programmable Controllers
Content
SPECIFICATION PREFACE SHEET
DEPARTMENT: Engineering / Instrumentation AREA: Grundartangi Reduction Plant
SHEET
1
OF
14 REV:C3
SPEC No: 00/07/TS009
STANDARD TECHNICAL SPECIFICATION FOR
PROGRAMMABLE CONTROLLERS
This Standard Technical Specification is subject to change without prior notice. The most current issue will at all times be located on the Nordural web site, www.nordural.is. REV
C1 C2 C3
BY
HRY HRY IMJ
DATE
27.09.1999 08.12.2000 2004-06-07
CHK’D
TDS/GH HRY TDS
APPROVED
TMS TPE ÓJ
REVISIONS
First Issue PLC Types Issued for Construction
NORÐURÁL – ENGINEERING
NORÐURÁL
NORDIC ALUMINUM
STANDARD TECHNICAL SPECIFICATION NA-00-07-TS009-C3.doc
CONTENTS
TECHNICAL SPECIFICATION _____________________________________ 3
1 2 3 4
4.1 4.2
INTRODUCTION _________________________________________________ 3 RELATED STANDARDS __________________________________________ 3 STANDARD DEFINATIONS ________________________________________ 4 SYSTEM TAGS __________________________________________________ 4
Facility Code________________________________________________________ 5 Instrument and Loop Number/Process Code and Identifier _________________ 5
5 6 7
7.1 7.2 7.3 7.4 7.5 7.6
DOCUMENTATION _______________________________________________ 5 SYSTEM REQUIREMENTS ________________________________________ 6 HARDWARE REQUIREMENTS _____________________________________ 7
LAN Networks_______________________________________________________ 7 PLC Hardware_______________________________________________________ 7 PLC Power supplies__________________________________________________ 8 I/O Connections _____________________________________________________ 9 Special Requirements regarding Ground _______________________________ 10 General requirements regarding Electrical Installations ___________________ 10
8
8.1 8.2 8.3 8.4
APPLICATION SOFTWARE REQUIREMENTS ________________________ 10
Software structure __________________________________________________ 10 Software licensing __________________________________________________ 11 Integration with other systems. _______________________________________ 11 File Organization ___________________________________________________ 12
9
SAFETY REQUIREMENTS. _______________________________________ 12
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TECHNICAL SPECIFICATION
1
INTRODUCTION
In this Document the following words and expressions shall have the meaning hereby assigned to them except where the context otherwise requires: Engineer: The Owner or any person or organization employed or engaged at any time by the Owner and authorized by the Owner, in writing, from time to time to act on behalf of the Owner in the execution of the items covered by this Document, in whole or in any part, for any or all purposes provided in this Technical Specification. Owner: Norðurál hf (Nordic Aluminum Corporation Ltd.), an independent legal entity owned by Century Aluminum. This document forms a standard of minimum requirements of Programmable Logic Controllers and describes the minimum hardware and software requirements of such controllers and shall be obeyed by contractors working on ICA systems at Norðurál. Documentation and Quality assurance procedures necessary for every ICA system design and installation should be similar to or as described in the Norðurál Standard Technical Specification NA-00-07-TS012.
2
RELATED STANDARDS
The Contractor is required to comply with all standards, which are relevant to the work, including amendments and addenda that are current at the time of order. Particular reference will be made to the following (or equivalent): Icelandic Government Electrical Codes and Regulations no: 264/1971 Icelandic Government Health and Safety at Work Act no: 46/1980 ISA S5.1 ISA S5.3 ISA S5.4 ISA S5.5 IEC 60617 EN 60751 EN 60584 EN 61131.1/2/3/8 Instrumentation Symbols and Identification Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems Instrument Loop Diagrams Graphic Symbols for Process Displays Symbols on Electrical Drawings Industrial Platinum Resistance Thermometers International Thermocouple Reference Tables Programmable Logic Controllers
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The Contractor may identify any other/different standards to which his equipment conforms and this must be submitted to the Engineer for approval prior to the commencement of work.
3
STANDARD DEFINATIONS
The following definitions apply to all the standards produced for use on the project: ICA ‘Industrial Control and Automation based upon programmable electronic systems.’ ICA Level 0 This level comprises plant level, field mounted devices and final elements (e.g. proximity switches, valves, motors, etc.) The hardware for level 0 is outside the scope of this specification. ICA Level 1 This level includes PLC systems, intelligent and non-intelligent MCC interfaces and Local control panel mounted operator terminals (MMI). ICA Level 2 This level equipment comprises a proprietary SCADA packages complete with PC software packages and peripherals. TAG Instrument tag or the definition of a single variable, arriving from an instrument or PLC to either to present information to the control system or carry commands from the control system to devices in the real world REAL PLANT TAG Physical signal generated from hardwired plant devices. DERIVED SYSTEM TAG Variable deriving from other control modules. (Data)
4
SYSTEM TAGS
System tags can be up to 20 characters long. The system tag is split into three components separated with a hyphen (-): • The letters NAL to meet the PLC requirements (1) • Facility Code (2) • Instrument and Loop Identifier (3). These are illustrated in the following diagram: 1 2 3 N A L * * * * * - * * * * * * *
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4.1
Facility Code
The facility code will be made up of a unique two letter, alphabetic / three digit, numeric code which identifies the plant functional area. The first two letters signify the type of system with the remaining three digits identifying the system number within the plant area and system type. Facility codes must be accepted by the Engineer, and shall be based on the equipment identification system adopted by Norðurál, the AKS-Identification system as stated in the Norðurál Standard Technical Specification NA-00-06-TS021.
