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VOLUME 2 OPERATING INSTRUCTIONS
PART VIII INSTRUMENTATION AND CONTROL
VIII-10 INSTRUMENTATION AND CONTROL
VIII-10-1 General
This document describes the design concept and overview with configuration of I & C system for Ras Al Khair Desalination Plant Project.
It defines the minimum requirements of the I&C systems supplied for the Thermal desalination and RO plant and related package systems equipment to ensure high reliability and proper functionality of the plant.
Adherence to this document also ensures that a single set of criteria is used for the I&C system design throughout the entire plant.
The Desalination Plant will be furnished with Distributed Control System (DCS) based control system for control of the plant from the operator stations located in control room.
The control and monitoring equipment to be provided shall be suitable for faultless, safe control and supervision of the entire plant during all phases of operation and shall be suitable for the location in which they shall be mounted.
The subsystems will be interfaced with the DCS via hardwired or data linked interface.
These subsystems may include various local proprietary control schemes forming plant packages.
The DCS shall provide the sole means of remote control and supervision of the plant from the Plant’s Central Control Room (CCR) located in package “P” area.
The plant control and monitoring system will have the capability to monitor, control, display, alarm, record and trend all assigned plant major inputs and outputs.
The plant to be covered by the Plant control and monitoring system shall include most of common service plant, Water plant and proper interfacing with the necessary status of local proprietary control systems.
The plant control and monitoring system will be fully integrated using microprocessor techniques and shall have a distributed architecture comprised of a family of independent functional processors.
Each functional processor shall be comprised of configurable module programmed to execute a specific tasks.
VIII-10-1.1 Scope of I&C Design
ü Distributed Control System (DCS) for Desalination plant
ü Large Screen for Desalination plant
ü Local Instrumentations
ü I&C Cables
ü Instrument Installations
ü Local Panels and Racks, Boxes
ü Interface to the Package “P”
According to Tender Volume-IX, D-B10, page 94 of 99, all design, supply and installation work shall be done by Package "P". But "D" shall provide all necessary information / documentation for planning and installation of this equipment and have to prepare precondition as below procedure,
First, related drawing shall be send to "P" as soon as possible,
Second, after "P" will design based on "D" drawing,
Third, "D" will review and check the detail design drawing and prepare precondition (e.g. space for/on cable trays, penetration at walls, floors, etc. or basic constructions for hangers, platforms, fixing points, etc.)
n Communication System
n Clock
n Surveillance and CCTV system
n Asset Management System
n Vibration Monitoring System
n Plant Management System
n CEMS Monitoring System
VIII-10-1.2 Reference Codes and standards
The design, materials, features and testing of I&C equipment will be made according to the following standards and codes :
ü ANSI American National Standard Institute
ü ASME American Society of Mechanical Engineers
ü ASTM American Society of Testing Materials
ü AWWA American Water Work Association
ü BS British Standard
ü DIN Deutsche Norm
ü EN European Norm
ü IEC International Electro-technical Commission
ü ISA Instrument Society of America
ü ISO International Organization for Standardization
ü SAMA Scientific Apparatus Makers Association
ü VDE German Electromechanical Commission
VIII-10-1.3 Protection Degree for I&C
ü DCS Cubicle : IP41
ü Local Instrument Panel : IP55
ü Junction Box : IP55
ü Transmitter : IP65
ü Switch : IP65
ü Gauge : IP65
VIII-10-2 DISTRIBUTED CONTROL SYSTEM (DCS)
VIII-10-2.1 General for DCS
This report for the instrumentation and control for the desalination plant part of the project Ras Al Khair Phase-1 is based on the Distributed Control System SPPA-T3000.
This concept is not binding in terms of final number of cabinets, number and type of interfaces to third party systems, etc. which will be subject to detail design.
This report describes the design for the Water Plant area.
