Professional Documents
Culture Documents
June 2010
Introduction .................................................................................................................................... 4
Abbreviations .................................................................................................................................. 4
Definitions ....................................................................................................................................... 5
DOCUMENT CONTROL
Introduction
This control system functional design specification shall be used by the systems integrator to
produce the programmable logic controller code and supervisory control and data acquisition
configurations required for a fully automated Poly mixing plant that is part of the ACME Waste
Water Treatment facility.
Abbreviations
The following abbreviations shall have relevance throughout this document:
• Pumps
• Conveyor belts
• Feeders
• Valves
• Gates
HMI HMI stands for Human Machine interface. The HMI is also referred to as
Operator system or Supervisory system.
INTERLOCKS These are devices (with output contact/s), related to the process, integrally
mounted on or near a piece of equipment. Process interlocks may be bypassed
under controlled conditions without endangering human and/or compromising
operating safety of machine/s, whilst Safety interlocks cannot be bypassed.
DEVICES (software These are software modules encapsulating the functionality of equipment
based) control and diagnostics. E.g. motors, valves, sequences, analogs etc
SCADA Supervisory And Data Acquisition (SCADA), is a system that allows operators to
control associated processes by means of keyboard actions and screen
displays. Also referred to as an MMI (Man Machine interface), or HMI (Human
machine Interface).
The PLC shall be an ABC Model 123 with conventional 24VDC digital inputs and outputs and 4..20mA
current loop analog inputs, all connected via marshaling terminals in a dedicated PLC panel to the
field instrumentation.
The Motor Control Circuits shall consist of conventional wired control circuits with 24VDC PLC inputs
and outputs.
The SCADA system shall be an Allesview Version 10 running on a conventional personal computer
with MS Windows XP professional.
A Poly batch mixing system is required as part of the sludge dewatering facility at the ACME Waste
Water Treatment facility. The Poly mixing system process design is shown on the Piping and
Instrumentation Drawing no 123 and must be read in conjunction with this Control Philosophy.
The Poly mixing system shall be able to operate in Automatic or Manual and shall deliver a solution
of granular poly dissolved in water to the dewatering plant.
An operator shall deposit a bag of Poly in the empty mixing tank and imitate a mixing sequence via
the control system which shall open the water supply control valve and fill the tank to a preset level.
Once the level has been reached the mixer shall be started and operate for a preset time interval
only. During this time interval the temperature of the solution shall be controlled to exactly 75deg
Celsius by a temperature sensor coupled with an electrical heater in the mixing tank. After the mixing
process has been completed, the extraction pump shall operate to transfer the solution to the
dewatering plant Poly holding tank.
• The level in the tank will be monitored by an ultrasonic level sensor and transmitter. This
shall be used to close the water supply valve if the tank is full and to stop the transfer pump if
the tank is empty.
• The water supply valve and transfer pumps shall also not operate if the mixer is running.
The following measurement shall be displayed and recorded in the control system:
All equipment operating status shall be monitored and faults reported on the control system
visualization system. Alarms will be generated and displayed on the control system which can only be
cleared when the fault conditions have been attended to and the alarm reset.
Daily and monthly mixing reports shall be provided by the control system.
Instrument List
The following instrumentation has been identified from the control philosophy and taken from the
P&ID:
Modes of operation
The control system shall provide the following modes of operation as reflected in the equipment
control circuits.
Maintenance Mode
The control system shall provide for maintenance operation of all equipment where “maintenance”
implies starting and stopping equipment from the MCC pushbuttons or field control stations.
In maintenance mode all process interlocks shall not apply however safety interlocks shall apply.
In this mode the PLC shall monitor the operation of the equipment but cannot control it. Status such
as running, tripped and e-stop shall be monitored and passed on to the visualization system for
display.
In Maintenance mode the SCADA system shall clearly indicate that the equipment is under
“Maintenance” control and all start and stops from the SCADA shall be inhibited.
“Maintenance” mode shall be selected from the MCC via a Maintenance / Off / Normal selector
switch on each starter with an input to the PLC to indicate “normal” mode.
The control system shall provide for manual operation of all equipment where “manual” implies
starting and stopping equipment from the visualization system.
In this mode the PLC shall monitor and control the operation of the equipment. Status such as
running, tripped, failed to start and e-stop shall be monitored and passed on to the visualization
system for display.
In manual mode the SCADA system shall clearly indicate that the equipment is under “Manual”
control and all start and stops from the SCADA shall be initiated via equipment faceplates.
“Manual” mode shall be selected from the SCADA device faceplate via an Auto/ Manual selector
switch which will be inhibited if the overriding sequence control is in Auto.
