PROGRAMMABLE LOGIC CONTROLLERS,
SCADA AND NETWORKS
PART 1 - GENERAL
1.00
DESCRIPTION OF WORK
A. This section describes the programmable logic controller (PLC), input/output (I/O)
equipment, operator interface (SCADA) equipment, all networking and communication
equipment including Ethernet and Profibus (fiber optic and copper), and the application
programming (in general terms) required for the Project. Devices, accessories,
programming, and appurtenances required for proper operation of a complete control
system shall be provided.
1. The control system shall be designed, coordinated, and supplied by a single system
integrator of PLC based data acquisition and operator interface graphic display
systems, who shall guarantee satisfactory operation of the installed control system.
2. Develop and provide the PLC and WinCC SCADA operator interface graphic
display applications programs and hardware needed to direct the process equipment
to perform the functional requirements specified or as required by the process
equipment manufacturers and as required by and described in these documents.
3. The Siemens S7-400 PLC’s as shown on the drawings shall be the PLC used at all
locations. Please refer to the drawings ### for specific models.
4. The plant PLC network shall be 100Mb Fast Industrial Ethernet TCP/IP (Optional
12Mb Profibus FMS). The network shall incorporate full duplex communication
and use network switches for connections. The network shall incorporate Fiber
Optic communication backbone connecting all switches. This backbone shall be
redundant. The PLC connections shall use ITP (Industrial Twisted Pair) cable from
the PLC to the switch. This backbone shall be redundant.
5. A new plant SCADA system shall be developed using Y2K compliant WinCC
SCADA software package. The new plant SCADA system shall consist of ###
operational stations (servers) and ### monitoring stations (clients). ### operation
stations are distributed at…………..(list locations) . The operator station, AA, shall
be configured as a full function SCADA Server Runtime with the appropriate
Profibus FMS or Ethernet I/O driver (server) and associate interface hardware. The
operator station, BB, shall be configured as a backup Runtime SCADA Server with
the same I/O drivers and hardware interface, but shall be configured as an operator
view node. ### monitoring systems (client modes) shall be distributed at ………(list
locations) . Operation stations and monitoring stations shall communicate via a
redundant SCADA Industrial Ethernet 100Mbaud TCP/IP network. This network
shall be separate from the PLC Ethernet network.
6. In general, communication network from structure to structure shall be via optic fiber
and communication network within a building shall be via copper.
7. Provide a Historical Server with latest version WinCC at Information Technologies
Building
8. All WinCC software provided shall include one year of Preferred Service and
Support.
PART 2 - PRODUCTS
2.00
PROGRAMMABLE LOGIC CONTROLLERS AND I/O HARDWARE
A. General
1. Provide PLC hardware including processors, redundant processors (as required)
power supplies, rack assemblies, interconnecting cables, grounding system,
communication modules, and accessories required to perform the control and
monitoring functions.
B.
Programmable Logic Controller (PLC)
1. The PLC shall be provided with the following minimum features:
a. The processor shall be the slot mount type, include at least 384K-Kbyte RAM
using front accessible memory cartridge, and shall have a scan time of 0.1
ms/K of logic, or less. Minimum acceptable CPU will be a 414-2DP.
b. The PLC system shall be able to accommodate the quantity and type of I/O
points shown and described plus 25-percent spares.
c. The processor shall have an integral 12Mbaud Profibus-DP and a 12Mbaud
multipoint interface (MPI) communication port. The 12Mbaud Profibus-DP
communication port is to establish communication with distributed I/O
modules, variable frequency drives and other Profibus DP devices as required.
A minimum of 96 I/O racks/devices shall be supported on this Profibus port.
Additional I/O racks/devices can be supported through the addition of
12Mbaud Profibus master modules in the S7-400 CPU rack. Both fiber optic
and copper media shall be supported with Profibus-DP and MPI. The MPI
communication port is to be used by maintenance personnel with the portable
programming device for program modification, data acquisition, and program
upload/download/archiving.
d. The CPU shall support 32,000 digital I/O and 2,000 analog I/O.
d. Each PLC system shall include one Industrial Ethernet module (Optional
Profibus-FMS) communication module. The Industrial Ethernet (optional
Profibus-FMS) communication module shall be used for permanent systemtype communications within PLCs throughout the plant and the plant SCADA
system. Data transfer rate shall be full duplex up to 100Mbaud using switched
Ethernet (12Mbaud for Profibus FMS).
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The PLC system including all Industrial Ethernet (optionally Profibus FMS)
shall operate over 0 to 60-degree centigrade temperature range, and a 0 to 95%
(non-condensing) humidity range.