VIII-10-2.2 Abbreviations and Definitions, Standards and References
VIII-10-2.2.1 Abbreviations and Definitions
AppServ Application Server
CCR Central Control Room
DCS Distributed Control System
ECS Embedded Component Services
FUM Siemens brand for centralized I/O Function Module system
MU Multi Unit
NTP Network Time Protocol
PMS Plant Management System
RDP Remote Desktop Protocol
SPPA Siemens Power Plant Automation
TCC Technical Contract Condition
VIII-10-2.2.2 References
SA1019-8100-BN00-000180 TCC “Description and General Philosophy for the Design of the Main DCS(Package “P”)”
SA1019-8100-DD04-000010 TCC “CCPP Automation Guideline”
SA1019-8100-DD04-000020 TCC “HMI Displays”
VIII-10-2.3 Type of Main DCS
For the Package “D” of the project Ras Al Khair The Siemens SPPA-T3000™ Distributed Control System (DCS) will be applied.
This system is designed for the specific needs of the power generation industry.
SPPA-T3000 stands for: Siemens Power Plant Automation Teleperm 3000
The 100Mbit Ethernet bus system (Application Bus and Automation Bus) provides the communication between the HMI, the Automation Units (Automation Servers) and the Application Server that provides all necessary functions for plant engineering, operation-monitoring, diagnostics and storing of process data. The connection to the field devices is implemented via I/O modules which are installed in I/O cabinets.
Embedded Component Services ©™ – ECS ©™ is the basic concept of the system that embeds all process-relevant data into every single component. This component-embedded appro0ach allows all data to be intrinsically available for operation, engineering or diagnostics.
An important advantage to this structure is keeping the user interfaces (Thin Clients) independent from other applications.
VIII-10-2.4.2 Hardware Architecture
SPPA-T3000™ consists of the following main hardware components:
• User Interfaces
• Power Services
• Networks
• Process Interfaces
VIII-10-2.4.2.1 User Interfaces
Thin Clients present information regarding engineering, operation, and diagnostics.
Standard industrial PCs running just a Web browser perform this task.
The web-based system structure allows the use of a wide range of hardware such as standard PCs or notebooks that can run a Web browser.
The Server/Client structure means that HMI applications are available at multiple locations. There is no need for special hardware or software for engineering and operation functions. Terminals are identical in access capability. Limitations need be defined only by the authorization system where the access rights are configured. This approach allows for highly flexible configurations for a wide range of desalination plant process control applications.
VIII-10-2.4.2.2 Power Services (Power Server)
Processing of data and execution of control algorithms are performed by the Power Services (ECS=Embedded Component Services). These services also perform the functions of archiving, engineering, alarm management, diagnostics, system configuration, access and change management.
The hardware platform for all Power Services consists of Application Servers and Automation Servers.
The Automation Server is a standard SIMATIC S7-CPU out of the SIMATIC product spectrum. This S7-CPU provides high-performance, deterministic automation functions at the I/O level. The number of Automation Servers depends on the desalination plant configuration and can be scaled depending on the complexity of automation tasks. The Automation Servers are equipped with an onboard PROFIBUS DP field bus connection.
The fault-tolerant Application Server performs the HMI, engineering, and system information functions. High reliability of the Application Server is achieved through extensive redundancy including processors, memory, disk drives, controllers, and power supplies.
VIII-10-2.4.2.3 Network (Bus System)
System communication is provided via networks that link the components together. A standard Industrial Ethernet network with TCP/IP realizes the upper tier communication. The communication between the Automation Servers to the Process Interfaces is established by PROFIBUS DP field bus.
The SPPA-T3000™ manages communication using Ethernet switch technology (Figure 2). This technology employs an intelligent switching communication management system that eliminates data collisions by managing the information flow from and to the interested network participants only. This anti-collision communication management technology maintains the integrity of the data throughput and increases the effective communication speed of the network. Time synchronization is performed as an integrated system function through all connected devices and nodes.
