DCS_1_Process_Control_System_2016_04.pdf

DESIGN CRITERIA AND STANDARDS
Electrical DCS
Process Control System
Edition January 2016
DESIGN CRITERIA AND STANDARDS
Electrical DCS
Process Control Systems
Edition April 2016

Electrical DCS – Process Control Systems
Edition April 2016 2/28
Table of contents
1 Introduction......................................................................................................................... 3
2 Definitions........................................................................................................................... 3
3 Codes and Standards ......................................................................................................... 3
4 General............................................................................................................................... 4
4.1 Project and System Language ..................................................................................... 4
4.2 Software Version and Licenses.................................................................................... 4
5 Process Control System (PCS)........................................................................................... 4
5.1 Approved PCS Suppliers ............................................................................................. 4
5.2 Basic Requirement for PCS ......................................................................................... 4
5.3 WEB-Server................................................................................................................. 6
5.4 Process Data Information System (PDIS) .................................................................... 6
6 PCS Basic Engineering....................................................................................................... 7
6.1 Analog Measurements List........................................................................................... 7
6.2 Process Interlocking Diagrams..................................................................................... 7
6.3 Employer’s Machine Interlocking.................................................................................. 9
6.4 Master Interlocking Matrix...........................................................................................10
6.5 PCS Hardware Structure.............................................................................................11
6.6 Server Hardware.........................................................................................................11
6.7 Operator Station Hardware .........................................................................................12
6.8 Engineering Station Hardware ....................................................................................12
6.9 Switches .....................................................................................................................12
6.10 Automation System (AS) PLC.....................................................................................13
6.11 Virtualization Software ................................................................................................13
6.12 Storage Area Network (SAN) ......................................................................................13
6.13 PCS – Structure for Employers plants (w/o VM)..........................................................14
6.14 PCS – Structure for Employers plants (with VM).........................................................15
7 PCS Software ....................................................................................................................16
7.1 General Requirements for HMI system .......................................................................16
7.2 PLC Programming ......................................................................................................17
7.3 PCS – Siemens CEMAT .............................................................................................18

1 Introduction
This document is the Design Criteria and Standard for the Process Control System
a)
works, and includes the following functions
1. Process Control System (PCS) itself – main functionality
2. WEB-Server for remote and secure access to all process information, HMI,
trends etc.
3. Process Data Information System (PDIS) – for long term saving of production
and process data and reporting system.
This document must be always applied together with Electrical DCS Electrical General
b)
Requirements.
2 Definitions
The following words and expressions shall have the meanings hereby assigned to them:
Term Explanation
WEB-Server shall have the meaning as web-, online-, internet-based platform
for all PCS information
VM shall have the meaning as Virtual Machine
HMI shall have the meaning as Human Machine Interface; monitor,
graphic interface of PCS
Programmer shall have the meaning as Contractor's personnel, or 3rd working
on behalf of the Contractor
Profibus-DP (Process Field Bus) is a standard for fieldbus communication in
automation technology. Profibus-DP is openly published as part of
IEC 61158.
PDIS Process Data Information System
PxTrend Standard for PDIS functionality
Solution Provider shall have the meaning as a contractor certified by the PCS
supplier (ABB, FLSA or Siemens) to perform engineering services
on CS's in accordance with the set rules and guideline
Table 1
3 Codes and Standards
See Electrical General Requirements DCS

4 General
4.1 Project and System Language
The process control system language shall be in English as first language and local,
a)
country language as second language.
All software including operating system on all computers and PLC’s shall be English.
b)
All steps of engineering, all comments, explanation, help tools, etc. shall always be in
c)
English language.
The online PCS system shall have the option to switch between English and local
d)
(Country) language. It means all user texts, all system texts visible for operator shall
exists in English and local language. Employer can provide translation for all user
texts.
4.2 Software Version and Licenses
Software used at the system shall be the latest available version and approved and
a)
agreed by Employer.
All licenses shall be provided for the whole system and the number of licenses shall
b)
include 25% spare expansion capacity.
5 Process Control System (PCS)
5.1 Approved PCS Suppliers
The Employer allows the following control systems only:
a)
1. Siemens PCS7 with CEMAT Minerals, latest version available on the market.
2. FLSA ECS with SIMATIC S7; HeidelbergCement standard, latest version available
on the market.
3. ABB System 800; based on the cement library;
The supply of all other process control systems require the explicit and written
b)
approval of the Employer.
5.2 Basic Requirement for PCS
5.2.1 Requirements for programmer
Programmers of the control system must be certified as Solution Provider by “original
a)
vendor” like Siemens, ABB or FLSA.