Automatic Mode
The control system shall provide for automatic operation of all equipment where “auto” implies
starting and stopping equipment from internal logic within the PLC.
In this mode the PLC shall monitor and control the operation of the equipment. Status such as
running, tripped, failed to start and e-stop shall be monitored and passed on to the visualization
system for display.
In auto mode the SCADA system shall clearly indicate that the equipment is under “Auto” control
and all manual start and stops from the SCADA shall be inhibited on the equipment faceplates.
“Auto” mode shall be selected from the SCADA device faceplate via an Auto/ Manual selector switch
which will be overridden if the hierarchical sequence control is switched between auto and manual.
Note: Switching a control sequence between auto and manual will switch the mode of all items of
equipment controlled by that sequence.
DEW_PID_001 Logic that marshals SCADA parameters to the Poly Mixing Tank
temperature control PID evaluates the internal registers for the PV,
SP and OP values for controlled devices, evaluates modes and
commands and writes status and alarms signals to internal registers.
This segment shall invoke FB_PID.
DEW_PUMP_001 Logic that marshals SCADA parameters to the Poly Transfer Pump
Function Block, evaluates the digital I/O values for PUMP_001,
evaluates modes and commands and writes status and alarms signals
to internal registers. This segment invokes FB_MOTOR
Each motor shall be controlled and monitored by a motor function block with basic logic as follows:
The motor function block shall have as its base control element a Set-Reset Latch with Reset
dominance to drive the final output that will close the contactor in the MCC to energize the motor.
The logic shall allow for Automatic and Manual starts where Auto starts and stops shall be taken
from other PLC logic (such as PID controllers and Sequence Controllers) and Manual start and stop
commands shall be accepted from the visualization system. In Maintenance mode the motor
function block shall only monitor the motor status and report back to the visualization system.
Failed to start and stop and safety trips shall be latched in the motor function block and cleared only
after a reset from the visualization system.
Physical Inputs and Outputs shall be marshalled to a call of the motor function block for each motor
in the poly mixing plant and external logic shall be used to evaluate and set the parameters to the
function block (such as interlocks) and to integrate it with the visualization system faceplate as
shown in the data structure.
Each motorized valve shall be processed by a valve Function Block with basic logic as follows;
The above logic shall be repeated for the CLOSE action of the valve and the OPEN and CLOSE latches
shall be cross interlocked such that both commands cannot be simultaneously issued.
The valve function block shall have as its base control element a Set-Reset Latch with Reset
dominance to drive the final output that will close the contactor in the Valve to energize the motor.
The logic shall allow for Automatic and Manual open and close where Auto open and close shall be
taken from other PLC logic (such as PID controllers and Sequence Controllers) and Manual open and
close commands shall be accepted from the visualization system. In Local mode the valve function
block shall only monitor the valve status and report back to the visualization system.
Failed to open and close and safety trips shall be latched in the valve function block and be cleared
only after a reset from the visualization system.
Physical Inputs and Outputs shall be marshalled to a call of the valve function block for each valve in
the poly mixing plant and external logic shall be used to evaluate and set the parameters to the
function block (such as interlocks) and to integrate it with the visualization system faceplate as
shown in the data structure.
Each Analog input (measured value) shall be processed by an Analog Function Block with basic logic
as follows:
The Analog Function Block shall invoke the PLC’s built-in Analog processing block and report on the
status of the measured value (ie healthy, line break or open circuit). It shall furthermore convert the
Raw value into engineering values for display on the visualization system and to perform limit value
monitoring on set engineering value limits. The limit alarms shall be processed by an Alarm function
block as described further below.
External logic shall be provided for each call to the Analog Function block to integrate it with the
Visualization system faceplate as described in the data structure.
An ON-OFF closed loop controller shall be programmed in the PLC to control the temperature in the
mixing vessel.
The PLC’s build in PID function block shall be used for this purpose and external logic shall be
provided to connect the Controller to the temperature sensor (PV) in the mixing vessel and the
Heater controller (Output) in the MCC. The PID loop shall control the temperature in the mixing
vessel to the set-point (SP) temperature entered by the Operator on the visualization system.
Further logic shall be provided to integrate the Controller with the Visualization system faceplate as
described in the data structure.
The implementation of the PID control function block shall be generally as follows:
The Poly Mixing plant shall be controlled by a mixing and transfer sequence to be implemented in
Sequential Flow Chart (SFC) in the PLC as described in the Flow Chart below:
The sequence control logic shall provide for automatic and manual mode and pass start and stop
commands to other sub logic blocks. Start-up, current step and transitioning status shall be
integrated to the visualization system faceplate as defined in the data structure.