The SPPA-T3000™ system employs the Simatic Network in a single fault-tolerant “ring” structure (Figure 3 and Figure 4).
The network is a fiber optic based “open ring”, with a master Ethernet switch (SCALANCE X-SERIES), which continuously monitors the health of the ring structure. The moment a fault is detected by this master Ethernet switch, an optical switch is activated, completing the communication path for all data to reach the affected participants. The unique, dual direction communication flow of the Simatic Network, not only assures that no data is lost, but that no communication delays occur.
VIII-10-2.4 System Overview of SPPA-T3000
VIII-10-2.4.1 System Architecture
The SPPA-T3000™ DCS is a hierarchical information and automation system (Figure 1).
The system uses continuous information flow, consistent data management and storage, flexible instrumentation and control (I&C) concepts, and uniform Human Machine Interface (HMI) platforms to perform necessary automation, operational control, and data monitoring for the plant.
The SPPA-T3000™ DCS design features include:
• A plant-oriented process control structure that provides operational functions, combined with monitoring and diagnostic capability
• A redundant, modular structure capable of future expansion by adding equipment as required
• An open local area network (LAN) structure for interfacing to other automation systems and external computer networks
The SPPA-T3000™ DCS consists of a ‘3-Tier’ architecture based on the server/client networking structure. This architecture along with the use of Web technology, Industrial Ethernet communications and a component-based software structure combine to form a state-of-the-art Distributed Control System that has been consistently tailored to the process engineering needs of modern desalination plants.
VIII-10-2.4.2.4 Process Interfaces
Process Interfaces comprise the interface between the Automation Servers and field measurement and control devices. The communication between the Automation Servers and the several I/O Process Interfaces is established by PROFIBUS DP field bus.
VIII-10-2.4.3 Software Architecture
SPPA-T3000™ uses the Embedded Component Services (ECS) approach for system software integration, task and data management (Figure 5). ECS means having all data for each process object located in the object itself. All services like Plant Display, Engineering, Alarms, etc., provide views out of this data pool or directly manage the data. There are no central databases to store or edit, which can cause performance or memory bottlenecks. Instead, these individual objects, creating a suite to integrate and exchange data seamlessly, build up the whole system.
The main benefits of the SPPA-T3000™ software architecture are:
• Consistent views at any time
• Only one data management location
• Integrated I&C, plant display, alarm, diagnostic and engineering
• No code generation and separate down-loading activities
• No subsystems such as engineering stations, operating stations and diagnostics computers
• Open XML interfaces inside and outside the system
SPPA-T3000™ provides a range of services to achieve power plant functionality. All functions are provided in a modular and independent manner. A single-user interface called Workbench provides the central interaction point that allows the operator, engineer, technician and manager to access all information, operate the plant, and perform required configuration and engineering tasks and troubleshooting tasks. All views are displayed in windows, and several windows can be placed on the workbench.
The following sections describe the functions of SPPA-T3000™ in more detail
VIII-10-2.4.3.1.1 Automation functions
The automation functions in SPPA-T3000™ are configured to support a high level of desalination plant automation. Closed-loop control and interlock logic functions are designed to support the full range of modes of operation. The Automation Processors provide a full range of control software building blocks from which the plant process control algorithms are formed. These algorithms are distributed in Automation Processors that correspond to major components and systems in the desalination plant.
VIII-10-2.4.3.1.2 Operation and Monitoring
Real-time data displays, high-speed and high-resolution process graphics, alarm screens and other views simplify the review and analysis of live and historical process data.
A complete set of process-based graphic displays are provided for the desalination plant. These displays and faceplates allow the operator to monitor and manipulate process control variables, as well as perform tasks such as operating devices, tuning loops, responding to alarms or changing set points.