The user application program area shall be protected by a battery or a flash
EPROM for non-volatile program storage.
The processor shall include front panel mounted diagnostic indicators for
power, mode, low battery, communications ports, and memory and I/O errors.
The PLC system shall allow on-line and off-line programming.
The PLC CPU shall include a front mounted removable key switch which when
removed in the correct position will protect the CPU from unauthorized
program changes.
The CPU’s shall have executive firmware which may be upgraded in the field
using an upgrade/download procedure which does not require the removal
and/or insertion of IC chip.
The PLC system shall communicate with 3rd party devices including Variable
Frequency Drives (VFD) via Profibus DP.
The application programs shall be developed using IEC 1131 compliant languages
including at a minimum Ladder Logic, Statement List and Function Block Diagram.
The PLC programming package shall be endorsed and approved by the “PLC
OPEN” organization. It shall run on Microsoft Windows 95/98/NT. Higher level
programming languages shall be available. The system shall fully support structure
programming techniques for optimized code development and execution. The
instruction set shall include, as a minimum, the following: contacts, coils, latches,
timers, counters, and special function blocks for math (double precision and floating
point), trigonometry, sequences, data transfer, and PID control. The programming
shall be performed on an IBM compatible personal computer.
A rack mounted power supply (quantity and size as required) shall be provided to
supply power to the processor and I/O modules. The supply voltage to the power
supply shall originate within the control panel and shall be 120 VAC. A separate 24
VDC power supply shall be provided to power the analog loops.
I/O modules shall be provided as required to accommodate the types and quantities
of I/O points identified. All I/O shall be rack mount modular style. All remote racks
shall support Profibus-DP at 12 Mbaud. Sample I/O point types include; dry contact
outputs, 4-20 mAdc analog inputs, 4-20 mAdc analog outputs, and 120 VAC
discrete inputs. Discrete inputs shall use 120 VAC as the voltage signal, and analog
loop signals that leave the control panel shall use a 4-20 mAdc current signal. I/O
module point density shall not exceed 16 points per module. Each I/O module shall
include front panel mounted diagnostic indicators for point status, fault conditions,
and active conditions. The I/O modules shall be able to be replaced while under
power and shall be keyed to prevent the wrong type of module from being inserted
in the wrong slot. All I/O modules shall have removable terminal blocks for
termination of field wiring. All terminal blocks shall be ‘keyed’ to prevent
application of terminal block to wrong I/O module. All I/O modules shall report to
the CPU should a terminal block fail or be removed. Analog input module
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resolution shall be configurable on a single module from 11 bit to 15 bit. Analog
output modules shall have a minimum resolution of 13 bits.
The PLC and I/O modules rack assemblies shall be housed in the control panels
specified in Section XXX.
The control panels shall be provided with sufficient I/O modules to allow 25 percent
spare installed and wired I/O points. Spares shall be provided for each different
type of I/O.
The PLC and I/O equipment shall be a standard industrial grade product
mechanically and electrically suitable for use in an industrial environment with a
satisfactory product history of at least five years.
REDUNDANT PROGRAMMABLE LOGIC CONTROLLER
1. As indicated on the drawing certain PLC systems shall be configured and installed as
a hot standby system. The PLC system shall include a redundant processor and
power supply. If the primary PLC system fails the standby PLC system shall assume
primary control functions within 30 milliseconds of the failure.
2. A failed component shall be able to be removed, replaced without removing the
power to the system rack. When a CPU is replaced, it shall be automatically and
bumplessly supplied with all current data (program, data blocks, and other dynamic
data). After installation of the replacement CPU reconnect the redundant
communication link and the CPU program reloads from the functioning CPU without
the need of a programming unit. The operating system in the PLC shall resynchronize the user program programs in the primary and backup CPU and
automatically resume the redundant operation.
3. No special application programming shall be required to implement the hot standby
PLC system. From the user's point of view, the Hot Standby system shall behave
much the same as a standard system. Standard PLC components shall be used with
guaranteed bumpless switchover. Configuration options shall support configuring,
programming, parameter assignments, start-up and diagnostics integrated in a
standard PLC programming package. It shall be possible for the user program to be
modified on-line without placing the system in stop or duplicating the program
changes in the standby processor.
4. The subunits shall be connected via fiber-optics cable and shall be able to be
mounted up to five hundred meters apart.