4.2
Instrument and Loop Number/Process Code and Identifier
This is an alphanumeric element code that will be used to identify either of the following: • Real Plant I/O - Physical signals generated from hardwired plant devices. • Derived System Tag - Variables derived from real I/O or other sources. EXAMPLE: NAL EG000-xxXXX NAL EG000 XxXXX Reads: Norðurál Material handling, Alumina Transfer System is the process code.
5
DOCUMENTATION
Documentation of the PLC installations is extremely important and shall be maintained by the Contractor similar to or as described in the Norðurál Standard Technical Specification NA-00-07-TS012.
Overall structure of the computer program(s) to be compiled for PLC use shall be properly documented using English, high-level structured language and supported with flowcharts where applicable.
All software is to be fully documented. Program listings shall be modularized, well structured, easy to read and traceable for debugging and maintenance. The documentation shall reflect the application hierarchy and show as a minimum the following: • • • • PLC list with Local and extended remote I/O's Parameters External I/O bus and data highway. (RIO) Internal I/O within a package and connections
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• •
Text strings and comments (in English) Names and references (in English)
The hierarchy and structure of modules within the software must be shown including module description, title, level and reference numbers. All software and documentation must be cross-referenced to the associated Structured Design documents, FDS etc.
6
SYSTEM REQUIREMENTS
The system is multifunctional and shall ensure and enable automation and operator control of the plant and equipment, information processing, maintenance and management information. This specification covers the ICA Level 1, which is a composite of PLC's, electromagnetic relays, discrete loop controls, recorders and alarm annunciators. All new installations should use the Allen Bradley ControlLogix 5000 controller platform for large PLC installations and use the Allen Bradley CompactLogix or FlexLogix controller platform for medium and small PLC installation's. It is allowed to install various Allen Bradley I/O systems as long as they are controlled by the Control Logix 5000 system. For I/O systems that are not of the Control Logix family (Block I/O, Compact Block I/O, Flex I/O etc.) or networked over e.g. Device Net, Control Net, etc. the Engineers approval is required before any installation or agreement to pay cost of such installations can take place. If the Contractor requires other type of PLC controllers, the acceptance of the Engineer is needed prior to installation. The system presents the required information via the ICA Level 2 (SCADA and HMI Systems) as appropriate. Where the system comprises a series of sub-systems, each sub-system shall be capable of autonomous operation. This autonomy is to be transparent at the Control Stations. (SCADA, HMI, etc.)
The response times of the system between any ICA Level 0 tag and the ICA Level 2 controls (SCADA, MMI) are required as follows: Item
1 2 3 4
Description
Operator Command Time Tag Resolution Display Update Event Burst Rate
Performance requirement
1 Second for acknowledgement at the operator station. 2 Seconds from command to field output action. +/- 5 msec 3 Seconds (normal) 5 Seconds (exceptional) 500 Tags / Second without data loss.
The system shall be provided with communication modules to communicate with local MMI control stations and a higher level PLC network for both: information sharing with SCADA systems and maintenance of the PLC over a LAN Network.
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Usually the following systems will be used: HMI to PLC PLC to PLC PLC to SCADA and Programming Serial, DeviceNet or ControlNet connection Allen Bradley Control net or TCP/IP Ethernet TCP/IP Ethernet
Normally a serial connection between the Local MMI and the PLC is acceptable as noise immunity is maintained throughout the system. I/O signals used in the system shall have the voltage of 24 Volts DC for discrete signals where applicable, otherwise 230 V AC is acceptable but usage of that signal should be kept at minimum. Analog Signals shall be within the signal range of 4-20 mA in a Current loop, without exceptions. Exception might be when thermocouples are used over short distances if special carefulness is observed regarding noise and interference. At longer distances shall Thermocouple signals be converted to current loop as described above. It is allowed to use Data Signals for I/O communication other then the usual remote I/O communication and if used, some well recognized data format shall be used e.g. DeviceNetet, ControlNet, Profibus or etc. For closed loop continuous control, individual electronic regulators may be used if they are of a SMART nature and can provide communication to the ICA System.
7 7.1
HARDWARE REQUIREMENTS LAN Networks
The LAN network used at Norðurál hf is Ethernet TCP/IP Protocol and the physical connections to the LAN are through 10 Base FL fibre optic system. 10 Base T CAT-5 UTP cables may be used to network locally grouped modules. However all connections to the central network Switch (hub) are 10 Base FL fibre optic. All 10 Base T CAT-5 connections intended to reach the main network have to be provided with appropriate Transceivers to the 10 Base FL fibre optic cables. All PLC's Installed at Norðurál hf are required to provide this connection to the LAN Network, a RS 232 serial port for direct programming, and the industrial recognized RS 422 serial port.