Alarm Sequence Displays (ASDs) provide the interface for users to view, analyze and control alarms. ASDs are used to display alarms in a list and can be sorted chronologically, by priority or by other user selectable criteria. All changes of alarm states are updated automatically. Alarm returns (gone alarms) can also be displayed. Alarm messages can be tailored to the specific demands of the plant. The content and ordering of the alarm lines can easily be changed in the same way as a spreadsheet. With the possibility to define and store several user specific ASD configurations, the layout and content can be easily customized according to individual project requirements, user needs or plant conditions.
Dynamic Function Diagrams are available that contain live data that indicates the status and operation of individual control loops and logic functions, including current signal values and the inputs and outputs of software blocks. Navigation from a display Faceplate to the corresponding Function Diagram is possible with a single mouse click.
VIII-10-2.4.3.1.3 Data Storage and Retrieval
The SPPA-T3000™ archive system is a configurable data storage and retrieval system capable of storing any data point in the DCS including events and operator actions. The data can be retrieved and analyzed in a wide variety of formats including trends and reports. Reports can be constructed manually or generated automatically. The stored data is managed among a collection of memory devices including short-term memory, long-term memory, and archival storage media. The data can be exported to commonly available software tools.
VIII-10-2.4.3.1.4 Engineering
The engineering system provides the tools needed to perform system hardware and software configuration functions. Flexible and graphical interfaces for the engineering steps are provided by the system Workbench. System features include:
• Integrated operation and control engineering with a single-user interface
• Single-user interface for all engineering tasks
• Data consistency
• No mapping of sub-systems, code generation, and downloads
• Online changes
• Simple drag & drop via different views
• Easy navigation between multiple views
VIII-10-2.4.3.1.5 Diagnostics
The diagnostic functions are enabled via the diagnostic view, which is the portal to efficient maintenance, service, and asset management of the plant. All SPPA-T3000™ components have built-in self-diagnostics and provide clear messages on uniform user interfaces for the entire DCS.
System monitoring and diagnostics are an integral part of SPPA-T3000™. They are available instantly without any additional configuration effort through use of the prior-engineered automation functions and proxies. The system monitoring creates messages that provide the plant staff with clear information about the error status of a process control component.
The access to the diagnostic view is independent from the state of the selected object (Figure 8). SPPA-T3000™ self-diagnostic features and intuitive representation enables plant personnel to quickly determine where a system problem has occurred
VIII-10-2.4.4 Time Stamping
Information for other functions (alerts, storage, diagnostics, etc) will be provided by using the Time Tagged Data (TTD) function.
Basically information can be divided into:
• information about signal-changing (binary states and analogue values)
• information about I&C errors
TTD-function will add the date of changing or error to afore mentioned information. Binary-signals will always be stamped at a status-change, a change from 0 → 1 or 1 → 0.
Analogue values will be stamped by exceeding a predefined tolerance after a specific cycle time.
The TTD’s will be processed within the Application Server and provided to the operators working with the SPPA-T3000 workbench.
The TTD’s will be used for:
• The Alarm sequence display
• Protocols
• Curves
• I&C overviews
The time stamped signals will be stored in the Application Server.
VIII-10-2.4.5 Time Synchronization
In the SPPA-T3000 system, the Master Clock supplied by Package “P” is composed of a redundant GPS and time server and the time server receives the time signal from a redundant GPS. the time is synchronized system-wide by a redundant time server for Industrial Ethernet. The time server is connected through a multiunit redundant router, interfaced cables and connection works provided by Package “P” to the Industrial Ethernet bus (Application Highway and Automation Highway) of Package “D” and supplies the first Application servers, all Automation Servers and other active bus components with the time to day.
Inside the SPPA-T3000 system, a logical NTP network is built by components connected to the Ethernet network and this NTP network spans all Ethernet subnets (Application Highway and Automation Highway) defined by SPPA-T3000. According to the NTP Request/Response procedure every 10s the time information will be sent and received by all active components simultaneously.
The time resolution is 1ms.
