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CONTROL SYSTEM AND SOFTWARE DETAIL SPECIFICATION

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CONTROL SYSTEM AND SOFTWARE DETAIL SPECIFICATION

1.    INTRODUCTION.. 3

1.1    SCOPE.. 3

1.2    APPLICABLE CODES.. 3

1.3     SUPPLY CONDITIONS.. 3

2.    CONTROL SYSTEM FEATURES. 4

2.1     CONTROL SYSTEM PHILOSOPHY 4

2.2     ARCHITECTURE.. 5

2.3     HMI SOFTWARE.. 5

2.4     PLC SOFTWARE.. 6

2.5     HARDWARE. 8

2.6     PERFORMACE.. 9

2.7     GRAPHICAL REQUIREMENT.. 10

3.    DESIGN CRITERIA.. 12

4.         TEST.. 12

4.1     FACTORY ACCEPTANCE TEST (FAT). 13

4.2     COMMISSION/SITE ACCEPTANCE TEST  (SAT). 13

4.3     FOLLOW-UP.. 13

4.4     TRAINING 13

5.    DOCUMENTATION. 14

6.    BASIC GUARANTEES. 15

1.         INTRODUCTION

1.1      SCOPE

This specification describes the functional requirements, enclosure design features, hardware,  and software performance and documentation required for control system .

This specification covers the design, installation and testing of the control system for  potable water plant located to Nam Theun 2, in Laos.

For the purposes of this specification, the control system is defined as one which provides a robust, secure, cost-effective and flexible solution.

The control system will be designed with the object to provide adequate facilities to install, high degree of availability and easy using proven equipment that will require minimum maintenance.

1.2      APPLICABLE CODES

All suppliers of system and equipment shall operate in a quality assurance system. This system shall be based on the principles of ISO9001.

Control system and relevant equipments must be supply in accordance as follows specifications:

Applicable contractual specifications

Section 6.5.3.4.17  Rev. E       02.12.04    “GTS Programmable controllers & device”

Applicable GE Ionics Italba specifications

2219M-A01-01      “P&I  Diagram”

2219M-H01-01/02 “Control system schematic diagram”

2219M-H01-A       “Control system configuration type”

2219M-H02-01      “Functional description”

2219M-H07-01      “Modbus serial interface comunication”

1.3     SUPPLY CONDITIONS

The VENDOR shall provide for software and hardware selection to guarantee suitability of all components, and shall submit to us all reference documentation and fully component list, GE Ionic Italba shall provide to buy PLC and HMI (operator panel) with relevant accessories for this scope.

The VENDOR shall provide for installation and software development in compliance with all the applicable specification above mentioned.

2.         CONTROL SYSTEM FEATURES.    

2.1     CONTROL SYSTEM PHILOSOPHY

The control system consist of  n. 2  control panels totally independent, with n. 1 programmable logic controller (PLC ) and n.1 operator panel (HMI) on board for each panel.

This specification cover the material selection, design configuration, installation and software development of both PLC and HMI installed in CP-001, CP-002.

PLC is a deterministic computer designated to handle large numbers of I/Os (input and outputs).  Typically, it works with digital and analog field signals.  The scope of supply include PLC software also it is divided into firmware, development software and application software.  Firmware is essentially the operating system that resides in the PLC for the purpose of managing the various combinations of PLC hardware configurations and for fetching and executing the application software.  The development software is the software tool PLC programmers used to write logic, sequences and controls to access physical I/O.  The software created by the programmer is known as the PLC application software.

HMI is the interaction point for operations, providing the direct control hardware for the plant. From the HMI the Operations group obtains the intelligence of the sensor/device level and direct access to the sensor/device level of hardware. Additionally, data collection and analysis tools are presented in the HMI hardware/software.

From HMI operator can enter set points; start and stop individual equipment; monitor unit operations; and place it in Auto/0/Manual mode.

HMI (operator panel) is graphical touch screen based software running on a dedicated Operating System platform.  This electronic device collects data from the PLC or any field instruments for the purpose of presenting operational information and controls of field instruments and devices.  It is also capable of data analysis, historical date logging, trends, alarm handling, etc.  Standard operator panel device provide the tools to design, program and animate graphical human machine interfaces with device controls, process schematics as well as various forms of data presentations and management.