7.2
PLC Hardware
The PLC manufacturer must have ISO 9001 Quality Assurance Certificate for his products. The recommended PLC manufacturer is Allen Bradley. Prior to engagement of this Standard Specification, other manufacturers where recognized and their products installed at the plant. They are still recognized but all new installations must use the recommendations of this standard specification.
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The recommended types will replace older installations of other types as maintenance and upgrade requirements arise. The PLC hardware to be prefered at Norðurál hf is as listed below: Allen Bradley Control Logix 5000, CompactLogix or FlexLogix. The Firmware release shall be at version 12. The PLC shall be equipped to meet the network requirements of the above section 7.1 and all the appropriate connecting cables shall be provided. The Contractor is required to provide necessary spare-parts for their installations and as a rule of thumb, 10% of installed modules shall be provided e.g. 10% more I/O's then required. If the installation exceeds certain limits the Contractor might be requested to provide a spare CPU, Communication and other special function modules and is that to be determined by the Engineer. The MMI hardware to be used at Norðurál hf should be: Allen Bradley Panelview, Color TFT touch screen types: 600, 900, and 1000
The recommended Control Logix PLC modules to use are as follows: Analog Inputs Digital 24 VDC Inputs Digital 24 VDC Inputs Analog Outputs Digital 24 VDC Outputs Digital 24 VDC Outputs Digital 230 VAC Outputs Digital Interposing relay Outputs AB AB AB AB AB AB AB AB 1756-IF16 1756-IB16 (16 bits) or 1756-IB32 (32 bits) 1756-OF8 1756-OB16E (16 bits) or 1756-OB32E (32 bits) 1756-OA16 1756-OW16I
Variations from these lists can be accepted if necessary and these lists are for general guidance only.
7.3
PLC Power supplies
The PLC shall be powered off the 230 Volt AC mains, where the need for power back-up is not required or availability of back-up AC voltage is provided e.g. from inverters running off the 110 Volt DC battery supplies. If full backup is required during events of total power loss and access to the 110-Volt battery back up is restricted, the PLC shall operate off a 24 Volt DC power supply with a 24-Volt battery back up provided with the equipment. The capacity of the backup is to be determined by the FDS and approved by the Engineer.
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The power source for the PLC shall be isolated from the mains by the use of transformer in both cases and shall supply, full floating voltage, with no connection to ground. All DC operating I/O's of the PLC shall be powered off the Instrument Auxiliary Power Supply. The power supply must be isolated from all other power applications, switching devices or other equipment that can cause noise or transients on the instrument DC supplies. The Power Supply must deliver full floating voltage with no connection to ground and shall under all circumstances, have ripple voltages content of 20 % of the accuracy of the most accurate instrument fed by the supply. Under no circumstances, shall the quality of the Power Supply be less then what the manufacturer of the instrument recommends. All DC operating I/O's of the PLC that switch inductive loads e.g. solenoid valves, large relay contactors, etc, or generates transients, shall be equipped with filtering devices. All DC solenoids shall have diodes, reverse biased across their terminals as close to them as possible. If necessary, these transient-generating elements may have to be, separately powered from an individual power supply without any connection to the Instrument Auxiliary Power Supply. This supply shall meet the same requirements as the power supply described above. All AC Operating I/O shall be powered from a 230 Volt AC source that is isolated from the AC mains with a Transformer. All AC operated relays and solenoids shall be equipped with a RC element connected, parallel across their terminals as close to them as possible.
7.4
I/O Connections
All analog I/O signals shall be carried in shielded twisted pair cables all the way from the field devices to the PLC I/O rack, and no power currents or digital signals are allowed to run within the same cables as the analog signals. The minimum number of turns per meter is 30 for each cable. The shield of the instrument cables must be only connected to ground at one end, at the Instrument ground terminal close to the PLC I/O rack. The shields must be consistent through the entire length of the cable, all the way to the field device and is not allowed to be grounded or share other cables grounding. Analog signals may be run without the screen, within the PLC enclosures if they are carrying current signals, however for voltage signals, shielded cables must be used. The Contractor is requested to install at lest 10% more I/O's as he intends to use, for future expansions of the system. Example if number of digital I/O's used is 100, 110 shall be installed and if analog inputs are 20, 22 shall be installed.
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7.5
Special Requirements regarding Ground
Each electrical enclosure containing analog signals shall be equipped with an isolated "Instrument Ground" terminal connector in addition to the conventional PE protection ground required in all electrical enclosures. The Instrument ground terminal shall be connected to the conventional PE ground using only one conductor, at the minimum gauge of 10 mm2. The terminal shall use the standard green / yellow colour of ground and in addition, be clearly identified as " INSTRUMENT GROUND" At the instrument end of the loop, or in any marshalling box along the loop path, other connections to ground or other conductors are strictly prohibited. PE ground connections for chassis of marshalling boxes along the path of an instrument loop shall be separately connected using a minimum of 4 mm2 gauge wire running to the nearest PE ground terminal. All Conduits, enclosures and marshalling boxes are not accepted as ground references or conductors, either for PE or instrumentation purposes. If the ground terminal at an instrument has other connections to ground, e.g. through the chassis of its body, all methods shall be used to isolate the instrument from that ground or the shield of the signal cable shall not be connected to the ground terminal of the instrument.