VIII-10-2.4.6 Management of intelligent Field Devices with SIMATIC PDM
SIMATIC PDM (Process Device Manager) is a universal cross-manufacturer tool for configuration, parameter assignment commissioning, diagnostics and maintenance of intelligent process devices and automation components. With SIMATIC PDM, you can use one soft-ware program to configure a number of field devices by different manufacturers using a single user interface. Process device data can be easily set, changed, checked for plausibility, managed and simulated. In addition, you can monitor selected process values, alarms and status signals of devices online.
The core functions are:
• Setting and changing device parameters
• Comparison of setpoint and actual parameter assignment
• Plausibility check on entries
• Simulation
• Diagnostics
• Management
• Commissioning function, e.g. measuring circuit testing of process device data
• Life List
• Protocol Functions
SIMATIC PDM Software is installed on the SPPA-T3000 Application Server and can be accessed by the workbench.
Devices with HART interface can be connected via FUM with HART analog input modules
VIII-10-2.5 DCS Configuration for Desalination Plant
The following is the simplified configuration of Distributed Control System
for Desalination Plant.
Refer to 70-CQ-EDB-500 DCS Configuration Diagram for Water Plant
VIII-10-2.5.1 DCS Configuration for Desalination Plant
The desalination plant areas the control and operation is realized in the plant main DCS.
Third party systems having their own control equipment (Vendor Packages) are incorporated with a signal exchange to an extent as necessary for them to be integrated in the overall plant operation, start-up and shutdown process.
The configuration for Package “D” will consist of 3 individual DCS systems for the various water bocks in the following structure:
1. One DCS system for MSF Block: This DCS system include the following
system parts of Package ”D”:
a. MSF #1&2 and Common Electrical System
b. MSF #3&4 and Common Electrical System
c. MSF #5&6 and Common Electrical System
d. MSF #7&8 and Common Electrical System
e. Ball Cleaning System (Vendor Package) for each MSF unit
2. One DCS system for Desalination Common Block: This DCS system
include the following system parts of Package ”D”:
a. Seawater Intake System
i. Seawater Screen System
ii. Seawater Supply System
iii. Auxiliary Cooling Water System
iv. Chemical Dosing System
v. Electrical System
vi. Hydraulic Non-return Valves (Vendor Packages)
n Interfaced to DCS with hardwire.
vii. Electro Chlorination System (Vendor Package)
n Interfaced to DCS with hardwire.
viii. VMS for Seawater Supply Pumps (Vendor Package)
n Interfaced to DCS with hardwire.
ix. HVAC, Fire Fighting, Cathodic Protection system (Vendor Package)
n Interfaced to DCS with hardwire.
b. Post Treatment System
i. Remineralization System
ii. Potable Water system
iii. Electrical System
iv. Gas Chlorination System (Vendor Package)
n Interfaced to DCS with hardwire.
v. Serial data link to Potable Water Pumping Station (PS1 of LDC)
3. One DCS system for RO – A & B Block: This DCS system include the
following system parts of Package ”D” :
a. Pretreatment - A and Electrical System
b. Reverse Osmosis – A and Electrical System
c. Pretreatment - B and Electrical System
d. Reverse Osmosis – B and Electrical System
VIII-10-2.5.2 User Interfaces
1. For One DCS system for MSF Block, the following user interface are provided :
1) MSF #1,2,3 & 4 Operator desk section in CCR:
a. 4 x T3000 Operator station (Thin Clients) with each two screens
b. 1 x Large Screen consisting of 4 modules
c. 1 x Hardcopy laser printer (A4)
2) MSF #5,6,7 & 8 Operator desk section in CCR
a. 4 x T3000 Operator station (Thin Clients) with each two screens
b. 1 x Large Screen consisting of 4 modules
c. 1 x Hardcopy laser printer (A4)
3) Engineering and Diagnostic Room (EDR)
a. 1 x Engineering and Diagnostic Station (Thin Client) with two screens
b. 1 x Color laser printer (A4)
c. 1 x Color laser printer (A4)
2. For One DCS system for Desalination Common Block, the following user interface are provided:
