TC65B, WG6. IEC Industrial Process Control Systems Guideline for evaluating process control systems. Micaela Caserza Magro Paolo Pinceti

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1 COMITATO ELETTROTECNICO ITALIANO TC65B, WG6 IEC Industrial Process Control s Guideline for evaluating process control systems Micaela Caserza Magro Paolo Pinceti

2 The origin of the idea F UK Group of Users of Instruments and s I NL Users espressed two requests: 1 Tool for the Technical Evaluation of the proposals from different PCS Makers 2 Common Procedures for Factory Acceptance Tests (FAT) of PCS 2

3 Goals of the Project 3

Number of P-members: 24 P-members voting: 20 March 2008 Result of Voting Approval Criteria Result P-members

4 COMITATO ELETTROTECNICO ITALIANO Project: PNW 65b-647 Ed.1 Industrial process control systems - Guidelines for evaluating the performance of Process Control s - PCS Number of P-members: 24 P-members voting: 20 March 2008 Result of Voting Approval Criteria Result P-members approving: 18 = 90 % > 50% APPROVED P-members ready to participate in the development >=4 (if <=16) APPROVED and approving addition of the proposal: 6 >=5 (if >= 17) 4

5 The Project Team 5

6 Liasons IEC TC65 Industrialprocess measurement, control and automation 65A aspects 65C Industrial networks 65E Devices and integration in enterprise systems 6

7 Liason D Exera (FR) Profibus Network Organisation Fieldbus Foundation 7

8 8

9 The process of PCS selection Check List User/Engineer Tech. Specs Function #1 Function #2 Function #n Evaluation/ Ranking Maker/Supplier Tech. Proposal Function #1 Function #2 Function #n 9

10 Air IEC Logical flow PROCESS REQUIREMENTS PCS UNDER TEST PCS TECHNICAL SPECIFICATIONS PCS TECHNICAL PROPOSAL 10 VENDOR SPECIFIC ARCHITECTURE

11 Function #1 Function #2 Function #n IEC 62603: Heuristic rules for voting the function is of little use the function would help the function should be implemented the function must be implemented weight: D weight: C weight: B weight: A Function #1 Function #2 Function #n the PCS does not meet the function vote: 0 the PCS does not meet the function, but it can be applied or created vote: 1 the PCS meets the function vote: 2 the PCS fully meets the function vote: 3 12

12 IEC 62603: Evaluating an offer For considering a bid acceptable, all the functions with weight A and B must have a vote not lower than C. For defining a global bid vote, first a numerical value must be assigned to weights and votes, then the average vote can be calculated with the following Equation Bid k value n ( w i 1 n i 1 i v i ki ( w ) ) where: n is the number of functions w i is the i-th function weight v ki is the vote of bid k for the i- th function Technical Requirement Weight Bid #1 Bid #2 Bid #3 Item #1 w 1 v 11 v 21 v 31 Item #2 w 2 v 12 v 22 v Item #n w n v 1n v 23 v 33 13

13 IEC 62603: a numerical example USER DEFINED WEIGHT FUNCTION WEIGHT BID 1 BID 2 BID 3 A B C D VOTE ,27 8,36 8,89 14

14 IEC Part 1 PCS Technical pos. 4.1 pos. 4.2 pos. 4.3 pos. 4.4 pos. 4.5 pos. 4.6 pos. 4.7 Architecture Installation Environment Characteristics Reliability & Availability Input/Output Specifications Software For the technical evaluation of a Process Control it is necessary that the Technical Specification of the required PCS defines a clear list of requirements to check-out. pos. 4.8 pos. 4.9 Communication Required Performances pos pos Technical Support FAT Specification 15

15 IEC How to use it 16

16 IEC How to use it 17

17 PCS technical requirements architecture PCS Technical pos. 4.1 pos. 4.2 pos. 4.3 pos. 4.4 Architecture Installation Environment Characteristics Reliability & Availability This part describes the general characteristics of the PCS, namely the physical structure and the preliminary sizing of the components. The scope of this part is to identify the general characteristics of the desired PCS, the fundamental technologies, the topology of the system and its size pos. 4.5 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos pos Input/Output Specifications Software Communication Required Performances Technical Support FAT Specification 18

