0 BR0_0_RBSC
1 B216_1 Q4.1 M0_10_CMD
2 B216_2 Q4.2 M1_1_SPR_CMD
3 B216_3 Q4.3 M0_1_SPR_CMD
B216 Q4
4 B216_4 Q4.4 M5_1_CMD
5 B216_5 Q4.5 M7_2_CMD
6 B216_6 Q4.6 V2_1_CMD
7 B216_7 Q4.7 V2_2_CMD
0 B217_0 Q5.0 V1_1_CMD
1 B217_1 Q5.1 V1_2_CMD
2 B217_2 Q5.2 V1_3_CMD
3 B217_3 Q5.3 V7_1_CMD
B217 Q5
4 B217_4 Q5.4 V7_2_CMD
5 B217_5 Q5.5 SPR_DO6
6 B217_6 Q5.6 SPR_DO7
7 B217_7 Q5.7 SPR_DO8
0 B218_0 Q6.0 SPR_DO9
1 B218_1 Q6.1 SPR_DO10
2 B218_2 Q6.2 SPR_DO11
3 B218_3 Q6.3 SPR_DO12
B218 Q6
4 B218_4 Q6.4 SPR_DO13
5 B218_5 Q6.5 SPR_DO14
6 B218_6 Q6.6 SPR_DO15
7 B218_7 Q6.7 SPR_DO16

ANALOG INPUT
256 B319_256 PIW 256 GO11_8_POS
B319 PIW
258 B319_258 PIW 258 QIR11_1_GV
260 B320_260 PIW 260 M0_1_SFB
B320 PIW
262 B320_262 PIW 262 M7_2_POS
264 B321_264 PIW 264 Poti
B321 PIW
266 B321_266 PIW 266 PDIC1_1_DPV
 268 B322_268 PIW 268 PDIC1_2_DPV
B322 PIW
270 B322_270 PIW 270 PDR0_1_DPV
272 B323_272 PIW 272 PIC0_1_DPV
B323 PIW
274 B323_274 PIW 274 TSA0_1_TV
276 B324_276 PIW 276 TSA0_2_TV
B324 PIW
278 B324_278 PIW 278 XSA0_1_VV
280 B325_280 PIW 280 PIR7_1_PV
B325 PIW
282 B325_282 PIW 282 PIR7_2_PV
284 B326_284 PIW 284 M1_1_SFB
B326 PIW
286 B326_286 PIW 286 M1_2_POS

ANALOG TC INPUT
288 B327_288 PIW 288 TR0_1_TV
B327 PIW
290 B327_290 PIW 290 TR11_1_TV
292 B328_292 PIW 292 TR11_2_TV
B328 PIW
294 B328_294 PIW 294 TR3_1_TV
296 B329_296 PIW 296 TR3_2_TV
B329 PIW
298 B329_298 PIW 298 TR5_1_TV
300 B330_300 PIW 300 TSA15_1_TV
B330 PIW
302 B330_302 PIW 302 TSA16_1_TV
304 B331_304 PIW 304 SPR_AITC1
B331 PIW
306 B331_306 PIW 306 SPR_AITC2

ANALOG OUTPUT
256 B432_256 PQW 256 M11_8_CO
B432 PQW
258 B432_258 PQW 258 M1_1_SSP
260 B433_260 PQW 260 M0_1_SSP
B433 PQW
262 B433_262 PQW 262 M7_2_CO
264 B434_264 PQW 264 SPR_AO1
B434 PQW
266 B434_266 PQW 266 SPR_AO2
268 B435_268 PQW 268 SPR_AO3
B435 PQW
270 B435_270 PQW 270 SPR_AO4
272 B436_272 PQW 272 SPR_AO5
B436 PQW
274 B436_274 PQW 274 SPR_AO6
276 B437_276 PQW 276 SPR_AO7
B437 PQW
278 B437_278 PQW 278 SPR_AO8
DIGITAL INPUT
System Local selection
System Remote selection
Automatic Start Pushbutton
Automatic Stop Pushbutton
System reset Pushbutton
Start/Stop Remote
Burn out ON
Cool down ON
Cicruit breakers no Fault
Emergency no fault
Saftey line fault
Combustion Air Blower VFD 11kw Operation
Combustion Air Blower VFD 11kw Fault
Gas select push button
Burner Operation
Burner Fault
Compressed Air pressure switch min.
Gas pressure switch (Siemens LDU valve leakage tester)
Gas pressure switch (min)
Gas pressure switch (max)
Safety tempeture limiter cumbustion chamber RTO
Only Dryer Signal
Production On
External release
Reactor 1 Waste Air In valve open feedback
Reactor 1 Waste Air In valve close feedback
Reactor 1 Clean gas out valve open feedback
Reactor 1 Clean gas out valve close feedback
Clean Gas Inlet to HE valve close feedback
Clean Gas Inlet to HE valve open feedback
Reactor 2 Waste Air In valve open feedback
Reactor 2 Waste Air In valve close feedback
Reactor 2 Clean gas out valve open feedback
Reactor 2 Clean gas out valve close feedback
Diesel RTO Level Switch
Heat exchanger out pressure switch
Heat Exchanger out flow switch
Diesel High pressure switch (max)
Diesel Low Pressure switch (min)
Diesel select push button
Diesel High pressure switch (max)
Heat Exchanger out temperature switch (max)
Burner Off/On
Waste Air Blower Vibration switch
Waste and fresh Air Blower VFD 200kw Operation
Waste and fresh Air Blower VFD 200kw Fault
Burner control socket UV-detector
Signal bypass
Combustion Air pressure switch min
Clean Gas to Stack HE out valve open feedback
 Clean Gas to Stack HE out valve close feedback
V7.1 Open feedback
V7.2 Open feedback
SPARE_I6.5
Combustion Air pressure switch min
Release Burner
Gas magnet ventil Valve(BMS) open feedback Main gas valve net side on
Trip Valve and regulating device(BMS) open feedback
Trip Valve(BMS) open feedback Main gas valve burner side on
TC Oven 1 reuse air valve open feedback
TC Oven 1 reuse air valve close feedback
TC Oven 1 reuse air valve open feedback
TC Oven 1 reuse air valve close feedback
TC Oven 2 reuse air valve open feedback
TC Oven 2 reuse air valve close feedback
TC Oven 2 reuse air valve open feedback
TC Oven 2 reuse air valve close feedback
Pressure Air Inlet valve open feedback
Pressure Air Inlet valve close feedback
ED Oven new reuse air valve open feedback
ED Oven new reuse air valve close feedback
ED Oven new reuse air valve open feedback
ED Oven new reuse air valve close feedback
ED Oven old reuse air valve open feedback
ED Oven old reuse air valve close feedback
ED Oven old reuse air valve open feedback
ED Oven old reuse air valve close feedback
Diesel Line valve open feedback
Diesel Line valve close feedback
Heat Exchanger Coil Input pump Healthy
Heat Exchanger Coil Input pump Run
Heat Exchanger Coil Input pump Thermistor
Sealing Air fan Healthy
Sealing Air fan Run
Sealing Air fan Thermistor
Diesel Inlet Pump Healthy
Diesel Inlet Pump Run
Diesel Inlet Pump Thermistor