The siren shall sound for 3 seconds before the mixer starts and shall inhibit the mixer by way of an
Interlock signal.
The SCADA server shall be connected to the PLC’s via Industrial Ethernet configured for static IP
addressing as shown below.
Data will be collected from the PLC by the SCADA server on a cyclical basis by the TAG server using
the Industrial Ethernet Protocol driver provided with the SCADA for the ABC PLC. Data shall be
collected in accordance with the data structure as described in Section 2 above.
The SCADA server shall run on a licensed copy of Microsoft Windows Profession version 2003 with
Service Pack 3.
All SCADA TAGS shall based on the convention described for naming in the PLC in section 2 above.
Mimic displays shall be based on the P&ID’s for the plant and a standard layout shall be adopted as
shown below:
A mimic hierarchy shall be provided consisting of a complete facility overview mimic followed by
individual plant detail mimics and within each plant mimic further detailed may be selected (such as
for the Poly Mixing plant) with final elements of control being displayed by way of equipment
faceplates.
All operator actions shall be via mouse clicks or keyboard entry. Left mouse clicks shall select
dynamic objects on the mimic and display a “tool-tip” with the element’s assigned unique identifier
TAG) along side it. Left mouse double clicks shall initiate actions where these are enabled on the
Where the process flow is from one mimic onto the other a suitable link shall be provided with an
appropriate description and clicking the link shall take the user to that mimic.
e.g.
All Mimics shall be drawn in colour on a light grey background. Non dynamic elements shall be
displayed in standard MS windows palette colours that are not used for displaying status
(animation), and all line thickness and font sizes for descriptive text shall be a minimum of 1pt black
and 10pt Arial Black respectively.
Air Lines
Process Water
Potable Water
Dilute Media
Fire Fighting
Fuel Oil
Flocculent
Hydraulic Oil
Ventilation
All controlled elements shall be represented by dynamic symbols with colour changes representing
status as described next.
Motors
Motor status shall be represented as per the table below. In addition to the dynamic colour changes,
flashing GREEN and RED shall be used to indicate the STARTING and STOPPING state. The flashing
state shall be inherent in the SCADA to provide immediate operator feedback when a device
command is initiated and will only revert to the steady state when the confirmation of the command
is received from the PLC. Any element that can NOT be animated shall be shown in the transparent
state for UNKNOWN (e.g. communications failure with the PLC)
Motorized, Actuated and Solenoid Valve status shall be represented as per the table below. In
addition to the dynamic colour changes, flashing GREEN and RED shall be used to indicate the
OPENING and CLOSING states. The flashing state shall be inherent in the SCADA to provide
immediate operator feedback when a device command is initiated and will only revert to the steady
state when the confirmation of the command is received from the PLC. Any element that can NOT
be animated shall be shown in the transparent state for UNKNOWN (e.g. communications failure
with the PLC)
Switch
All digitally switched signals (e.g. a flow switch) shall be represented on the mimic by way of a simple
semaphore whose state is indicated as per the table below. Communications failure to the PLC shall
be indicated in the “transparent” state. Digital states shall all be “fail safe” such that a positive signal
is given when the operational condition is normal and /or safe.
Each analog instrument shall be represented on the SCADA mimic by a dynamic text field indicating
the current instantaneous measurement, in engineering value, including its units. The display shall
include a status block along side indicating whether the instantaneous value is “healthy” (ie no Line
Break or Short circuit in the current loop between the PLC and instrument) and whether the reading
is in an alarm range. Alarm values shall be entered via the instrument’s faceplate as described
further below.
When the measured value is unknown (e.g. communications break) the text representing the
instantaneous value shall indicate ###.## so as to clearly indicate no reliable reading is available.
Motors
Each motor on the mimic shall be linked to a faceplate which shall be displayed when the motor
symbol is double clicked. The faceplate shall be positioned at the bottom right hand size of the
mimic display by default but shall be repositioned by the operator as and when required. When
another motor is double clicked, it’s faceplate shall be displayed and any other faceplates
automatically closed such that the mimic screen is not cluttered with control faceplates. The
individual elements of the faceplates shall be dynamic as described in the annotations.
Equipment run-hours
Each control valve on the mimic shall be linked to a control faceplate which shall be brought up
when the motor symbol is double clicked. The faceplate shall be positioned at the bottom right hand
size of the mimic display by default but shall be repositioned by the operator as and when required.
When another valve is double clicked, it’s faceplate shall be displayed and any other faceplates
automatically closed such that the mimic screen is not cluttered with control faceplates. The
individual elements of the faceplates shall be dynamic as described in the annotations.