18 PCS technical requirements architecture PCS Technical pos. 4.1 pos. 4.2 Architecture Installation Environment This part describes the general characteristics of the environment in which the PCS and its components are installed. pos. 4.3 pos. 4.4 pos. 4.5 Characteristics Reliability & Availability Input/Output Specifications The operating conditions for the PCS components are divided into four main categories, according to the classification made by the standard IEC family: Software pos Technical the climatic conditions of the location in which the components are installed (i.e. Support temperature, humidity, etc.); pos FAT Specification the power supply to which the components are connected: the minimum EMC requirements in terms of immunity and the power supply characteristics; mechanical influences to which the components are exposed during their operation (i.e. vibration, shock, etc.); corrosive and erosive influences to which the components are exposed during their operation (i.e. sand, gases, corrosive liquids, etc.) 19 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 Communication Required Performances

19 PCS technical requirements characteristics PCS Technical pos. 4.1 Architecture expandability pos. 4.2 pos. 4.3 Installation Environment Characteristics pos. 4.4 Reliability & Availability pos. 4.5 Input/Output Specifications Programming languages for control Characteristics that influence the PCS structure and capability. scalability Integration of subsytems pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos Software Communication Required Performances Technical Support pos FAT Specification Documentation configuration: on-line, offline, graphical, etc. 20

20 PCS technical requirements Reliability and availability Reliability: self diagnostic, fault tolerance, hot swappable components Availability: admissible degraded conditions, stand-by configurations, redundancy criteria Maintainability: strategies for maintenance, spare capacity of the system Safety: emergency shut-down, safety requirements (SIL) PCS Technical This part deals with the concept of system DEPENDABILITY, that includes: reliability, maintainability and maintenance pos. 4.1 pos. 4.2 pos. 4.3 pos. 4.4 pos. 4.5 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos pos Architecture Installation Environment Characteristics Reliability & Availability Input/Output Specifications Software Communication Required Performances Technical Support FAT Specification 21

21 repair NORMAL Failures & Operating Modes Transitions non-critical failure DEGRADED NO redundant architecture? critical failure repair Redundancy is the key for achieving high system availability YES 2nd failure ALARM 2nd failure FAULT repair 22

22 PCS technical requirements Input/output PCS Technical pos. 4.1 Architecture Specifications of the Input/Output of the PCS: conventional I/O (4-20 ma, 0-10 V), digital I/O, Hart I/O and fieldbus. For each type of I/O the user should specify the resolution, the accuracy and the repeatability. pos. 4.2 pos. 4.3 pos. 4.4 pos. 4.5 pos. 4.6 Installation Environment Characteristics Reliability & Availability Input/Output Specifications Software According to IEC 60050, the following definitions apply: resolution (for measurement): smallest change in the measurand, or quantity supplied, which causes a perceptible change in the indication; resolution (for analog converters): the maximum capability of a system that is used to convert an analog signal into a proportional digital value. Generally, resolution is expressed in bits, from which the actual resolution may be determined (bits per word); accuracy: the ratio of error to the full-scale output or the ratio of the error to the output, as specified, expressed as a percentage; repeatability (cfr. ISA (R1982)): is the ability of a transducer to reproduce output readings when the same measurand value is applied to it consecutively under the same conditions and in the same direction pos. 4.7 pos. 4.8 pos. 4.9 pos pos Communication Required Performances Technical Support FAT Specification 23

23 PCS technical requirements Software This part deals with the requirements for software used in a PCS: the database, the simulator as well as cyber security and access management database requirements Cyber security Software simulator Remote supervisory functions PCS Technical pos. 4.1 pos. 4.2 pos. 4.3 pos. 4.4 pos. 4.5 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos pos Architecture Installation Environment Characteristics Reliability & Availability Input/Output Specifications Software Communication Required Performances Technical Support FAT Specification 24

24 PCS technical requirements The requirements include: Control room hardware: architecture, machines, monitors, Control room software Local operator interface Alarm management Event management Historical archiving Trend and statistics management PCS Technical pos. 4.1 pos. 4.2 pos. 4.3 pos. 4.4 pos. 4.5 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos pos Architecture Installation Environment Characteristics Reliability & Availability Input/Output Specifications Software Communication Required Performances Technical Support FAT Specification 25