1) Desalination Common Operator desk section in CCR
a. 3 x T3000 Operator station (Thin Clients) with each two screens
b. 1 x Large Screen consisting of 4 modules
c. 1 x Hardcopy laser printer (A4)
2) Engineering and Diagnostic Room (EDR)
a. 1 x Engineering and Diagnostic Station (Thin Client) with two screens
b. 1 x Color laser printer (A4)
c. 1 x Color laser printer (A4)
3) LCR for CO2 + limestone Plant
a. 2 x T3000 Operator station (Thin Clients) with each two screens
b. 1 x Logs laser printer (A4)
c. 1 x Hardcopy laser printer (A4)
3. For One DCS system for RO - A & B Block, the following user interface are provided :
1) RO-A Plant Operator desk section in CCR:
a. 2 x T3000 Operator station (Thin Clients) with each two screens
b. 1 x Large Screen consisting of 4 modules
c. 1 x Hardcopy laser printer (A4)
2) RO-B Plant Operator desk section in CCR
a. 2 x T3000 Operator station (Thin Clients) with each two screens
b. 1 x Large Screen consisting of 4 modules
c. 1 x Hardcopy laser printer (A4)
3) Engineering and Diagnostic Room (EDR)
a. 1 x Engineering and Diagnostic Station (Thin Client) with two screens
b. 1 x Color laser printer (A4)
c. 1 x Color laser printer (A4)
Remark
1. Furniture (desks and chairs) in CCR shall be supplied by Package “P”
because of identical design of these pieces of furniture.
2. The electrical power required for all DCS equipment (including above the user interfaces and LAN/Server cabinets) supplied by Package “D” in CCR shall be fed from the fail safe 230VAC or 24VDC power supply and distribution cabinets supplied by Package “P”.
3. For PMS and crosswise operation, one station with one monitor per above
each operator desk section in the CCR shall be provided by Package “P”.
Package “D” will provide the information and data required for
the engineering of PMS and crosswise operation by Package “P”
according to the related Tender requirements and configuration diagrams.
VIII-10-2.5.3 Process Interfaces
The following process interfaces will be applied:
• Desalination Plant will apply the FUM version of the IO modules.
VIII-10-2.5.3.1 Consideration of redundancy
Redundancy of analogue and binary input modules will follow the redundancy of the field equipment or signal (e.g. signals from redundant transmitters will be connected to different IO modules in different racks, Figure 10).
Triple redundant signals from temperature measurements derived from duplex elements will be assigned to three different I/O modules in the following manner:
Measurement | I/O Module |
Temperature 1A | 1 |
Temperature 1B | 2 |
Temperature 2A | 2 |
Temperature 2B | 3 |
Temperature 3A | 3 |
Temperature 3B | 1 |
Analogue and binary output signals will be read out using two redundant output modules. In case output signals are already generated redundant in the DCS those signals are read out using different IO modules in different racks, the individual signal itself must not be read out using a redundant output (Figure 11).
Drive modules will be configured redundant for drives used for open and closed loop control. Pumps/Motors and that are provided redundant in the field will be controlled from different I/O drive modules. Due to the field redundant configuration these drive modules will not be configured redundantly.
VIII-10-2.5.4 Implementation of Third Party Systems (Vendor Packages)
Signal exchange to third party systems (Vendor Packages) is realized hardwired or using a communication link.
The selection of the type of signal exchange will be decided during detail design depending on the relevance of the signal, extent of integration of the vendor package and the quantity of signals to be exchanged.
Relevant control and interlocking signals will be exchanged hardwired.
VIII-10-2.5.5 Power Supply
Redundant power supply to DCS cabinets will be provided.
Redundant DC infeeds from a safe 24VDC UPS are connected to a common DC bar inside the cabinet and are decoupled by diodes. From this common bar all cabinet internal I&C consumers are supplied redundantly.