 

The PLC & power control panels are dedicate for the following plant section  :

-          CP-001   for   Potable water unit

-          CP-002   for   Water treatment unit (Biocide injection)

Each control panel has its own dedicated PLC with its associated I/O modules. 

The software is organized and built in a similar methodology based on the S-88 standard.  Software are defined into 4 layers:

·         Control module

·         Equipment module

·         Units

·         Process cells

A control module is a device (e.g. a valve, motor, flow rate, etc).  Each device has a unique definition for controlling I/Os and for interfacing with the HMI for visualization.

The equipment modules are defined based on a collection of control module to perform a sub-process activity.  An example would be a Filter.

A unit is a collection of equipment modules that will perform a major process activity such as a group of equipment as dosing pumps.

The final layer is the process cell that consists of a plant section.  That it will produce a batch or product for example potable water unit or biocide injection.

The above development stems applies to HMI and PLC development.  In addition, HMI will also be programmed and configured for alarming, historical trending, security features, event logging, diagnostic, etc. etc. .

2.2     ARCHITECTURE

The control system architecture shall allow system functions such as data acquisition and control by a graphical panel view interface that we calling HMI (human machine interface)

The system shall also support a fully interface with customer DCS for remote operation using standard ModBUS protocol  (RS422/485).

The HMI seat on top of the system and through Ethernet TCP/IP, it its linked to the PLC systems. 

The data communication rate is typically 100Mb.  Each computer stations and PLC system have to be configured with a unique IP address to identify itself to the rest of the users in the network, IP address must be in accordance to customer address list.

The HMI (operator panel) and PLCs will be installed with Ethernet LAN connection with relevant switch Ethernet device for increased reliability.  PLC station will be predisposed for DCS Client/Server communication, suitable interface RS 422/485  for communication with customer DCS  must be provide on each PLC, ModBus protocol is request.

The PLC’s are field programmable through the Ethernet data highway without removing the system from service, this is very usefull in the case of system maintenance and system upgrades.  Most of the system upgrades can be made without effecting system operation.

All PLC’s and all HMI are powered by UPS (UN-interruptible power source) a dedicate 220VDC incoming line by customer care.

 

PLC’s  shall be GE Fanuc  VersaMax type, architecture and configuration should be in accordance with:

doc. N. 2219M-H01-A     Control system configuration type.

Further material shall be include by VENDOR to complete the system configuration, a fully list of component shall be submitted to us for approval.

2.3     HMI SOFTWARE

 

The task of the HMI software is to collect data from the PLC and present the information in graphical animation format that is easily comprehendible by operators from a top down approach.  The process screens will show the process flows, instruments and devices.  The graphics will be constructed with drilldown details.

HMI including all relate standard Software licenses, will be able to manage the following functions:

Plant Monitoring

Alarms Management

Manual Commands Management

Automatic Sequences Management               

Events and data balance historical archives 

Printing Management 

For example, a screen for a process area will show instrument readings and device status (control modules), click on the device will pop-up a window with detail controls for that device.

The following graphical interface shall be developed with relevant control pop-up or page:

Control module

Valve (with feedback)

Direct drive (if any)

PID controller (if any)

Analog input instrument

Flow Counter

Lead-lag function for pumps

Equipment module

Equipment start-up sequences (e.g. filters, dosing unit and transfer pumps)

Unit and process cell

Overview Process screens and detail process area screens

HMI data management

Trending screens

Diagnostic screens

Alarm summary

The process screens shall be developed based on the P&ID (Process & Instrumentation drawing) drawings with devices and instruments arranged according to its process area.

Instruments and input devices shall have control faceplate features for Auto/0/Manual selection, alarms, process value display and operator data entry.

Output devices shall have control faceplate feature for Auto/0/Manual selection, start/stop, on/off, device status, alarms, operator override and permissive.

Besides the screen development, the HMI will also be programmed and configured with security features, event logging, alarm printing, etc. according to the SCADA package selected.