25 Communication plays a key role in a PCS. Usually communication networks may be divided into three or four levels according to the technology used PCS technical requirements Communication The levels of communication networks are: corporate network communicati on between the PCS and the ICT. Fieldbus between the field devices and the controllers. (e.g. Fieldbus Foundation) control room network it supports the interface between the controllers and the workstations in control room. PCS Technical controller network it guarantees horizontal communicati on. pos. 4.1 pos. 4.2 pos. 4.3 pos. 4.4 pos. 4.5 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos pos Architecture Installation Environment Characteristics Reliability & Availability Input/Output Specifications Software Communication Required Performances Technical Support FAT Specification 26

26 Fieldbus Fieldbus Fieldbus LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 Fieldbus Fieldbus Fieldbus LEVEL 1 LEVEL 2 LEVEL 3 PCS technical requirements Communication Corporate Network EWS SRV Corporate Network EWS SRV Control Room Network Server Control Room Network Controller Network 27 4 level communication network (PLC based) 3 level communication network (DCS)

27 PCS technical requirements Performances PCS Technical pos. 4.1 Architecture pos. 4.2 Installation Environment This part specifies the performances the PCS should guarantee for satisfying the requirements of the controlled process. Assett management: system benchmark, definition of KPI, definitionof OEE, generation of maintenance requests Time performances: response time, timestamp, absolute time synchronization, switch over time, etc. Controller performances: real time requirements, scan time, etc. pos. 4.3 pos. 4.4 pos. 4.5 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos pos Characteristics Reliability & Availability Input/Output Specifications Software Communication Required Performances Technical Support FAT Specification performances: call-up time, refresh time, real-time, etc. 29

28 PCS technical requirements Technical and commercial support This part defines the technical/commercial services that should be offered : Training of the personnel for support Warranties Hardware/software upgrade References of the company Core competencies Application experience References for similar applications PCS Technical pos. 4.1 pos. 4.2 pos. 4.3 pos. 4.4 pos. 4.5 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos pos Architecture Installation Environment Characteristics Reliability & Availability Input/Output Specifications Software Communication Required Performances Technical Support FAT Specification 30

29 PCS technical requirements FAT Specification PCS Technical pos. 4.1 pos. 4.2 pos. 4.3 Architecture Installation Environment Characteristics General definitions and procedures of the Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT) for a PCS are described in the IEC Standard The type and the extension of the PCS testing must be defined in the specifications, and may represent an important item to be evaluated pos. 4.4 pos. 4.5 pos. 4.6 pos. 4.7 pos. 4.8 pos. 4.9 pos pos Reliability & Availability Input/Output Specifications Software Communication Required Performances Technical Support FAT Specification 31

30 FAT LEVELS OF DEPTH FAT Levels CONTROLLER TERMINATION FIELD PROCESS 32

31 FAT LEVELS OF DEPTH FAT Specs CONTROLLER TERMINATION Function Level Extension notes configuration % FIELD Graphic screens % Control loops and sequences 3 30 % only critical functions PROCESS Safety related functions % Interface with external systems 4 5 % only selected data Redundancy check 3 100% Alarm check 2 5 % Advanced control functions % Specific 33

32 A Level 5 architecture: SoftPLC Fieldbus Manager Remote I/O PCS I/O cards & fieldbus interfaces SW interface (e.g. OPC) Process Simulator Fieldbus converter Hardwired connection fieldbus connection 35

Part 1: General considerations and methodology Part 2: Assessment methodology Part 3: Assessment of system functionality Part 4: Assessment of system performance Part 5:

33 Part 1: General considerations and methodology Part 2: Assessment methodology Part 3: Assessment of system functionality Part 4: Assessment of system performance Part 5: Assessment of system dependability Part 6: Assessment of system operability Part 7: Assessment of system safety Part 8: Assessment of non-task-related system properties 36

Implementation Guide for the DoseControl Dosimetry System

Implementation Guide for the DoseControl Dosimetry System 1.0 SCOPE The GEX DoseControl System is intended for use as a single dosimetry system solution, specifically developed to satisfy the generic dosimetry needs of radiation sterilization application users