Solution Provider certificate and reference list (of involved programmers not
b)
Contractor as company) to be presented to Employer.
5.2.2 Design requirement and concepts
Long term software and hardware support must be ensured.
a)
Standard PC hardware shall be used.
b)
Compliance of IEC 1131 shall be ensured.
c)
HMI with full redundancy and flexibility shall be ensured.
d)
Critical safety interlocking must be hard-wired and must have a feedback to the
e)
“PLC”. For example CO measurement for protecting electrostatic filter, pull rope
switches.
Autonomous PLC function; the PLC function must stay active even if the HMI system
f)
is down.
All custom code program (Sub-controls) and subroutines for all levels of the control
g)
system may be developed by a third party. A standard library of subroutines to
access data base and HMI screen shall be provided and these routines shall allow
access to all data base fields.
The shutdown of one independent process system PLC shall not interfere with the
h)
operation of other process systems.
The process control system shall have redundant server capabilities running on
i)
standard computers. All information from all systems and other information sources
can be displayed and controlled by each operating station (monitor).
If communication is lost or a PLC-CPU shuts down, all HMI’s including operating
j)
systems shall retain full control and monitoring functions of all other process sections
(fail safe operation).
At any time, the interruption of bus connections shall not cause malfunction of PLC's
k)
or the control system, for example with a watchdog function.
There shall be 3 Ethernet communication layers:
l)
1. The 1st layer, automation net, is between the HMI-Servers and the PLC’s.
2. The 2nd layer, terminal net, is between the HMI-Servers and operating
stations, engineering systems e.g. PDIS, kiln scanner, energy management,
automated laboratory etc.
3. The 3rd layer, production net, is between the Process Data Information
System (PDIS) bus segment and the IT network.
5.2.3 System installation requirements
All PLC central units, all servers and PC’s shall be located in a separate computer
a)
room. It is very important, that computer room is equipped with air conditioning and
PCS will have their own, 20 kVA or larger, UPS.
The power sockets for the servers and OP stations must be individually protected
b)
against over current and short circuit.
The temperature of the devices must be monitored according to their technical
c)
needs. Precautions against too high temperatures have to be foreseen.

Bus connectors to devices shall be surge protected. Best way to accomplish is by
d)
cabling with fiber optics, at least outside of buildings.
The installation of operator workstations shall be possible at any place on the
e)
process network.
5.2.4 Communication, Bus Systems
Bus redundancy is not required
a)
TCP/IP communication protocol is preferred for the local network between PLC and
b)
HMI:.
No direct connection between process control network and IT network. However if
c)
this is required both networks may be connected via firewall only. The security
concept must be discussed and approved by Employer.
For power measurement equipment at LV- and MV- power distribution a separate
d)
Profibus-DP line (separate Profibus-DP card) shall be used.
Profibus-DP as fieldbus shall be used to connect the following systems:
e)
1. VFD
2. Weight feeder
5.3 WEB-Server
To increase the security of the process control system, all remote accesses to online
a)
information shall never go to the real process control server or work station. A WEB
server shall be used for this purpose.
All systems outside of CCR shall be WEB-Based systems.
b)
All HMIs, curves, alarms and other information in WEB-format shall be available for
c)
viewing, without additional engineering effort.
5.4 Process Data Information System (PDIS)
Contractor shall utilize Employer’s standard system which is the Software “PxTrend”.
a)
Contractor shall provide all services needed to:
b)
1. Basic and project related configuration and set up of the server, interface PC,
full-clients and web-clients
2. Long term storage of all process and production data for at least for 24
months.
3. Provide reports for any needed key performance indicators
4. Provide reports for any production and quality
5. Provide diagrams of all process and production data to be used within the
web-client

