Informations-, Prozess- und Kommunikations-Systeme GmbH

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Informations-, Prozess- und Kommunikations-Systeme GmbH Modernization of the TELEPERM Control Level (OS520) for Chemical Production Processes 11 May 2009 IPKS GmbH Dresdner Bank Erlangen D-91058

1 Informations-, Prozess- und Kommunikations-Systeme GmbH Modernization of the TELEPERM Control Level (OS520) for Chemical Production Processes 11 May 2009 IPKS GmbH Dresdner Bank Erlangen D Erlangen D Duisburg Geschäftsführer: Kto.: Am Weichselgarten 36 Salvatorweg 22 Bernd Kinnen, Hubert Pflug BLZ: Tel.: +49 (0) 91 31/ Tel.: +49 (0) 2 03/ Amtsgericht Fürth HRB 3079 Fax: +49 (0) 91 31/ Fax: +49 (0) 2 03/ USt.-Idnr.: DE

2 Publisher IPKS Prozess-Software-Entwicklungs GmbH Am Weichselgarten 36 D Erlangen Tel.: +49 (0)9131/ Fax.: +49 (0)9131/ info@ipks.de Contact person: Mr. Bernd Kinnen Copyright 2009 IPKS GmbH The content of this document is the sole property of IPKS. No part of this publication may be reproduced or distributed in any form or by any means, without the prior written permission of IPKS GmbH. Any person who does any unauthorized act in relation to this publication may be liable to criminal prosecution and civil claims for damages. Limitation of Liabilities While every precaution has been taken in the preparation of these specifications, the publisher assumes no responsibility for errors or omissions, or for damages resulting from the use of the information contained herein. Subject to change without notice. Trademarks Trademarks or patents generally protect all references to software or hardware used in this document. IPKS GmbH All rights reserved. IPKS GmbH Page 2 of 19

3 Contents 1 Introduction Subject of the... 5 The Starting Point (Current State) Process Control Level The Tasks Objective of the Modernization Project The Proposed Solution General Objectives Architecture of the Proposed System The "Soft Migration" Concept General New Process Control Technology Hardware Software Operator Control Interface Representation of the OS Functions Operator Control in Multi-Monitor Mode Messages Reports, Analyses Connection CS 275 New Process Control System Installation of the System Devices IPKS GmbH Page 3 of 19

4 List of Figures Figure 1: Current state of the production process control level based on TELEPERM...6 Figure 2: Proposed system with Windows computers...9 Figure 3: Plant overview, visualization example...12 Figure 4: Boiler overview diagram, visualization example...13 Figure 5: Section of the available "NOBIs", visualization example...13 Figure 6: Step sequence diagram, visualization example...14 Figure 7: Curve diagram, visualization example...14 Figure 8: Signaling diagram, visualization example...15 Figure 9: Operator control in multi-monitor mode, visualization example...15 Figure 10: Message sequence representation, visualization example...16 Figure 11: Functions of the gateways in the communication structure...17 Figure 12: Installation of the system devices...18 List of Tables IPKS GmbH Page 4 of 19

5 1 Introduction 1.1 Subject of the This example provides solutions for the future-oriented modernization and expansion of the control level for the plant's production processes. The approach outlined in this example incorporates the existing TELEPERM M/ME system (AS controllers and CS275 automation bus) and the existing SIMATIC S5 control equipment, which remain unchanged. With the connection of the existing equipment to the new visualization system, all I/O assignments and structure data of the legacy system will be preserved and ported to the new platform. Presently the process control level consists of the Siemens TELEPERM OS (Operator Communication Systems). The table lists the subsystems with the components to be modernized and the data to be taken into account: Computers of the process control level: Operator control equipment in the control room: Process data: Interfaces, bus systems: OS Host systems for process control and monitoring (OS525 computers) HP-UX BES Batch X System OS525 terminals Automation level with six AS488 controllers SIMATIC S5 controllers CS275 automation bus Hardware of the Process Control Level The proprietary hardware components of the process control level (OS525 host systems and terminals) are discontinued by the supplier (Siemens). Future provision of replacement parts cannot be guaranteed as the required hardware components will no longer be available on the market. Also, the use of aging stock parts increases the risk of a plant standstill. Functional Scope of the Process Control System The functional scopes of the plant's OS systems and Batch system meet the current requirements so that these systems are not necessarily in need of replacement. The introduction of a modern visualization system offers the possibility to bring the existing operator control concept in line with today's standards of efficient and ergonomic plant control and open it for future expansion. Operator Control Level I/O equipment such as workstations communicates with the OS systems via bus connections and is distributed over several workplaces. Automation Level The plant's automation level consists of Siemens AS488 controllers connected to the process control level via the CS275 bus, and SIMATIC S5 controllers. The automation level with CS275 bus remains untouched. IPKS GmbH Page 5 of 19

The Starting Point (Current State) 1.2 Process Control Level The plant's production process control level comprises the following systems (see Figure 1).