HMI operator panels shall be GE Fanuc Quick Panel View 12” touch screen type

Mentioned Panel view should be in accordance with:

doc. N. 2219M-H01-A     Control system configuration type.

2.4     PLC SOFTWARE

PLC software shall be provide according to doc.:     2219M-H02-01         “Functional description”    it shall be divided into two main activities, system configuration and application software.  System configuration refers to the PLC hardware configuration as system parameters have to be entered into the PLC CPU in order for it to recognize the hardware I/O and communication modules connected.

PLC will be able to perform the activity of field interfacing, the continuous survey of the equipment/instrumentation signals and the logistic working management of the Plant.

In automatic operation conditions the PLC application program generates the opportune actions:

-          Automation:

PLC, according to the parameters received from the field and/or of the eventual operator’s commands, based on the algorithms contained in the main program, will elaborate the opportune actions towards the involved apparatus.

-          Processing:

on the captured variables basis, PLC provides for the events and the working hours calculation for the different consumers of own pertinence. Logical and mathematic algorithms will be implemented for data processing.

-          Command:

The PLC system is independent for the automatic plant conduction.

The CPU shall be able to accept an external time synchronization, for adjust its internal clock.

The PLC application software shall be programmed in languages that are conforming to the IEC 1131-3 standard.

  The software shall be organized in a modular structure for easy maintenance and for future expansions.  Detail comment of logic and algorithm is a standard requirement. 

PLC software shall be provide complete of address symbols itemization, program single block description, reference comment for each program rung and relevant cross-reference list.

Instruments and devices shall be programmed in modular software blocks that will interface with SCADA database for the device control faceplate to achieve the total control concept.

The following control and equipment modules will be developed:

Control modules:

Valve (with feedback)

Direct drive

PID controller (if any)

Analog input instrument

Flow Counter

Lead-lag function for pumps

These blocks are the library of devices that becomes the building block for the various units and process cells.

The controller shall support the following I/O quantity requirements:

PLC 1  (Plc & Pwr  control panel CP-001)

Analog Input:

 4

Analog Output:

1

Digital Input:

160

Digital Output:

50

PLC 2  (Plc & Pwr  control panel CP-002)

Analog Input:

 0

Analog Output:

0

Digital Input:

60

Digital Output:

30

The I/O quantity already includes 20% spare installed and wired by Scada Vendor.

The I/O modules shall have the following features:

- Analog Input: 4 or 8 inputs. ( 12 bits resolution as minimum)

- Analog Output: 4 or 8 outputs. ( 12 bits resolution as minimum)

- Digital Input: 16 inputs.

- Digital Output: 16 outputs.

System shall have a 20% spare of equipped and wired I/O.

The I/O cards will be of the type with insulation channel and insulation between the electronic part and the rack back-plane.

An adequately CPU shall be provided by GE Ionics Italba (Correct size shall be under Vendor responsibility) considering CPU RAM memory shall be sized in order to have 25% as final spare.

PLC software logic should be in accordance with:

Section 6.5.3.4.17  Rev. E       02.12.04    “GTS Programmable controllers & device”

Very Important:

All application software used for development/edit of program (PLC/HMI) must be original software only, with relevant authorization disk and relevant licence for use certificate.

The use of not original software are not acceptable by GE Ionics Italba.

All application software used for development/edit of programs (PLC/HMI) must be provide by GE Ionics Italba, therefore after FAT  VENDOR must return to GE Ionics Italba all the following documentation:

.  Software installation disks  (including further additional drivers and service packs)

.  Software Authorization code/key (software or hardware)

.  All the cables for device connection (e.g. cables/connectors used for software uploading)

.  All the certification in original copy included with software(as  licence for use)

.  Operating and program Manual.

2.5     HARDWARE.

           Control system for CP-001 will constist in:

             n. 1 PLC on two Racks  (GE Fanuc – VersaMax )

             n. 1 HMI Operator Panel  (GE Fanuc – Quick panel view 12” TFT)

             n. 2 Jet ink color printer

             n. 1 Switch Ethernet (6port 10/100)

             further accessories.