6 PCS Basic Engineering
PCS design is based and dependent on process, mechanical and electrical design, and
a)
all documents developed by others.
All PCS basic engineering documents, specified in this DCS shall be developed and
b)
presented to Employer for approval.
6.1 Analog Measurements List
Such a list shall contain all analog measurement points, based on process flow diagram,
for all points. The measurement unit, measurement range, all limits to be controlled and
monitored in the system shall be defined. Employer’s requirements to be followed, are
illustrated below:
Table 2
6.2 Process Interlocking Diagrams
Based on process flow diagram, motor device list, Instrumentation list and machine
function description Contractor shall develop the process interlocking diagrams. Process
interlocking shall also contain the group, route and selection list with all corresponding
equipment, alarms and measurements.

Figure 1: Interlocking Diagram
Figure 2

6.3 Employer’s Machine Interlocking
All machine safety related or safety signal shall be shown just at the machine
a)
interlocking diagrams for each type of machine (Belt conveyor, Rotary feeder, mill
main motor etc.). Speed sensor, misalignment switches, rope safety switches, shall
just be shown at the machine- and not at process- interlocking diagrams.
Only approved interlocking diagrams shall be utilized for programming.
b)
Interlocking diagrams and eventually other important documents shall be available at
c)
the control system as PDF file organized by process areas and located under “system
information”
Figure 3: Machine Interlocking

Figure 4: Machine Interlocking
6.4 Master Interlocking Matrix
Master process interlocking matrix shall define all important process interlocking
a)
especially between process areas. Contractor shall develop a matrix showing all
master interlocking.
An example of the master interlocking matrix (just part of it) is shown below:
b)

Figure 5: Master Interlocking Matrix
6.5 PCS Hardware Structure
The following requirements are to be followed:
Siemens or ABB PLC Hardware
a)
Industrial Ethernet (TCP/IP) for communication PC-PLC and PC-PC only (No for any
b)
communication to the field, or I/O Racks).
Profibus-DP communication between PLC CPU and I/O Rack or smart devises
c)
Server-Client architecture only.
5-7 clients equipped with two (2) monitors on each PC.
d)
One (or two) engineering systems for the whole control system (all components): PLC,
e)
PC, Servers, Laboratory and Expert system programming shall be equipped with
respective software. Engineering station shall also be equipped with two Monitors.
Employer’s IP addresses and MAC addresses have to be used.
f)
Two (2) laser printers shall be for the following applications:
g)
1. Report & alarm printer
2. Color Printer for graphics.
Preferred brand of computer hardware is “DELL Inc.” and HP.
h)
6.6 Server Hardware
19” Rack mounted Server hardware.
a)
Latest generation of processors and at least 8 GB RAM.
b)

For VM solution the server must support VT-x and be VM certified.
c)
Redundant power supply.
d)
Raid 1 for Operating System with two (2) hard drives, the third (3.) hard drive shall just
e)
be installed as hot spare.
All hard drives shall be accessible from outside for easy change.
f)
Hard drives size > 750GB
g)
Siemens Network Card CP1623 for PLC communication or Siemens softnet in case of
h)
using a standard network card.
English keyboard, mouse and > 19” LCD-monitor for each server.
i)
6.7 Operator Station Hardware
Standard PC. Form factor to be approved by Employer.
a)
At least 4 GB RAM
b)
Dual screen graphic card with HD resolution.
c)
Two (2) 24“-Flat Monitors with 1920 x 1080 (full HD) resolutions on each.
d)
KVM extenders for; monitors, English keyboard, mouse and speakers for > 20 m.
e)
Only digital input (HDMI or DVI) of the monitors shall be used. If cable extension were
f)
chosen then just an HDMI cable shall be used.
As an option thin clients can be used, especially when a VM configuration is used.
g)
6.8 Engineering Station Hardware
Standard PC, rack mounted (tower, or desktop possible).
a)
At least 8 GB RAM
b)
Siemens Network Card CP1623 or Siemens Softnet in case of using a standard
c)
network card for PLC communication
Double screen graphic card with HD resolution.
d)
Two (2) 24“-Flat Monitors with 1920 x 1080 (full HD) resolutions.
e)
English keyboard, mouse.
f)
6.9 Switches
Only managed switches shall be used
a)
Preferred brands are:
b)
1. Siemens Scalance
2. Cisco
3. HP