6 The Starting Point (Current State) 1.2 Process Control Level The plant's production process control level comprises the following systems (see Figure 1). HP-UX BES Batch X OS525 Terminal 1 OS525 Terminal 4 OS525 Terminal 2 OS525 Terminal 3 ES500 Engineering Station AS Bedienplatz SSV 104 SSV 104 Industrial Ethernet OS 525 Host 1 Host 2 Prozeßbus CS275 OS 525 TELERPERM M AS Allgemein BATA 0/1 AS488 AS Ansatzvor. BATA 0/2 AS488 AS Linie 1 BATA 0/3 AS488 AS Linie 2 BATA 0/4 AS488 AS Linie 3 BATA 0/5 AS488 AS Linie 4 BATA 0/6 AS488 EG183U ET100 S5-115U Waage EG183U S5-115U EG183U S5-115U EG183U S5-115U ET 200M S5-115U ET100 ET100 EG183U S5-115U EG183U EG183U Waage EG183U ET 200M Waage ET100 ET100 ET100 ET2 ET100 ET100 Siwarex P ET100 Simovert FU Siwarex M Automation concept Figure 1: Current state of the production process control level based on TELEPERM OS Systems Two (2) OS525 Host systems as productive systems One (1) HP-UX Batch x system CS275 Automation Bus The OS Host systems are connected to a CS275 bus system by means of interface modules. The CS275 bus system is the interface to the automation level which remains unchanged. Automation Level The automation level is based on the Siemens AS488 automation system and SIMATIC S5 control equipment. I/O Equipment The I/O equipment of the OS Host systems consists of four (4) OS525 video display terminals which communicate with the OS HOST systems via bus connections. Test and Structuring An ES500 Engineering Station with PROGRAF AS and BIPRO is used for the OS/AS system structuring. IPKS GmbH Page 6 of 19

2 The Tasks 2.1 Objective of the Modernization Project The aim of this project is the future-oriented modernization and expansion of the plant's process control level.

would be involved in reprogramming or entering the information from scratch.

7 2 The Tasks 2.1 Objective of the Modernization Project The aim of this project is the future-oriented modernization and expansion of the plant's process control level. All structure parameters and I/O allocations of the 'old' system shall be safely and consistently ported to the new system to avoid the high error rate and considerable engineering expenditure that would be involved in reprogramming or entering the information from scratch. The core of the project is the systematic reengineering of the process and operator control level and the data and systems involved on the basis of new nonproprietary hardware and modern operating systems on the one hand, and the connection of the existing automation concept to the new visualization system on the other hand. The conversion and reorganization work is conducted without having to interrupt the running operation of the plant. The starting point: Block control with TELEPERM M/ME Proprietary graphic display screens and video terminals located in the block control room Siemens computers running the OS 525 process control systems CS275 automation bus ASxxx automation equipment Proprietary components of the "old" system Sustainable re-engineering based on open standard technologies Standard Windows workstations for operator control in the block control room. Redundant commercial off-the-shelf servers with Windows operating system, SQL database and modern SCADA system. TCP/IP-LAN network ensures open system architecture. 'Transparent' gateway black box handles the CS 275 <->TCP/IP message transmission. No programming required! The automation level with Asxxx controllers, CS275 bus and all wiring remains untouched. Modernized system based on open standard technologies Migration concept IPKS GmbH Page 7 of 19