            Control system will cover the follows requirements :

            

Type :                                                  HMI

CP-001  :                                            HMI 1

CP-002  :                                            HMI 1

Network :                                            Industrial Ethernet 100Mb/s

             Cpu 1     :                                            VersaMax  1C200CPUE05

             Cpu 2     :                                            VersaMax  1C200CPUE05

All Hardware components should be supplied by GE Ionics Italba  in accordance with :

doc. N. 2219M-H01-A     Control system configuration type.

This document shall be completed/revised by Vendor and submitted to GE Ionics Italba for approval before to our order issue.

   

2.6     PERFORMACE

Software licences is in the scope of  supply VENDOR must indicate properly size of the system, considering a suitable sizing to manage whole system, VENDOR must guarantee the follows minimum performance required :

FUNCTIONS

PID controller :                                                                      3

Digital i/o monitoring :                                                      300

Operating hours counter :                                                    30

Interlock display :                                                                30

Measured –value monitoring :                                             30

Motors digital controlled :                                                   30

Switching cycle counter :                                                     10

Valve digital control :                                                          30

Valve analog control :                                                           1

GRAPHICS SYSTEM

Number of video dinamic pages :                                       30

Number of object per page :                                                30

Number of video setting pages :                                          10 

Number of accessible value per page :                                30

Number of faceplates per page :                                          10 

Maximum Refreshing  time display :                                1 ÷ 2 sec.                                     

             ARCHIVING OF PROCESS DATA

Follow-up archiving :                                                      100 values/s

Cyclic buffer archiving :                                                   30 values/s

Cyclic buffer archiving in Dbase format :                       300 values/s 

PLC data capacity :                                                        t.b.d.  by Vendor

             TRENDS

  

Total historical trend number :                                           30

Number of curves per display :                                            3

Recording cycle for measur. Value :                                  30 curves / 1s

             ALARM SYSTEM

              Number of alarms :                                                           300 

              Number of alarm for archiving :                                     20 per 10s

              PERFORMANCE TIME

              PLC / HMI start up maximum time:                                     30s  

              Selection of curves using measuring point max. time          1s

              Alarm initial selection maximum time:                                2s

              Alarm new list maximum time:                                            2s

              Alarm history maximum time:                                             2s

 2.7     GRAPHICAL REQUIREMENT

              This section define graphical requirement relevant to HMI screen views.

            

               COLOR CODE

Air                                          Blue

Water                                     Green

Hypochlorite                          Yellow

Aluminium sulfate                  grey

Polyelectrolyte                        Dark white

Calcium chloride                    violet

Sodium bicarbonate                orange

Biodispersant                          violet

Background pages                  Light grey

Text                                        Black

Motor run                                 Red

Motor stop                                Green

Motor fault                                color status on yellow blinking

Valve open                                  Red

Valve close                                 Green

Valve fault                                  color status on yellow blinking

Alarm up                                      Red blinking

Alarm acknowledgement             Red fixed

Alarm down                                 Black

Alarm down unacknowledged     Blue

 UNIT OF MEASURE

Variable

Metric Units

Length

Millimeter

mm

Meter

m

Kilometer

km

Area

Square millimeter

mm2



Square meter

m2

Volume

Milliliter

ml

Liter

l

Cubic meter

m3

Weight

Milligram

mg

Kilogram

kg

Metric tonne

t

Metric tonne per year

t/yr

Temperature

Celsius

°C

Force

Newton

N

Pressure

Bar absolute

bara

Bar gauge

barg

Millibar

mbar

Energy

Kilocalorie

kCal

Kilowatt-hour

kWh

Power

Watt

W

Kilowatt

kW

Flow rate (for Process Documents)

Cubic meter per hour

m3/h

Flow rate (for Instrument & Automation Documents)