7.6
General requirements regarding Electrical Installations
All Electrical installations at Norðurál shall be according to related international and local standards and regulation and shall comply with the Norðurál Standard Technical Specification NA-00-06-TS021, NA-00-06-TS022, NA-00-06-TS023.
8 8.1
APPLICATION SOFTWARE REQUIREMENTS Software structure
The objectives for system software at all levels are trace ability, reliability, security, testability and maintainability. The system is to be configured using standard software functional packages. The development of new algorithms is to be avoided. Programs shall be generated in a structured format and follow a logical progression. Software shall be written using the English language at the highest possible level. Only programming based on the standard EN 61131,8 is acceptable, this comprises the two languages IL, LD. FBD, and SFC as well as higher level language as C++ is acceptable if a program changes can be made online with the controller in run state.
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All instructions in the program that do not have obvious meaning nor refer directly to process drawings, shall be commented in English and shall be cross referenced to further explanations if necessary, to FDS, PID's or other documents. Methods will be adopted so that each program or sub-program is functionally selfcontained. A high-level program block library (Motor Control, Valve Operation, and Continuous control) is to be standardized and referenced to the standard EN 61131,8. These standard program blocks shall always be used for application programming of the system. Where a specific function block is to be used several times within an application program or module it shall not be written each time it is required. Software is to be organized so that data transfer between software modules does not interact. Software shall be capable of being corrected, changed or added to either on-line or off-line. The programming features of the Allen Bradley Control Logix PLC's shall be utilised where applicable as this can make the software more legible and to save memory.
8.2
Software licensing
It is required that licensing agreement for proprietary software products (operating systems, program compilers, etc.) used as part of the system functional software packages be included for the Owner. Operating software and related manuals are to be included in the scope of supply. The Standard PLC and system programming software shall be: • • • • • Rockwell Rockwell Rockwell Rockwell Wonderware RS Logix 5000 RS Linx RS NetWorx RS View In-Touch 7.1 AB Programming Interface AB Communication Driver AB Net configuration software AB HMI configuration software SCADA configuration software
All operating system and supporting packages are to be approved industry standards. Clear instructions for installation, set-up and troubleshooting, shall be provided. Copies of the PLC source code and development/configuration software are to be provided to the Contractor.
8.3
Integration with other systems.
The software structure shall allow easy access and integration of other systems as: • Shared displays, HMI's and other control stations
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• • •
Further development of the SCADA system Computer interface for programming over LAN network Other equipment, in-use or to be in-use by Norðurál hf that needs to share information or be synchronized with the supplied equipment
To maintain the above requirements, a well explained and defined program and data structure is necessary with an easy operator later intervention. A clear definition of interlocking requirements between the Contractors equipment and Norðurál equipment is required for the last item listed above, for smooth integration. Failing to state this leaves the responsibility of malfunctions with the Contractor.
8.4
File Organization
Data files must be designed and organized so they can be developed further in the future. This can be accomplished by allowing later insertions of data strings between older data strings without any necessary modification of the data structure. When data files are structured, the recommended practices of the software / PLC manufacturer shall be observed. Data and program files must be kept in an organized and hierarchical manner and whenever a file is altered, changed or modified, a copy of the original revision of the file shall be kept adjacent to the new file for later comparison purposes. This is of special importance when the files in question contain operator-modified data; all methods shall be used to keep those files together in a directory. All file structures shall be organized with an extensive network in mind. They shall be capable of up / downloading of files and programs from remote as local sites. The system must be fully capable of sharing data and except control commands from the InTouch SCADA system. The SCADA and MMI systems shall read their data from data file tables configured in the PLC for exclusive use of the SCADA and MMI systems. These data tables shall reflect the status of the actual working data tables of the PLC. All provisions must be made to filter data as necessary in these tables by sending average values over a period of time, to the SCADA system instead of a continuous stream of the same data. Also filtering of abnormal transient changes of data shall be provided with respect to normal rate of change of that same data.
9
SAFETY REQUIREMENTS.
Functions, interlocks and control commands and actions that are vital for personal safety or potentially dangerous processes shall be hardwired and safeguarded for shut-off purposes and under no circumstances routed through the PLC for control.
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All provisions must be made to ensure that the plant is not left in a potentially or dangerous state if a failure or malfunction occurs in the PLC or the control system. Before acceptance of work, the Contractor is required to submit to the Engineer a PLC Operation Certificate, with all necessary test and check sheets for the PLC installation attached.