8 3 The Proposed Solution 3.1 General Objectives The proposed modernization of the existing systems is guided by the following targets and requirements: The proposed solution is based on state-of-the-art technologies and recognized standards, both operator control and automation level are future-oriented and open for further development and expansion. The proposed solution is based on nonproprietary concepts both for the process control system and the employed hardware components. The proposed solution is scalable and can be easily adapted to future expansion of the quantity structure. The proposed solution can be adapted to changed requirements, such as modifications to the structure and operational mode of the overall system. The proposed solution is based on open interfaces: - Open interfaces to the automation level with OPC (OLE for Process Control) - Open interfaces for programming tasks (Visual Basic, VB-Script, C) - Open interfaces for data management tasks (SQL, ODBC) - Open interfaces for data archiving and data backup Both the computer system and the security system concept with its high degree of availability are future-proof, easy to maintain and based on nonproprietary standard hardware and software components. The operator control concept is future-proof, easy to maintain and independent of modifications to the network structure (Intranet) or operator terminal designs. The proposed solution allows the integration of the process control system in companywide applications and the company's information technology. 3.2 Architecture of the Proposed System The system architecture shown in the figure below meets the specified criteria. The existing automation system with the CS 275 automation bus remains unchanged. Gateways connect the automation system to the TCP/IP network - opening the system to new standards in computer and process control technology. IPKS GmbH Page 8 of 19

Figure 2: Proposed system with Windows computers The OS525 Host systems will be replaced by a redundant WinCC Server system. The OS525 Terminals are replaced by WinCC Client PCs.

9 Figure 2: Proposed system with Windows computers The OS525 Host systems will be replaced by a redundant WinCC Server system. The OS525 Terminals are replaced by WinCC Client PCs. The functions of the Batch x system are implemented in the WinCC Server system. A separate Client PC is used for operating the new batch functions. 3.3 The "Soft Migration" Concept General As the existing automation system with its structure data and the CS 275 automation bus shall continue to run unaffected by the modernization process, we recommend our method of "soft migration": the 'old' system continues to operate without interruption while it is being replaced step by step by the new SCADA system In order to preserve and secure the structure data of the existing OS systems and avoid reprogramming or entering the information from scratch, the 'old' system shall be safely and consistently ported to the new system. All structure information and I/O addressing of measuring values, analog and binary values, arithmetic values, etc., is migrated from the old systems to Windows files. New process graphics are created for the new process control scheme, but there will be no need for a reconfiguration of the basic "wiring". This also applies to the existing batch and recipe data. The UNIX / ORACLE system migrates all recipes to the new batch system. IPKS GmbH Page 9 of 19

10 3.4 New Process Control Technology Hardware All discontinued hardware components of the process control level are replaced by commercial off-the-shelf hardware based on standard operating systems. This applies to the following components: OS systems Batch X systems Replacement of the computer hardware old: 2x OS525 Host systems new: redundant WinCC Server (2x Windows Server) Replacement of the operator stations old: 4x OS525 Terminals new: 4x WinCC Client (4x Windows computer) Replacement of the computer hardware old: HP-UX new: no longer used, will be integrated in the WinCC Server Replacement of the operator station new: additional WinCC Client computer A new process control system based on WinCC is installed in parallel to the existing OS systems. The new process control system consists of highly available WinCC server systems (2x Windows Server) in a redundant arrangement. The time synchronization of the new systems (WinCC servers, terminal computers) is based on a LAN network and an NTP Time Server with integrated highly accurate DCF-77 radio clock. The system is operated by means of three (3) terminal computers which communicate with the WinCC master computers over the LAN. An additional terminal computer is used for recipe management and control. Using a MultiVGA card it is possible to connect up to two (2) modern TFT screens to one terminal computer. The process diagrams on the terminal computer's video screens are operated with mouse device and keyboard. The connection of a large screen projection is possible. The two servers and the terminal computers communicate with each other over a redundant local fiber optic LAN (control room LAN). It is possible to connect network printers to the control room LAN with the terminal computers. All systems are designed to allow expansion of both the hardware components (processor performance, storage capacity,...) and the software components (quantity structure, Web functions,...) Software The new process control and visualization concept is based on the SCADA system WinCC. WinCC offers the benefits that fit your specific needs: Process control and visualization based on latest technology Not a proprietary system restricted to specific industries IPKS GmbH Page 10 of 19