5. Comprehensive self-tests shall be executed both on start-up and continually during
operation. On start-up, each PLC subunit shall run all self-test functions in their
entirety. During cyclic operation, the operating system shall sub-divide the self-test
functions into small time slices. The user shall specify the number of time slices per
cycle. Whenever possible, these self-tests shall not only detect errors, but also
identify and locate them. The following components and functions are tested, and
every fault or error detected by the self-tests is reported:
A. Link between central controllers
b. Central controller modules
c. Memory
6. The hot Standby system shall switch bumplessly from primary to standby and vice
versa. "Event-driven synchronization” shall be required to insure that the two PLC
subunits are executing synchronized programs. This involves the exchange of
information and the comparing of data. The synchronization procedure shall ensures
that both subunits always have the same data at their disposal and that, in the event
of a malfunction, the standby controller will be able to take over in the precise
program step where the master controller failed. The synchronization method shall
be "event-driven synchronization". In this method synchronization takes place
whenever any event occurs which could result in different internal states in the two
subunits. Some examples of events that shall re synchronize the processors are:
a. Updating of the process image
b. Instructions for direct I/O access operations
c. Interrupts and alarms
d. Updating of the timers
e. Modification of data using communication functions
7. "Event-driven synchronization” shall insure that the user need not worry about the
synchronization of the two subunits. Data matching takes place at precisely the right
place. The operating system handles the entire synchronization process. The user
shall not be required to utilize special functions to insure the synchronization of the
primary and backup programs.
8. The Hot Standby diagnostic and signaling concept shall be identical to that of a
standard PLC system with the addition of the Hot Standby messages. This shall
ensure that programs written for standard controller systems can be used without
modification in a Hot Standby system.
9. The SCADA communication to the Hot Backup system shall include highavailability communication transparent to the user. With the use of High
Availability connection, availability is increased by standby connections, which
come into use automatically upon communications failures.
10. Cabling and connection redundancy shall have no repercussions on the user program.
The redundancy function shall be defined exclusively through parameter
assignments. The number of standby connections depends on the topology of the
network and on the number of Communication Processors used. This shall be
automatically determined by the parameter assignment software and presented to the
user for selection. Up to a maximum of 4 connections (one active connection and
three standby connections) may be configured by the user.
11. Redundant PROFIBUS DP communication cables shall be required for connection to
all distributed I/O racks. Two bus connections shall be built into the CPUs with
expansion to 10 I/O additional DP busses possible in a single rack. The bus media
shall be selectable as copper wire or Fiber Optic. The CPU shall be capable of
connecting to up to 155 distributed I/O racks at a distance of up to 10000 meters via
redundant PROFIBUS DP. The bus selection logic shall reside the distributed I/O
modules to allow an I/O connection to fail over to the back up CPU without
requiring the central system to switch control the back-up processor. The
communication data transfer rate shall be selectable up 12 Mega Baud with either
media.
12. The redundant CPUs shall be expandable to 20 Mega Bytes of RAM. The system
shall have capable of total of 12,000 digital points and 8,000 analog points. The
Scan time of the redundant CPU shall be 0.1 millisecond per 1000 binary
instructions and 0.48 milliseconds per 1000 analog instructions.
13. The standard PLC programming package used to program the standard CPU shall be
use to program the Redundant CPUs and shall be IEC 1131-3 compliant and
approved by the “PLC OPEN” organization
C.
PLC Portable Programming Terminal
1. Provide a portable IBM compatible computer based PLC programming terminal.
The programming terminal shall be pre loaded with the PLC programming software
Provide the programming terminal with the following minimum features, and
provide additional performance features as recommended by the PLC or operator
interface programming software manufacturer (or technologically its equivalent or
better at time of purchases):
a. A Pentium processor, 333 MHz, w/256K Full speed L2 Cache
b. 12” XGA Active Matrix TFT color display
c. Lithium or NiMh batteries and 120 VAC power sources
d. Internal 1.44 MB 3.5-inch floppy drive
e. Internal 4 GB hard drive
f. Detachable keyboard
f. Parallel printer port
g. 34 MB SO-DIMM SDRAM
g. 3COM 10/100 baseT Ethernet adapter(PCMCIA)
h. Integrated Profibus and MPI interfaces
i. 56kbps Modem
l. Integrated 16-bit Wavetable Sound with stereo speakers, line-in and line-out
jacks.
m. Interconnecting cables
n. Windows NT operating system software
2.1
OPERATION STATION SCADA SOFTWARE
A.