6.10 Automation System (AS) PLC
Siemens S7 S7-400 Family:
a)
1. 9 Slots Rack UR2
2. CPU S7 416-3, approved by the Employer
3. CPU 410-5H with the amount of process objects approved by Employer
4. CPU S7 416-2 or 414-3 –for ECS
5. Power supply PS407, 10A
6. Ethernet CP443-1
ET200M:
b)
1. Rail: 195
2. Profibus-DP: IM153
3. DI, 16 x 24V: 6ES 321-1BH02…
4. DO, 16 x24V: 6ES 322-1BH01…
5. AI, 8 x 12: 6ES 331-7KF02…
6. AO, 4 x 12: 6ES 332-5HD01…
AC 800X requires the approval of Employer.
c)
For ABB System CPU’s only an ABB PLC shall be used.
d)
I/O cards can be either Siemens or ABB.
e)
6.11 Virtualization Software
Preferred Virtualization software is VMware VSphere latest version
6.12 Storage Area Network (SAN)
In a virtualized environment the use of a SAN shall be used to provide backup and
a)
restore capabilities that are easy to maintain with high levels of availability and
reliability.
Preferred brand is NETAPP
b)

6.13 PCS – Structure for Employers plants (w/o VM)
Figure 6

6.14 PCS – Structure for Employers plants (with VM)
Figure 7

7 PCS Software
7.1 General Requirements for HMI system
All HMI pictures: overview, process, details must be developed as static picture first
a)
and only after approval shall be utilized for system connections.
For each type of pictures the Employer can provide examples.
b)
Screen background shall be Light grey
c)
7.1.1 Colors of Process pictures
Material routes and pipes:
a)
1. Material routes: black
2. Air-routes: light blue
3. Gas: yellow
4. Water: green
Material storage and silos:
b)
1. Cement: gray
2. Clinker: dark red
3. Gypsum: light yellow
4. Slag: light pink
5. Limestone: brown
6. Coal: black
7. Gas: light red, yellow
8. Oil: cyan
9. Air: blue
Screen-buttons / Function-button:
c)
Function Color foreground
Color
background
Font
Function button White Dark blue 12,bold,Arial
Fast stop White Red 12,bold,Arial
Screen button Black Gray 12,bold,Arial
Picture select Black Gray 12,bold,Arial
Table 3

7.2 PLC Programming
7.2.1 PCS general statement
All equipment and signal names and all equipment and signal description texts must
a)
everywhere be the same.
PCS programming must be based on system documentation, state of the art, best
b)
practice and Employer requirements. All programming mistakes must be cleaned,
corrected and optimized by the Contractor. All efforts related to programming,
commissioning, optimizing or cleaning of the PCS even when help of 3rd parties’
programmers are needed shall by on behalf of the Contractor.
PCS programming shall contain WEB-Server and PDIS parametrization as well.
c)
7.2.2 PCS Alarming System
Good interlocked alarming system provides just one alarm for one reason; all other
a)
alarms must be blocked (interlocked). Alarming interfaces shall be used on each
module to make sure that nuisance and not relevant alarms are being blocked.
Detail machine interlocking must be based on approved machine interlocking
b)
diagrams.
During and after commissioning “hit list” – Alarm system function showing the most
c)
frequently alarms shall be used to identify all of the “not-perfect” ones and optimize
them.
7.2.3 Default PCS module parameters
Based on system documentation and long term experience useful default parameters
shall be used from very beginning. To avoid unnecessary alarms the first set-up shall be
adjusted dependent on application already, examples:
Drive:
a)
1. Start delay = 2s
2. Stop delay = 2s
3. Feedback delay = 3s
Damper:
b)
1. Limit switch delay = 2s
2. Run-time monitoring = 90s
Analog measurement:
c)
1. In generally delay live zero = 3s; hysteresis = 2s
2. Current or power measurement: Spike suppression time = 3s; Smoothing
time = 5s
3. Pressure measurement: Spike suppression time: 1s;
During commissioning and first operation all parameters shall be optimized and saved
back to original project (engineering station) to make them default for this project

7.2.4 Final process and system parameters
All system parameters shall be written not just in the online system but also in the
a)
off-line program at engineering station to avoid losing them when system must be re-
loaded.
After commissioning and optimizing of the system all system and process
b)
parameters shall be saved and additionally documented in a text or excel file.
7.3 PCS – Siemens CEMAT
7.3.1 Software Structure of HMI system
Employer requires standards structure for all process areas, for each process areas
a)
shall be a fixed structure:
Overview HMI shall be able to operate the whole area (like cement mill) control
b)
groups, analog measurements and analog curves.
At least for the clinker production one master screen shall be developed containing
c)
all main machines and process values, enough to operate the entire production line.