Each measured valve (analog input) on the mimic shall be linked to a faceplate which shall be
brought up when the instrument symbol is double clicked. The faceplate shall be positioned at the
bottom right hand size of the mimic display by default but shall be repositioned by the operator as
and when required. When another instrument is double clicked, it’s faceplate shall be displayed and
any other faceplates automatically closed such that the mimic screen is not cluttered with control
faceplates. In addition, a single mimic page with all the analog faceplates permanent arranged
alongside one another shall also be provided. The individual elements of the faceplates shall be
dynamic as described in the annotations.
Each closed loop controller in the PLC shall be linked to a faceplate which shall be brought up when
the control loop symbol is double clicked. The faceplate shall be positioned at the bottom right hand
size of the mimic display by default but shall be repositioned by the operator as and when required.
When another controlled element is double clicked, it’s faceplate shall be displayed and any other
faceplates automatically closed such that the mimic screen is not cluttered with control faceplates.
The individual elements of the faceplates shall be dynamic as described in the annotations.
Controller Mode selection, AUTO or Manual Control Loop Trend, can be “shown” or
“hidden” by clicking the “TREND>” button
Each group of equipment that must operate together, whether sequentially or continuously shall be
linked to a faceplate which shall be brought up when a controller symbol on the mimic is double
clicked. The faceplate shall be positioned at the bottom right hand size of the mimic display by
default but shall be repositioned by the operator as and when required. When another controller
symbol is double clicked, it’s faceplate shall be displayed and any other faceplates automatically
closed such that the mimic screen is not cluttered with control faceplates.
Sequence and Control face plates shall clearly indicate to the operator the control that is being
executed in the PLC. All step commands and transition conditions, as defined in the control system
requirements, shall be clearly indicated and any wait states or time-outs indicated such that the
operator is never left in any doubt as to the automatic control state. Control logic shall also be safe-
guarded such that the control can always be reset or cleared if the sequence or control operation is
perceived to have become “hung-up” or “in-deterministic”.
The individual elements of the faceplates shall be dynamic as described in the annotations.
• Event : Any change in state of controlled equipment such as starting, stopping, opening or
closing which is NOT as a result of a fault condition.
• Warning : A change of state that warrants operator attention and possibly action but poses
no immediate threat to production.
• Alarm : A change of state that warrants operator intervention and poses a real threat to
production.
Alarms shall be grouped per process module and shown on a page accessible from that module.
Alarms shall be prioritized such that the latest occurring alarm be displayed on the top of the list and
historically alarms at the bottom of the list.
The latest three alarms shall always be displayed along the bottom of the SCADA screen as described
in the standard layout.
Alarms shall be suppressed for equipment that is out of service or where communications with the
PLC has failed.
Alarms shall be date and time stamped and written to a log file from where they can be exported in
a common data interchange format such as XLS or CSV (Comma Separate Values)
Trends shall be grouped per process area and process module and each trend shall be drawn in a
“line” style with different pen colour.
Trend screens shall clearly indicate the engineering value and full range of measured values on their
X-Y axis and the trend shall provide for a cursor position sliding bar indicating the instantaneous
values at the point of selection.
The trend shall furthermore include a legend along the bottom where the trend and pen colours are
identified and the minimum, maximum, average and instantaneous trend value reading over the
selected period shall be shown.
It shall furthermore be possible to select the trend resolution, range and starting date and time for
each group of measured values.
All of the Analog inputs listed in Section 1 shall be logged and trended for the Poly Mixing Plant.
Trend Navigator
Trend Graphic
Trend Legend
Reports shall be compiled from the SCADA system log file and shall be invoked by clicking on the
REPORT button in the mimic navigation menu.
It shall be possible to chose the time interval for each report and the reports shall be layout out as
follows:
Security shall be provided by the underlying MS Windows Operating System as integrated with the
Allesview SCADA Package. At least three levels of security shall be provided.
System:
When the system boots up the SCADA Server shall start as an OS service. The SCADA user interface
shall then be automatically loaded.
After the UI has been loaded a “logon” mimic shall be displayed. This will force the operator,
supervisor or administrator to logon before accessing the live mimics so that an audit log of all users
activities can be kept.
All conventional OS Desktop operations shall be inaccessible. The Task Manager shall not be
accessible from the keyboard. The OS Explorer application shall not be accessible.
Operators:
All plant operators must logon to be able to perform the following functions:
Supervisors:
In addition to the permissions of operators, supervisors shall be able to perform the following
functions:
Shall have access to all SCADA design time/ configuration menu items and functionality.
A mimic shall be available with buttons for easy access to the following: