DCS cost estimating

Cost components
Hardware components
Operator console( CRTs, archiving discs, tape
units, printers, engineering station)
Data highway( traffic director, interface for PLC)
Field mounted equipments(LCUs, DAQ units, I/O
files)
Non hardware equipments
Software-configuration, special displays etc
System integration, factory acceptance testing,
documentation, project management, training
maintenance

DCS Definition
First step is to define and size the
main components of the system
Eg: batch process
o 2 fully reduntant operator
consoles(each containing 3 CRTs, 2
printers, and one disk)
o 4multiloop control units
o 2 DAQ multiplexers
o 2 interfaces for communication with
PLC and computer

Filed mounted devices -5 sections

2 areas- own control and ACQ
Tank farm 1 control
Utility area- 1 control
Storage area- PLC
I/O requirements are identified
ACQ provided with integral I/O and
power supply

Hardware estimate
Operators console and related items
Obtain price lists from a no: of DCS suppliers
Establish applicable discount rates
Engineer must first size and specify the required
system components, specify their features and provide
the type of data required
1. Operators console-3 CRTs and keyboard: $70000
each
2. Archiving unit-400MB hard disk and tape drive:
$30000 each
3. High speed hard copy printer: $3000 each
4. An engineering station with intel 486 processor, 80MB
hard disk, two diskette drives, color monitor,
keyboard, laser printer: $30000

Communication Related items

Determine the type of communication
network required
Select the traffic director- appropriate for
number and type of devices supported
by the data highway
Specify the interface devices (COMM)
needed to connect the microprocessor
/computer based devices to DCS

Software cost estimate

DCS manufacturers include only very
small sum ($15000 to $25000)- actual
expenditure is 10-30 times higher
Reason: estimate does not include special
control algorithms, graphic displays, or
sequencing requirements the projects will
have..---- supplier assume standard
software library will suffice to support the
project--- only include linking of existing
software blocks

multiplexing and party line

systems
Enable multiple signals to time share
common equipments( signal
conditioners, communication
channels and data processing
equipment)
Sharing for economic reasonsperforming functions sequentially is
necessary than simultaneous
execution

In the figure
2-more input signals connected to a
switching mechanism
can route any one of the signals
connected at the input terminals to
common output terminals a driver mechanism operates the
switching mechanism
Multiplexer terminal address decoder
provided
Shared signal conditioning equipment
Inpit can be either analog or digital

Party line
Refers to method of
communication
Common
communication
channel shared by
equipments
At each station the
equipment sends
and/ or receives
information from
other stations
along part line

 A station contains local multiplexing systems

allowing multiple systems to share the station and
partly line- integral part
RTU share place din filed to minimize wiring costs
by performing both the multiplexing and ADC
locally
RTU functions
Local storing of data
Logging
timing,
Sequential scanning
checking for alarm limits,
Thermocouple linearization
reference junction compensation
Some limited computational capability

 Each measurement signal transmitted

from sensing element in the filed to the
control room on individual channels
typically pneumatic tubing or electrical
conductors
Displayed on individual indicators
Certain displays share by signals
Eg: multipoint thermocouple
Equipment that selects and switches the
individual thermocouple leads was less
costly than required for separate
compensation