Table 4
CEMAT Screens Overview (PCS7)
11. Material Unloading 21. Preheater & Calciner 31. Transport to Cement mill 41. Cement handling
12. Raw Material Handling 22. Kiln 32. Cement mill 1 42. Packing & loading
13. Coal Handling & burners 23. Clinker Cooler & Transport 33. 43. Power, Air, Water
14. Raw Mill 24. Slag Handling 34. Cement transport 44. Reports / System / Service
11. Material Unloading Main HMI -Overview GU01, GU02, GS01, PLC1
Group -overview " - "
Measuring -Overview " - "
Closed control loops -Overview " - "
Curve / trends -Overview " - "
Detail HMI 1:
Detail HMI 2:
Detail HMI 3:
Detail HMI 4:
12. Raw Material Handling Main HMI -Overview MC01, MC02 , RH01, RH02 PLC1, 3
Detail HMI 1:
Detail HMI 2:
…
14. Raw Mill Main HMI -Overview RM01, RT01, RH03 PLC3
Detail HMI 1:
Detail HMI 2:
…
22. Kiln Main HMI -Overview KL01, FC01-02, KE03-04 PLC2, 4, 5
Detail HMI 1:
Detail HMI 2:
…
32. Cement mill 1 Main HMI -Overview CM01, CT01 PLC6
Detail HMI 1:
Detail HMI 2:
…
43. Power, Air, Water Main HMI -Overview Emergency power PLC1, 2, 6,
Group -overview GA20, -40; -50; GW02, -04, -05
Detail HMI 1: Emergency Power
Detail HMI 2: Compressed air
Detail HMI 3: Process water
…..
44. Reports / System / Service Main HMI - Overview Production Reports All
System overview PCS Overview (all PC, all PLC)
System overview PLC 1-8 with profibus
Interlocking Diagrams PDF
CEMAT Documentation PDF

7.3.2 Naming system for HMI pictures
Overview Area:
a)
1. “pso_xxzz.pdl” = Process-picture system overview
Overview Pictures:
b)
1. “ppo_xxzz.pdl” = Process-Picture overview
2. “pmo_xxzz.pdl” = Process-Measurement overview
3. “plo_xxzz.pdl” = Process-Closed loop controller overview
4. “pco_xxzz.pdl” = Process-Curves overview
5. “pgo_xxzz.pdl” = Process-Groups overview
6. “pzo_xxzz.pdl” = Process-Recipes overview
Process-, Detail-Pictures:
c)
1. “pd_xxyyz.pdl” = Process-Detail picture
Number designation:
d)
1. xx = Plant-section-identification
Process Area Overview no. 11, 12…44
2. yy = Process picture number
3. z = Serial picture no. 1-9
7.3.3 Definition of pictures
Process-Pictures overview:
a)
1. Main HMI of each process area, inclusive of all groups, routes and main
equipment shall provide status overview of the production area with groups,
routes, motors and alarms.
2. Main HMI can be used to operate respective process area or call up other
detail pictures as necessary.
Process-Measurement overview:
b)
It is the overview of all measurements for each process area. Based on
groups or Tag of individual measurement a detail bar-picture can be selected.
Process-Closed loop controller overview:
c)
It is the overview of all close-loop controllers for each process area. Based on
groups or tag of individual measurement or controller a detail bar-picture can
be selected.
Process trend overview:
d)
It is the overview of all pre-defined groups of curves for each process area.
Based on groups or tag of individual measurement the trend-picture can be
selected.

Process-Groups overview:
e)
It is the overview of all groups, routes and selections for each process area.
This picture can be used to operate the master group (one group starting all
other groups).
Process-Detail pictures:
f)
Process Detail Graphic provides all details for part of the process area.
Example: detailed graphic for lubrication system or main equipment with all
the analog measurements, digital alarms, timers, counters etc.
7.3.4 HMI Pictures Example
For each process area the following HMI graphics shall be provided:
Process overview HMI: to be used mainly to operate the process and shall contain all
a)
important information, all groups and routes.
Master group HMI: to be used to operate and see all groups, routes and shall contain
b)
all groups, routes and selection modules.
Analog measurements: to make finding of needed measurements easier and shall
c)
contain all analog measurements organized in logical groups.
Close loop controllers: to make finding of needed controller easier and shall contain
d)
all close loop controllers organized in logical groups.
Trends HMI: logical for process, pre-designed trends HMI for 2-6 trends in one
e)
picture for easier finding and operating.
Process detail HMI: 1-5 or 6 pictures to show all details available to be used for
f)
diagnosis, or when more details needed.
For the whole system following HMI picture shall be provided (under system
g)
information)
1. Electrical energy measurement HMI showing power consumption with status
of the devices.
2. Emergency power HMI to operate power generator and all consumers
connected to it.
3. Servers, PLC, I/O rack status HMI showing the status of the system,
especially for diagnosis and maintenance. MCC status picture with all detail
signals field by field.
4. Interlocking diagrams and other important documents as PDF, available to
operators on PCS screens.

Figure 8 - Screen 01: Process area overview
All HMI pictures shall have the following format:
h)
1. HMI Picture name to be placed on top of each picture
2. Alarm group to be placed on each picture, top right side
3. All groups and routes to be placed at the picture at the side
4. Push buttons for selection of detail HMI (F1-F7)
5. Numbers of colors for the static pictures shall be limited

Figure 9 - Screen 02: Measurements overview
Figure 10 - Screen 03: Trends overview

Useful groups of measurements (mill bearing lubrication).
i)
If not enough space, second overview shall be created.
j)
Picture name at the first line on top.
k)
List of the groups shall be approved by Employer.
l)
Figure 11 - Screen 04: Closed loop controller overview

Figure 12 - Screen 05: Emergency Power (Diesel generator)
In case of loss of electrical power the diesel generator and all equipment powered by
m)
emergency power must be available and controlled from one central place with all
information needed for very quick actions.

Figure 13 - Screen 06: Example for MCC overview
Figure 14 - Screen 07: Profibus overview example

Figure 15 - Screen 08:Production report #01
7.3.5 PCS CEMAT users
Example for user groups and user rights shown in figure 16.

Figure 16
7.3.6 PCS WEB-Server engineering
Contractor shall perform all parameterization, set-up or programming required to make
WEB-Server functioning properly.
7.3.7 PDIS engineering
PDIS as part of PCS system shall be included into engineering, delivery and
commissioning of the whole system. Contractor shall include all available data for
archiving and provide at least one common and one production report for each process
area.
No.
User Group
Rights
Operation / activities Operator
Shift
Leader
Mainten.-
Supervisor
Process
Supervisor
System
Administrator
1 User administration System configuration x
2 Authorisation for Area System configuration x x x x
3 System change System configuration x
4 Monitoring Call-up of the faceplates x x x x x
5 Process controlling
Manual operation,
changing the operation mode,
Changes of set points
x x x x
6 Higher process controlling Limits value of the controller x x
7 Report system Not used anymore
18 Modify warnings limits Measuring value x x x
19 Modify alarm limits Measuring value x x x
20 Modify switching limits Measuring value x x x
21 Controller parameters Change of parameters of controller block x x
22 Object parameters Change of process values x x
23 System operations Reset function x
24 Interlocking signals Override and simulation function x x x
25 Enter Recipe Receipe handling (later use) x x
26 Read Recipe Receipe handling (later use) x x x x
27 Modify info-dialog General settings in the info dialog x x
28 Object info-parameters Service Tab in the info dialog x x x x
29 Maintenance Change of device information in the maintenance dialog x x x
1000 Remote activation System configuration x
1001 Remote configuration System configuration x
1002 Web Access monitoring only System configuration x
1100 Highest process controlling System configuration x

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