The equipment located in the CCR requires AC power supply. For the power distribution to these components a power distribution cabinet will be provided having two infeeds from the safe 230VAC UPS supply (to be provided by Package “P”). Inside the cabinets two infeeds are separately distributed to different infeeds to the power distribution cabinet.
Example:
• Operator Stations (Thin Clients): One operator station is connected to infeed GW021, the other operator station is connected to infeed GW022.
• Application Server: One half of the redundant Application Server is supplied from infeed GW021, the other half of the redundant Application Server is supplied from infeed GW022.
VIII-10-2.6 Multi Unit configuration
The Application Highway and the Automation Highway of 3(three) DCS systems of Package “D” will be connected each other and integrated with Power Plant DCS Blocks through a multiunit redundant router, interfaced cables and connection works provided by Package “P”
This configuration provides:
• means for signal exchange between the Automation Highways of the individual blocks (software communication link)
• the possibility for the operator to log into every block from any operator station of Package “D” thus providing access to every system in the DCS of the desalination plant from any operator or engineering/diagnostic station. Login into up to 4 blocks at the same time is possible.
1.1.
1.2.
1.3.
1.4.
VIII-10-3 Operating Instructions of DCS
VIII-10-3.1 Pre-start Checks
Before putting the whole instrument and control and system, or any part thereof into operation for the first time, or after a long shutdown period of the plant, the local and/or CCR operators should confirm that the following equipment are receiving proper power supply, and are, therefore, ready for energization/operation:
· Operation desks in CCR
· Process station cabinets
Step | Action |
VIII-10-3.2 Start-up
VIII-10-3.2.1 Purpose
These instructions are designed to provide the procedures that ensure the safe and reliable start-up of all the instrument and control equipment, including the CCR desks, automation system cabinets, bus system, cubicles and panel instruments. The related equipment should first be energized so that control and monitoring of the main plant items can be performed.
VIII-10-3.2.2 Summary
After positive confirmation of the pre-start checks, the instrument and controls will be ready for operation. Start-up of the desks is initially performed once, or after recovery from an emergency shutdown, by closing the breakers supplying the panels with electric power.
VIII-10-3.2.3 Prerequisites
Local Operator | Ready |
CCR Operator | Ready |
Electronic Room Operator | Ready |
Relevant Control Power Sources | Available |
VIII-10-3.2.4 Start-up Procedure
Step | Action |
1. | Power Energization of Control Cubicles |
1.1 | Verify by voltmeter reading that an adequate power supply is fed to each I&C cubicle to be energized from the 24 V DC main distribution boards.. |
1.2 | Close the breakers that supply the power to cubicles |
1.3 | Check the LED status for ready |
2 | Power Energization of Control Desks |
2.1 | Make sure that all process systems are ready. |
2.2 | Make sure the AC power availability |
2.3 | Switch on the uninterrupted power supply (UPS). |
2.4 | Confirm that the DM and SU are Running. |
2.5 | Switch on all graphic server computers |
2.6 | Switch on server computers |
2.7 | The server shall start automatically. The start-up basic display appears on each monitor of the server. Mouse and keyboard operations are then possible. |
end |
VIII-10-3.3 Shutdown
VIII-10-3.3.1 Purpose
The shutdown procedure instructions are designed to provide the proper and sage shutdown operation of the control and monitoring equipment, when required.
VIII-10-3.3.2 Summary
The shutdown procedure is only performed in case of emergency or when maintenance work has to be performed. The procedure includes the steps that should be performed by qualified personnel to obtain shutdown in a safe and efficient manner.
VIII-10-3.3.3 Prerequisites
Control voltage | Ready |
Local operation | Informed and Ready |
Relevant control power sources | Available |
The shutdown procedure of the control panels, CCR desks, shift supervisor operating and process computer station, PC stations, engineering station and other control and monitoring equipment is never performed during normal conditions.