Provide an operator interface software package that, when combined with the operator
station computer hardware, will gather, display, and store real-time operating
information. The operator interface software package shall be sized according to the
appropriate I/O point count and shall be able to accommodate 25 percent additional I/O
in the future, but as a minimum shall accommodate 1,500 I/O. All base and optional
software modules required to achieve the desired functionality described below shall be
provided.
B.
Operator Interface Software
1. The operator interface software package shall provide the following minimum
functions:
a. Windows NT operating system.
b. The software package shall be provided with the appropriate Ethernet (or
optionally Profibus FMS) I/O server/driver software. Required PC Ethernet (or
optionally Profibus FMS) hardware interfaces and required Ethernet/Profibus
FMS communication/configuration interface software shall be provided by
Siemens or approved equal.
c. 32 bit WinCC unlimited tag SCADA node. (Runtime and Development)
d. The ability to store historical data (analog or digital) to daily, weekly, or
monthly files and the ability to archive historical data to tape.
e. Analog data shall be configured to be stored as average, minimum, maximum,
or instantaneous values, in the proper engineering units.
f. A complete alarm handling package shall be provided that shall annunciate
alarms in an alarm queue and allow them to be displayed on the process
graphic displays with messages or by changing colors or otherwise massaging
graphic display symbols. An alarm summary screen shall be provided. Alarms
shall be able to be acknowledged by an operator at the operator station CRT on
an individual or screen basis and nuisance alarms shall be able to be disabled.
Alarms shall be logged to the alarm printer.
g. Password protection for the various levels of access (day-to-day functions
versus configuration changes), Log in and Log out at all times and Auto log off
with set time.
h. The data base points shall be identifiable by tag numbers or name.
i. Day-to-day functions shall be available from the keyboard and mouse.
i. The entire system configuration, including database, shall be able to be backed
up onto floppy disks or tape, and CD.
j. A reporting package shall be built in. This package shall come with sample preconfigured reports and shall let the user develop custom reports as required.
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2.11
Database sharing and remote access of other databases is accomplished over
TCP/IP Ethernet networks. While the Primary and Secondary Servers SCADA
both connected to the PLC network, both shall independently poll the PLC’s as
primary and Backup SCADAs. The backup SCADA is configured to be a view
node to primary SCADA via Ethernet. Upon primary failure the backup can be
set to automatically or manually poll the PLC’s and look at its own database
for GUI functions.
Software shall be as provided by Siemens WinCC.
MONITORING OPERATOR STATION CLIENT SOFTWARE
A. Provide a client node software package for each monitoring operator station. The
software shall be similar to the one to be provided at the Administration Building except
it only provides monitoring function and has no access to the plant control system (PLC
Network). The software shall be able to communicate with the primary and backup
WinCC operator stations via Ethernet.
2.2
COMMUNICATION NETWORKS
A. General
1. Fiber optic links shall be provided to connect all Optical switch Modules (OSM) in
a redundant ring configuration. PLC’s and Operator Stations will connect to the
OSM’s via Industrial Twisted Pair (ITP) cables. The fiber optic backbone
communication systems shall use industrial modular components. Provide all
necessary components, power supplies, cables, connectors, and components
necessary for a complete and operable fiber optic communications system. Both the
PLC and the SCADA networks shall use full duplex switched 100Mbaud Industrial
Ethernet TCP/IP and shall incorporate redundancy at the fiber optic backbone level.
No user programming shall be required at any level to configure and set up the
redundant network.
B.
Fiber Optic Ethernet Switch Hardware
1. Provide industrially hardened Optical Switch Modules (OSM) as shown on drawing
####. Each switch (OSM) shall be housed in a metal enclosure and shall be rated for
operation from 0-60 degrees Centigrade. Each OSM shall support a redundant Fiber
Optic backbone and up to 6 ports will be provided for device ITP (PLC or SCADA
PC) connection. The power supplies shall operate on 24 VDC. No special
configuration software or hardware shall be required to setup and configure the
OSM. The optical interface module shall incorporate, transmit and receive
indicators. The fiber optic communications system shall operate in full duplex
mode at 100Mbit per second using switch technology at up to 3000 meters distance
between switches. Each ITP connected device (PLC or SCADA PC) may be up to
100 meters from the OSM. Network failover and recovery shall be transparent to the
user and shall occur automatically with no user intervention. The OSM’s shall be as
manufactured by Siemens.
C.
Fiber Optic Cable
1. The fiber optic cable required shall be industry standard 62.5/125 micron glass
cable.
2. Provide a fiber optic termination kit. The termination kit shall include tools and
connectors necessary to repair or replace the fiber optic cable connectors. Provide
one of each different type of connector.