11 Established SCADA system for control rooms and centers in many industries, including power stations Future-proof system, well-established on the market Open for other bus systems, such as Profibus, field bus, etc. and automation systems (e.g., Siemens, ABB, OPC interface) PM Control is used as the new system for batch / recipe management and control Operator Control Interface The existing operator control concept will be reproduced with the WinCC process control software and further enhanced according to customer specifications. The process control concept is based on the templates created in close cooperation with the customer and the existing R&I scheme. The actual number of process screens to be created will be determined in the feasibility study. The present systems comprise the following: 4 lines with the following scope - 10 overview screens - 10 detail screens - 10 general screens - 10 curve group screens - 1 Alarm + Nora 1 AS Preparation with the following scope: - 10 overview screens - 10 detail screens - 10 general screens - 10 curve group screens - 1 Alarm + Nora 1 AS General with the following scope: - 10 overview screens - 10 detail screens - 10 general screens - 10 curve group screens - 1 Alarm + Nora 20,000 data point approx. The figures below show examples of plant diagrams created for similar modernization projects in power plants and waste-fueled power stations. The implemented structure and control concept can in principle also be applied to the control of production processes. IPKS GmbH Page 11 of 19

12 Figure 3: Plant overview, visualization example IPKS GmbH Page 12 of 19

13 Figure 4: Boiler overview diagram, visualization example Figure 5: Section of the available "NOBIs", visualization example IPKS GmbH Page 13 of 19

14 Figure 6: Step sequence diagram, visualization example Figure 7: Curve diagram, visualization example IPKS GmbH Page 14 of 19

Figure 8: Signaling diagram, visualization example 3.4.

Existing parameters will be migrated to the new system whenever possible. 3.4.

15 Figure 8: Signaling diagram, visualization example Representation of the OS Functions OS functionality is determined by the existing OS systems and will be implemented in the new process control and monitoring system. Existing parameters will be migrated to the new system whenever possible Operator Control in Multi-Monitor Mode The four WinCC workstations in the control room are equipped with one (1) video screen each (up to two video screens can be connected to each workstation). The plant diagrams can be moved across these screens and operated with one mouse device and keyboard. Figure 9: Operator control in multi-monitor mode, visualization example IPKS GmbH Page 15 of 19

3.4.6 Messages Process messages and local events are recorded by the process control and monitoring system and stored in the standard WinCC message archives.

16 3.4.6 Messages Process messages and local events are recorded by the process control and monitoring system and stored in the standard WinCC message archives. The message parameters from the existing systems are migrated to the new system whenever possible. Layout and colors of the message lines will be determined in cooperation with the customer. An example from a similar modernization project in a power plant is shown below. Here the messages are divided into alarms, warnings, states and system errors. Figure 10: Message sequence representation, visualization example Reports, Analyses Reports and analyses are created in Excel table format for further processing. 3.5 Connection CS 275 New Process Control System The existing CS275 bus is the interface to the automation level. On the automation level, the AS488E automation devices are connected to the CS275 bus system. In the proposed system, the structure information of the AS488E automation devices is not directly connected to the superposed process control system. The existing AS488 devices are connected to the new process control system by means of gateways. These gateways have the following tasks: Conversion of the communication interface The CS275 bus is a proprietary bus system for TELEPERM M/ME systems. The CS275 gateway communicates with the CS275 bus over a local bus connection and converts the CS275 data traffic to the TCP/IP transmission standard. The CS275 automation level is thus furnished with an open, standard communication interface. Due to the use of a gateway the process data are now available on a standard communication medium (TCP/IP). User-specific control and visualization requirements can be more easily implemented. Conversion of the data and access structures The data and access structures of the AS488E automation devices are adapted to the proprietary TELEPERM M/ME process control system. The CS275 gateway converts the data and access structures of the AS488E automation devices to a general data and access structure. In the new superposed process control system, the AS488E specifications are no longer visible. The existing AS488E control systems are configured just like new standard automation devices. The figure below illustrates how the CS275 gateways are integrated in the communication structure of the process control system WinCC. The process control system communicates with the AS488E automation devices in the same way as with SIMATIC control systems or other automation systems connected via OPC. IPKS GmbH Page 16 of 19

17 Figure 11: Functions of the gateways in the communication structure IPKS GmbH Page 17 of 19

18 3.6 Installation of the System Devices The system devices are assembled and installed as shown below. Devices installed in the computer room: Two WinCC servers Two gateways Console with KVM for the operation of the servers and gateways Two fiber optic switches One NTP Time Server with integrated highly accurate DCF-77 radio clock Devices installed in the control room: Five Windows terminal computers (4x WinCC Client, 1x Batch) Two fiber optic switches Figure 12: Installation of the system devices IPKS GmbH Page 18 of 19

19 Notes: IPKS GmbH Page 19 of 19

PDC Server. Process Data Collection. Manual

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