To avoid damage to the plant equipment in the event of a major failure of the distributed control system (DCS), a central safe emergency shutdown of the plant must be performed. This is carried out by using the emergency shutdown pushbuttons provided on the CCR operating consoles for each of the respective equipment of the power plant units.
In case that shutdown has to be performed, for the purpose of maintenance or due to the breakdown of a component, the following procedure should be followed after the related plant is stopped.
VIII-10-3.3.4 Shutdown Procedure
Step | Action |
1. | Control Desk-CCR |
1.1 | Shut down OWS manually. |
1.2 | Shutdown Server manually. |
- | |
2. | Shutdown of the Engineering Console and the PC stations |
3. | Shutdown of the control cubicles. |
4. | Shutdown of the Bus system. |
end |
VIII-10-3.4 Normal Operation and Routine Checks
The indicating and command equipment located on the local control panels (LCPs) should be regularly checked. Also, the control and monitoring equipment mounted on the control cubicles and the CCR equipment should be inspected periodically. Carry out the checks in the following procedure.
Step | Action |
1. | Check that an adequate power supply is fed to each I&C cubicle. |
2. | Verify that the critical hardware modules are not overheated. |
3. | Check that the deviation of each control loop is nearly zero. |
4. | Verify the absence of any leakage from the impulse lines. |
5. | Verify that the seals of the cable connections to the control cubicles are properly installed so as to prevent the ingress of dust or vermin, or the propagation of possible fires. |
6. | Verify that the paint coating that protects the control cubicles against rust and corrosion is free from any marks, scratches or damage of any kind. |
7. | Remove any dust or dirt deposits from all control and monitoring equipment. |
8. | Check that no abnormal lamp is lit in the CCR or on any of the control panels. |
9. | Check that no diagnostics alarm is activated. |
10. | Check that the visual display units (VDUs), mounted on the control desks of the CCR, are in correct operating condition. |
11. | Verify the proper functioning of all keyboards arranged on the control desks of the CCR, and clean any dust and dirt deposits. |
12. | Verify the good functioning and indication of the digital clock installed on the control desk of the CCR. |
end |
VIII-10-4 Alarm Procedure
The basic alarm concepts regarding Alarm Sources, alarm types and alarm status are described below.
Alarm Sources
Alarms are created by Alarm Sources. Alarm Sources are either configured during the engineering process, or exist by default as standard system settings.
Alarm Types
Alarms are characterized by an alarm type. The alarm type is configured at the alarm source. Alarm types have two categories:
There are several default Alarm Types available, others can be created during the engineering process. The default Alarm Types are listed in the table below:
Alarm Type | Abbreviated Name | Name | Description |
The Abbreviations and Names of the alarm types are used throughout the system e.g. in parameter masks, or in an ASD.
Alarm Status
An alarm can be in one of two states, it is either active or deactive. When an alarm becomes active it is raised, when it becomes deactive it is gone. This principle is shown in the diagram below:
Manual Operator Response
A Manual Operator Response (MOR) is an SPPA-T3000 alarm type . It will appear when a malfunction occurs on certain devices. The control logic for these devices require a malfunction to be acknowledged with the faceplate Reset button. The MOR type alarm reminds the operator that, that a Reset is required.
MOR Alarm Indication
When an MOR alarm is generated it is indicated in the same way as other alarms i.e. :
Required Operator Action
To reset the failure status of the device proceed as follows:
The MOR alarm will be Gone and automatically acknowledged.
Alarm Sequence Display
Alarm Sequence Displays provide the interface for users to view, analyze and control alarms. An ASD is a very flexible interface, and can be customized to meet project requirements, or individual users needs. In an ASD alarms are displayed in chronological order.
A default ASD is always available and provides a standard interface for all users. Users may also develop user specific ASDs if required.
The general layout of an ASD is described, as well as the options for customizing it. ASDs can be displayed in either a chronological or an alarm point view, and provide various options for alarm controls.
Many users can access ASDs simultaneously, and there are measures for multi user operation.
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