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DEPARTMENT: Engineering / Instrumentation AREA: Grundartangi Reduction Plant
SHEET
1
OF
14 REV:C3
SPEC No: 00/07/TS009
STANDARD TECHNICAL SPECIFICATION FOR
PROGRAMMABLE CONTROLLERS
This Standard Technical Specification is subject to change without prior notice. The most current issue will at all times be located on the Nordural web site, www.nordural.is. REV
C1 C2 C3
BY
HRY HRY IMJ
DATE
27.09.1999 08.12.2000 2004-06-07
CHK’D
TDS/GH HRY TDS
APPROVED
TMS TPE ÓJ
REVISIONS
First Issue PLC Types Issued for Construction
NORÐURÁL – ENGINEERING
NORÐURÁL
NORDIC ALUMINUM
STANDARD TECHNICAL SPECIFICATION NA-00-07-TS009-C3.doc
CONTENTS
TECHNICAL SPECIFICATION _____________________________________ 3
1 2 3 4
4.1 4.2
INTRODUCTION _________________________________________________ 3 RELATED STANDARDS __________________________________________ 3 STANDARD DEFINATIONS ________________________________________ 4 SYSTEM TAGS __________________________________________________ 4
Facility Code________________________________________________________ 5 Instrument and Loop Number/Process Code and Identifier _________________ 5
5 6 7
7.1 7.2 7.3 7.4 7.5 7.6
DOCUMENTATION _______________________________________________ 5 SYSTEM REQUIREMENTS ________________________________________ 6 HARDWARE REQUIREMENTS _____________________________________ 7
LAN Networks_______________________________________________________ 7 PLC Hardware_______________________________________________________ 7 PLC Power supplies__________________________________________________ 8 I/O Connections _____________________________________________________ 9 Special Requirements regarding Ground _______________________________ 10 General requirements regarding Electrical Installations ___________________ 10
8
8.1 8.2 8.3 8.4
APPLICATION SOFTWARE REQUIREMENTS ________________________ 10
Software structure __________________________________________________ 10 Software licensing __________________________________________________ 11 Integration with other systems. _______________________________________ 11 File Organization ___________________________________________________ 12
9
SAFETY REQUIREMENTS. _______________________________________ 12
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TECHNICAL SPECIFICATION
1
INTRODUCTION
In this Document the following words and expressions shall have the meaning hereby assigned to them except where the context otherwise requires: Engineer: The Owner or any person or organization employed or engaged at any time by the Owner and authorized by the Owner, in writing, from time to time to act on behalf of the Owner in the execution of the items covered by this Document, in whole or in any part, for any or all purposes provided in this Technical Specification. Owner: Norðurál hf (Nordic Aluminum Corporation Ltd.), an independent legal entity owned by Century Aluminum. This document forms a standard of minimum requirements of Programmable Logic Controllers and describes the minimum hardware and software requirements of such controllers and shall be obeyed by contractors working on ICA systems at Norðurál. Documentation and Quality assurance procedures necessary for every ICA system design and installation should be similar to or as described in the Norðurál Standard Technical Specification NA-00-07-TS012.
2
RELATED STANDARDS
The Contractor is required to comply with all standards, which are relevant to the work, including amendments and addenda that are current at the time of order. Particular reference will be made to the following (or equivalent): Icelandic Government Electrical Codes and Regulations no: 264/1971 Icelandic Government Health and Safety at Work Act no: 46/1980 ISA S5.1 ISA S5.3 ISA S5.4 ISA S5.5 IEC 60617 EN 60751 EN 60584 EN 61131.1/2/3/8 Instrumentation Symbols and Identification Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems Instrument Loop Diagrams Graphic Symbols for Process Displays Symbols on Electrical Drawings Industrial Platinum Resistance Thermometers International Thermocouple Reference Tables Programmable Logic Controllers
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NORÐURÁL
NORDIC ALUMINUM
STANDARD TECHNICAL SPECIFICATION NA-00-07-TS009-C3.doc
The Contractor may identify any other/different standards to which his equipment conforms and this must be submitted to the Engineer for approval prior to the commencement of work.
3
STANDARD DEFINATIONS
The following definitions apply to all the standards produced for use on the project: ICA ‘Industrial Control and Automation based upon programmable electronic systems.’ ICA Level 0 This level comprises plant level, field mounted devices and final elements (e.g. proximity switches, valves, motors, etc.) The hardware for level 0 is outside the scope of this specification. ICA Level 1 This level includes PLC systems, intelligent and non-intelligent MCC interfaces and Local control panel mounted operator terminals (MMI). ICA Level 2 This level equipment comprises a proprietary SCADA packages complete with PC software packages and peripherals. TAG Instrument tag or the definition of a single variable, arriving from an instrument or PLC to either to present information to the control system or carry commands from the control system to devices in the real world REAL PLANT TAG Physical signal generated from hardwired plant devices. DERIVED SYSTEM TAG Variable deriving from other control modules. (Data)
4
SYSTEM TAGS
System tags can be up to 20 characters long. The system tag is split into three components separated with a hyphen (-): • The letters NAL to meet the PLC requirements (1) • Facility Code (2) • Instrument and Loop Identifier (3). These are illustrated in the following diagram: 1 2 3 N A L * * * * * - * * * * * * *
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NORDIC ALUMINUM
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4.1
Facility Code
The facility code will be made up of a unique two letter, alphabetic / three digit, numeric code which identifies the plant functional area. The first two letters signify the type of system with the remaining three digits identifying the system number within the plant area and system type. Facility codes must be accepted by the Engineer, and shall be based on the equipment identification system adopted by Norðurál, the AKS-Identification system as stated in the Norðurál Standard Technical Specification NA-00-06-TS021.
4.2
Instrument and Loop Number/Process Code and Identifier
This is an alphanumeric element code that will be used to identify either of the following: • Real Plant I/O - Physical signals generated from hardwired plant devices. • Derived System Tag - Variables derived from real I/O or other sources. EXAMPLE: NAL EG000-xxXXX NAL EG000 XxXXX Reads: Norðurál Material handling, Alumina Transfer System is the process code.
5
DOCUMENTATION
Documentation of the PLC installations is extremely important and shall be maintained by the Contractor similar to or as described in the Norðurál Standard Technical Specification NA-00-07-TS012.
Overall structure of the computer program(s) to be compiled for PLC use shall be properly documented using English, high-level structured language and supported with flowcharts where applicable.
All software is to be fully documented. Program listings shall be modularized, well structured, easy to read and traceable for debugging and maintenance. The documentation shall reflect the application hierarchy and show as a minimum the following: • • • • PLC list with Local and extended remote I/O's Parameters External I/O bus and data highway. (RIO) Internal I/O within a package and connections
NORÐURÁL -5-
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NORÐURÁL
NORDIC ALUMINUM
STANDARD TECHNICAL SPECIFICATION NA-00-07-TS009-C3.doc
• •
Text strings and comments (in English) Names and references (in English)
The hierarchy and structure of modules within the software must be shown including module description, title, level and reference numbers. All software and documentation must be cross-referenced to the associated Structured Design documents, FDS etc.
6
SYSTEM REQUIREMENTS
The system is multifunctional and shall ensure and enable automation and operator control of the plant and equipment, information processing, maintenance and management information. This specification covers the ICA Level 1, which is a composite of PLC's, electromagnetic relays, discrete loop controls, recorders and alarm annunciators. All new installations should use the Allen Bradley ControlLogix 5000 controller platform for large PLC installations and use the Allen Bradley CompactLogix or FlexLogix controller platform for medium and small PLC installation's. It is allowed to install various Allen Bradley I/O systems as long as they are controlled by the Control Logix 5000 system. For I/O systems that are not of the Control Logix family (Block I/O, Compact Block I/O, Flex I/O etc.) or networked over e.g. Device Net, Control Net, etc. the Engineers approval is required before any installation or agreement to pay cost of such installations can take place. If the Contractor requires other type of PLC controllers, the acceptance of the Engineer is needed prior to installation. The system presents the required information via the ICA Level 2 (SCADA and HMI Systems) as appropriate. Where the system comprises a series of sub-systems, each sub-system shall be capable of autonomous operation. This autonomy is to be transparent at the Control Stations. (SCADA, HMI, etc.)
The response times of the system between any ICA Level 0 tag and the ICA Level 2 controls (SCADA, MMI) are required as follows: Item
1 2 3 4
Description
Operator Command Time Tag Resolution Display Update Event Burst Rate
Performance requirement
1 Second for acknowledgement at the operator station. 2 Seconds from command to field output action. +/- 5 msec 3 Seconds (normal) 5 Seconds (exceptional) 500 Tags / Second without data loss.
The system shall be provided with communication modules to communicate with local MMI control stations and a higher level PLC network for both: information sharing with SCADA systems and maintenance of the PLC over a LAN Network.
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Usually the following systems will be used: HMI to PLC PLC to PLC PLC to SCADA and Programming Serial, DeviceNet or ControlNet connection Allen Bradley Control net or TCP/IP Ethernet TCP/IP Ethernet
Normally a serial connection between the Local MMI and the PLC is acceptable as noise immunity is maintained throughout the system. I/O signals used in the system shall have the voltage of 24 Volts DC for discrete signals where applicable, otherwise 230 V AC is acceptable but usage of that signal should be kept at minimum. Analog Signals shall be within the signal range of 4-20 mA in a Current loop, without exceptions. Exception might be when thermocouples are used over short distances if special carefulness is observed regarding noise and interference. At longer distances shall Thermocouple signals be converted to current loop as described above. It is allowed to use Data Signals for I/O communication other then the usual remote I/O communication and if used, some well recognized data format shall be used e.g. DeviceNetet, ControlNet, Profibus or etc. For closed loop continuous control, individual electronic regulators may be used if they are of a SMART nature and can provide communication to the ICA System.
7 7.1
HARDWARE REQUIREMENTS LAN Networks
The LAN network used at Norðurál hf is Ethernet TCP/IP Protocol and the physical connections to the LAN are through 10 Base FL fibre optic system. 10 Base T CAT-5 UTP cables may be used to network locally grouped modules. However all connections to the central network Switch (hub) are 10 Base FL fibre optic. All 10 Base T CAT-5 connections intended to reach the main network have to be provided with appropriate Transceivers to the 10 Base FL fibre optic cables. All PLC's Installed at Norðurál hf are required to provide this connection to the LAN Network, a RS 232 serial port for direct programming, and the industrial recognized RS 422 serial port.
7.2
PLC Hardware
The PLC manufacturer must have ISO 9001 Quality Assurance Certificate for his products. The recommended PLC manufacturer is Allen Bradley. Prior to engagement of this Standard Specification, other manufacturers where recognized and their products installed at the plant. They are still recognized but all new installations must use the recommendations of this standard specification.
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The recommended types will replace older installations of other types as maintenance and upgrade requirements arise. The PLC hardware to be prefered at Norðurál hf is as listed below: Allen Bradley Control Logix 5000, CompactLogix or FlexLogix. The Firmware release shall be at version 12. The PLC shall be equipped to meet the network requirements of the above section 7.1 and all the appropriate connecting cables shall be provided. The Contractor is required to provide necessary spare-parts for their installations and as a rule of thumb, 10% of installed modules shall be provided e.g. 10% more I/O's then required. If the installation exceeds certain limits the Contractor might be requested to provide a spare CPU, Communication and other special function modules and is that to be determined by the Engineer. The MMI hardware to be used at Norðurál hf should be: Allen Bradley Panelview, Color TFT touch screen types: 600, 900, and 1000
The recommended Control Logix PLC modules to use are as follows: Analog Inputs Digital 24 VDC Inputs Digital 24 VDC Inputs Analog Outputs Digital 24 VDC Outputs Digital 24 VDC Outputs Digital 230 VAC Outputs Digital Interposing relay Outputs AB AB AB AB AB AB AB AB 1756-IF16 1756-IB16 (16 bits) or 1756-IB32 (32 bits) 1756-OF8 1756-OB16E (16 bits) or 1756-OB32E (32 bits) 1756-OA16 1756-OW16I
Variations from these lists can be accepted if necessary and these lists are for general guidance only.
7.3
PLC Power supplies
The PLC shall be powered off the 230 Volt AC mains, where the need for power back-up is not required or availability of back-up AC voltage is provided e.g. from inverters running off the 110 Volt DC battery supplies. If full backup is required during events of total power loss and access to the 110-Volt battery back up is restricted, the PLC shall operate off a 24 Volt DC power supply with a 24-Volt battery back up provided with the equipment. The capacity of the backup is to be determined by the FDS and approved by the Engineer.
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The power source for the PLC shall be isolated from the mains by the use of transformer in both cases and shall supply, full floating voltage, with no connection to ground. All DC operating I/O's of the PLC shall be powered off the Instrument Auxiliary Power Supply. The power supply must be isolated from all other power applications, switching devices or other equipment that can cause noise or transients on the instrument DC supplies. The Power Supply must deliver full floating voltage with no connection to ground and shall under all circumstances, have ripple voltages content of 20 % of the accuracy of the most accurate instrument fed by the supply. Under no circumstances, shall the quality of the Power Supply be less then what the manufacturer of the instrument recommends. All DC operating I/O's of the PLC that switch inductive loads e.g. solenoid valves, large relay contactors, etc, or generates transients, shall be equipped with filtering devices. All DC solenoids shall have diodes, reverse biased across their terminals as close to them as possible. If necessary, these transient-generating elements may have to be, separately powered from an individual power supply without any connection to the Instrument Auxiliary Power Supply. This supply shall meet the same requirements as the power supply described above. All AC Operating I/O shall be powered from a 230 Volt AC source that is isolated from the AC mains with a Transformer. All AC operated relays and solenoids shall be equipped with a RC element connected, parallel across their terminals as close to them as possible.
7.4
I/O Connections
All analog I/O signals shall be carried in shielded twisted pair cables all the way from the field devices to the PLC I/O rack, and no power currents or digital signals are allowed to run within the same cables as the analog signals. The minimum number of turns per meter is 30 for each cable. The shield of the instrument cables must be only connected to ground at one end, at the Instrument ground terminal close to the PLC I/O rack. The shields must be consistent through the entire length of the cable, all the way to the field device and is not allowed to be grounded or share other cables grounding. Analog signals may be run without the screen, within the PLC enclosures if they are carrying current signals, however for voltage signals, shielded cables must be used. The Contractor is requested to install at lest 10% more I/O's as he intends to use, for future expansions of the system. Example if number of digital I/O's used is 100, 110 shall be installed and if analog inputs are 20, 22 shall be installed.