        *Liquid/Steam

        *Gas/Vapor

        *Purge Rotameter

Cubic meter per hour

Normal cubic meter per hour

Liter per hour

m3/h

Nm3/hr

l/hr

Viscosity

Centipoise

cP

Conductivity

Microsiemens per centimeter

mS/cm

PH

pH

Turbidity

Nephthelometric Turb. Units

NTU

Density

Kilogram per cubic meter

kg/m3

Level

Percentage

%

Concentration

Parts per billion

ppb

Milligrams/liter

mg/l

Grams/liter

G/l

Percentage (mol)

mol%

Time

Second

sec

Minute

min

Hour

Hr

Day

day

Year

Yr

Electrical

Ampere

Milliampere

A

mA

Volt

V

Watt

W

Volt-ampere

VA

Millivolt

mV

Hertz

Hz

rev/minute

rpm

3.                  DESIGN CRITERIA

             

Compliance by the VENDOR with the provision of this specification does not relieve him of responsibilities of furnishing equipment and materials of proper design, hardware and software suited to meet operating guarantees at the specified service conditions.

4.         TEST

The Factory and Site Acceptance Test procedure (FAT / SAT procedure) relevant to the software, written by the Vendor and approved by GE Ionics Italba, shall be used as guideline to conduct the factory acceptance test. During the factory acceptance test, the Vendor shall demonstrate to Italba and Partner’s representative, the completeness and proper operation of Control system as DCS communication (integrated communication test shall be done at Vendor staging area if any).

Functional test for all equipment installed shall be totally performed at 100%.

The control system shall be connect to the simulator with switches, lamps and potentiometers for analog signals and 4-20 mA display in number equal to signals used.

In addition, digital switches and leds for simulation  (start/stop etc.) will be provided to check the interface between the control system and field.

Vendor shall notify  the test date by fax 30 days before.

The following tests shall be performed :

Visual checks.                         ( performed at 100% )

Field signals simulation test.  ( performed at 100% )

Communication test.               ( performed at 100% )

Functional test.                        ( performed at 100% )

Alarm and shutdown test.        ( performed at 100% )

Check of compliance to this specification according to :

doc. N. 2219M-V05-01    “Inspection and Test Plan”

      

4.1     FACTORY ACCEPTANCE TEST (FAT)

The PLC/HMI system will be erected at VENDOR workshop, where a simulation will demonstrate its effective operation.  The client will be given the opportunity to carry out an acceptance test at VENDOR workshop to become convinced of the effective operation of the system.  The system will be finished and implemented only after the client has approved it.

VENDOR will provide a software FAT-test document for this FAT-test at least four weeks before starting the test.  So GE Ionics Italba can give her input on the required tests, after approved FAT plan and procedure, the test can be perform.

A minimum of 20 days at staging area of Control system VENDOR shall be scheduled and budgeted in this scope for the SOFTWARE FAT

4.2     COMMISSION/SITE ACCEPTANCE TEST  (SAT)

The following activities are part of the SAT plan and procedure (approved by GE Ionics Italba):

I/O test (software of the digital/analog signals).

Communication Test.

Adjusting and fine-tuning the controls.

Trial run.

Stand-by (3 days) during production.

 

The client shall carry out an acceptance test, after which we will as soon as possible remedy any inadequacies established in mutual consultation.

If circumstances not due to faulty operation of the system supplied by us require considerably more time for the commissioning then the additional costs will be charged to your account.

VENDOR will include in job bid daily price and costs for software specialist on site assistance.

VENDOR will provide a software SAT-test document for this SAT-test at least four weeks before starting the test.  So GE Ionics Italba can give her input on the required tests, after approved SAT plan and procedure, the test can be perform.

4.3     FOLLOW-UP

If the commission is followed by problems due to software errors in the application supplied by VENDOR, then such will be remedied under the normal guarantee terms.  In all other cases, the further costs will be balance.  By follow-up is meant all elements desired by client in the field of maintainability, assistance and stand-by.  For this, VENDOR can also provide solutions made to measure (‘tailor-made’).

4.4     TRAINING

When the application is installed and tested on location, 5 days of training are request on location about the application.  This training will includes 3 days for operator dedicated to explanation about the working of the application with the help of an operator manual and 2 days for engineer with training dedicated how to configure the system.  The cost of training shall be included in this scope, more days of training are possible, but the costs will be balance. Of course it is possible for operators or other customer personnel to join for the FAT or commission so they can learn by practice.