DIGITAL OUTPUT
System On
Combustion Air Blower Start command
Bruner On Command
Reset Command
Burner Reset command
Waste and fresh Air Blower Start Command
Waste and fresh Air Blower Jog Command
Positioner hot bypass damper
RTO System on temperature
System waste air operation
Open waste Air Damper 1
Open Clean Air Damper 1
 Clean Gas Inlet to HE valve command
Open waste Air Damper 2
Open Clean Air Damper 2
Clean Gas to Stack HE out valve command
Pressure Air Inlet valve command
ED Oven new reuse air valve command
ED Oven old reuse air valve command
TC Oven 2 reuse air valve command
Waste and fresh Air Blower Reset Command
Valve move to open position
Collective breakdown
Valve move to close position
Combustion Air Blower Jog Command
Combustion Air Blower Reset Command
Burner on/off command
Temp. controller burner heating
Temp. controller burner Cooling
Diesel Inlet Pump Start/Stop Command
Sealing Air Blower Start/Stop Command
Horn
Reset burner tightness RTO
TC Oven 1 reuse air valve command
Combustion Air Blower Spare Command
Waste and fresh Air Blower Spare Command
Heat Exchanger Coil Input pump Start/Stop Command
Clean Gas Inlet to HE valve command, valve power on
Compress Air Blow out line valve command
Compress Air Cooling air line valve command
V1.1 Command
V1.2 Command
V1.3 Command
V7.1 Command
V7.2 Command
SPARE_Q5.5
SPARE_Q5.6
SPARE_Q5.7
SPARE_Q6.0
SPARE_Q6.1
SPARE_Q6.2
SPARE_Q6.3
SPARE_Q6.4
SPARE_Q6.5
SPARE_Q6.6
SPARE_Q6.7

ANALOG INPUT
Clean Gas Inlet to HE valve position feedback
Gas sensor
Waste and fresh Air Blower VFD 200kw Speed feedback
Clean Gas Inlet to HE valve position feedback
Poti converted 0 -10 V
Differential pressure Combustion Air blower
 Differential pressure before burner
Differential pressure waste air
Differnetial pressure
Waste Air Blower bearing temperature-1
Waste Air Blower bearing temperature-2
Waste Air Blower Vibration value
Diesel line pressure sensor-1
Diesel line pressure sensor-2
Combustion Air Blower VFD 11kw Speed feedback
Position control and position feedback

ANALOG TC INPUT
Waster Air Inlet temperature
Clean Gas HE Inlet temperature
Clean Gas HE outlet temperature
Oxidation Chamber-1 temperature
Oxidation Chamber-2 temperature
Heat Exchanger water out temperature
Below Reactor 1 temperature
Below Reactor 2 temperature
SPARE_PIW304
SPARE_PIW306

ANALOG OUTPUT
Clean Gas Inlet to HE valve command out position
Combustion Air Blower VFD 11kw Speed setpoint
Waste and fresh Air Blower VFD 200kw Speed setpoint
Clean Gas Inlet to HE valve command out position
SPARE_PQW264
SPARE_PQW266
SPARE_PQW268
SPARE_PQW270
SPARE_PQW272
SPARE_PQW274
SPARE_PQW276
SPARE_PQW278
 Spare calculations
In Between Total Total
Total Channels Spare Spare Available Assigned Total Spare Total %
I/O Type Modules per module Modules Channels Channels Channels Channels Spare
AI 11 2 0 0 22 16 6 27.27
AI-TC 5 2 0 0 10 7 3 30.00
AO 6 2 0 0 12 4 8 66.67
DI 11 8 0 0 88 87 1 1.14
DO 7 8 0 0 56 40 16 28.57
Total 40 0 0 188 154 34 18.09