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7.5
Special Requirements regarding Ground
Each electrical enclosure containing analog signals shall be equipped with an isolated "Instrument Ground" terminal connector in addition to the conventional PE protection ground required in all electrical enclosures. The Instrument ground terminal shall be connected to the conventional PE ground using only one conductor, at the minimum gauge of 10 mm2. The terminal shall use the standard green / yellow colour of ground and in addition, be clearly identified as " INSTRUMENT GROUND" At the instrument end of the loop, or in any marshalling box along the loop path, other connections to ground or other conductors are strictly prohibited. PE ground connections for chassis of marshalling boxes along the path of an instrument loop shall be separately connected using a minimum of 4 mm2 gauge wire running to the nearest PE ground terminal. All Conduits, enclosures and marshalling boxes are not accepted as ground references or conductors, either for PE or instrumentation purposes. If the ground terminal at an instrument has other connections to ground, e.g. through the chassis of its body, all methods shall be used to isolate the instrument from that ground or the shield of the signal cable shall not be connected to the ground terminal of the instrument.
7.6
General requirements regarding Electrical Installations
All Electrical installations at Norðurál shall be according to related international and local standards and regulation and shall comply with the Norðurál Standard Technical Specification NA-00-06-TS021, NA-00-06-TS022, NA-00-06-TS023.
8 8.1
APPLICATION SOFTWARE REQUIREMENTS Software structure
The objectives for system software at all levels are trace ability, reliability, security, testability and maintainability. The system is to be configured using standard software functional packages. The development of new algorithms is to be avoided. Programs shall be generated in a structured format and follow a logical progression. Software shall be written using the English language at the highest possible level. Only programming based on the standard EN 61131,8 is acceptable, this comprises the two languages IL, LD. FBD, and SFC as well as higher level language as C++ is acceptable if a program changes can be made online with the controller in run state.
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All instructions in the program that do not have obvious meaning nor refer directly to process drawings, shall be commented in English and shall be cross referenced to further explanations if necessary, to FDS, PID's or other documents. Methods will be adopted so that each program or sub-program is functionally selfcontained. A high-level program block library (Motor Control, Valve Operation, and Continuous control) is to be standardized and referenced to the standard EN 61131,8. These standard program blocks shall always be used for application programming of the system. Where a specific function block is to be used several times within an application program or module it shall not be written each time it is required. Software is to be organized so that data transfer between software modules does not interact. Software shall be capable of being corrected, changed or added to either on-line or off-line. The programming features of the Allen Bradley Control Logix PLC's shall be utilised where applicable as this can make the software more legible and to save memory.
8.2
Software licensing
It is required that licensing agreement for proprietary software products (operating systems, program compilers, etc.) used as part of the system functional software packages be included for the Owner. Operating software and related manuals are to be included in the scope of supply. The Standard PLC and system programming software shall be: • • • • • Rockwell Rockwell Rockwell Rockwell Wonderware RS Logix 5000 RS Linx RS NetWorx RS View In-Touch 7.1 AB Programming Interface AB Communication Driver AB Net configuration software AB HMI configuration software SCADA configuration software
All operating system and supporting packages are to be approved industry standards. Clear instructions for installation, set-up and troubleshooting, shall be provided. Copies of the PLC source code and development/configuration software are to be provided to the Contractor.
8.3
Integration with other systems.
The software structure shall allow easy access and integration of other systems as: • Shared displays, HMI's and other control stations
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• • •
Further development of the SCADA system Computer interface for programming over LAN network Other equipment, in-use or to be in-use by Norðurál hf that needs to share information or be synchronized with the supplied equipment
To maintain the above requirements, a well explained and defined program and data structure is necessary with an easy operator later intervention. A clear definition of interlocking requirements between the Contractors equipment and Norðurál equipment is required for the last item listed above, for smooth integration. Failing to state this leaves the responsibility of malfunctions with the Contractor.
8.4
File Organization
Data files must be designed and organized so they can be developed further in the future. This can be accomplished by allowing later insertions of data strings between older data strings without any necessary modification of the data structure. When data files are structured, the recommended practices of the software / PLC manufacturer shall be observed. Data and program files must be kept in an organized and hierarchical manner and whenever a file is altered, changed or modified, a copy of the original revision of the file shall be kept adjacent to the new file for later comparison purposes. This is of special importance when the files in question contain operator-modified data; all methods shall be used to keep those files together in a directory. All file structures shall be organized with an extensive network in mind. They shall be capable of up / downloading of files and programs from remote as local sites. The system must be fully capable of sharing data and except control commands from the InTouch SCADA system. The SCADA and MMI systems shall read their data from data file tables configured in the PLC for exclusive use of the SCADA and MMI systems. These data tables shall reflect the status of the actual working data tables of the PLC. All provisions must be made to filter data as necessary in these tables by sending average values over a period of time, to the SCADA system instead of a continuous stream of the same data. Also filtering of abnormal transient changes of data shall be provided with respect to normal rate of change of that same data.
9
SAFETY REQUIREMENTS.
Functions, interlocks and control commands and actions that are vital for personal safety or potentially dangerous processes shall be hardwired and safeguarded for shut-off purposes and under no circumstances routed through the PLC for control.
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All provisions must be made to ensure that the plant is not left in a potentially or dangerous state if a failure or malfunction occurs in the PLC or the control system. Before acceptance of work, the Contractor is required to submit to the Engineer a PLC Operation Certificate, with all necessary test and check sheets for the PLC installation attached.
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