5.         DOCUMENTATION.

All the documents indicated in this section must be provide by VENDOR as include in this scope of supply.

Within 15 days from the date of order the VENDOR must send us for approval   n. 3 hardcopies  and  n.1 softcopy on electronic file for each panel of the following documents:

·                    I/O List with PLC reference address                    2219M-H05-01

·                    Control system PLC configuration

·                    PLC components list and accessories to be procured by GE Ionics   

·                    Control system technical specification

·                    Manufacturer work schedule

Within 30 days from the date of order for approval to construction VENDOR must send us n. 3 hardcopies  and  n.1 softcopy on electronic file of the following documents:

    

·                    HMI video pages                                              2219M-H03-01/02

·                    Sequence chart                                                      2219M-H10-01/02

·                    Alarm and shut down list                                2219M-H11-01 

·                    Set-point table and Variable list                           2219M-H11-02

·                    Manufacturer quality control plan

30 days before the date of FAT  VENDOR must send us the for construction version of all documents above mentioned including also n.3 hardcopies  and  n.1 softcopy on electronic file of the following documents:

·                    Control logic diagram                                             2219M-H08-01/02

·                    Control system user guide (Preliminary)            2219M-M11-01

·                    Control system FAT procedure                               2219M-V01-11

·                    Control system SAT procedure                               2219M-V01-12

·                    Control system factory acceptance test  (FAT)       2219M-V06-11

·                    Control system site acceptance test  (SAT)             2219M-V06-12

·                    Control system manufacturer certificates.

·                    Control system instruction manual for all equipments supplied.

·                    Control system spare parts list for two years with prices.

N. 3 hardcopies and n.1 softcopy on electronic file within 10 days after the positive FAT  with all documents above mentioned in as built version, including also:

·                    Control system PLC software programs print-out          2219M-H04-01/02

·                    Control system HMI software programs print-out          2219M-H04-11/12

·                    Control system user guide (Final)                              2219M-M11-01

·                    Control system PLC and HMI software programs files   (CD Rom)

·                    Control system instruction manual and  licences for all software installed.

            

N. 3 hardcopies and n.1 softcopy on electronic file within 10 days after the positive SAT  with all documents above mentioned in final version, including also further modify made during the test.

Vendor is responsible for the respecting of the delivery dates for dispatching the documents.

The required documentation is an integral part of the supply and its omission shall be considered as non-fulfillment of the Purchase Order.

Symbology and line numbering of Process and Instrumentation Diagram (P&ID) shall be in accordance to the legend provided by Ge Ionics.

All wording on drawings and on HMI system shall be in English.

All issues of all drawings and documents shall be submitted both on paper and on electronic support.

All documents shall be prepared on ISO rules, in such a way as to facilitate microfilming.

The electronic support shall be CD-ROM.

Each CD-Rom  shall be labeled as follows:

-          project number;

-          Material Requisition/Purchase Order Number;

-          Vendor name;

-          cd n°. of

Each electronic support must include an Excel spreadsheet listing all drawings contained in the above support.

The following commercial software shall be used:

-          AutoCAD  2000.

-          MS Office 2000.

It is mandatory for copies to be of the highest quality, so as to avoid unsolvable reproduction problems.

All drawing revisions subsequent to the first issue shall be identified and contain a brief description of all changes made, indicating the area(s) of the drawing involved by the revision.

Documents and drawings, which are difficult to read in parts, shall be rejected.

Vendor shall send to Ge Office, the required number of copies as follows:

n°1 copy for FIU.

n°1 copy for FCO.

6.         BASIC GUARANTEES

The Vendor warrants that all supplied equipment and documentation shall be free from defects, either in materials, design or workmanship, and shall be suitable in all respect for the purposes of which it is required and specified in this document.

The warranty period shall cover twenty-four (24) months from the date of starting up of the equipment or forty-eight (48) months from date of shipment, whichever is earlier.

If, following completion of the warranty period, the equipment will not achieve the guaranteed performances, the Vendor shall undertake replacement or repair of the equipment until the contract conditions have been met at no additional cost to GE Ionics.

This warranty does not apply to those replaceable parts or components subject to normal wear and tear.

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