np automation concept v1 0 revised by mm07!12!10

Novi Popovac plant 1 / 54

Automation Concept

Novi Popovac Plant

Remarks to this document:

This document defines the basics of the automation concept for the Novi Popovac (NP) plant. The basis for it was a draft document done by the NP personnel.

This new release has been worked out during an E-workshop in November 2007 by the NP plant personnel together with HGRS assistance.The document will serve as basis to work out all needed mechanical end electrical documents to apply this new automation standard for PCS upgrade projects and new projects in Novi Popovac plant.

The here described concept refers as much as possible to the Holcim standard criteria which have to be taken in consideration in unclear understanding.

The document is mostly complete yet. Several topics have to be completed by the plant.They are marked in red.

document.doc 928.11.2007


Modifications

Version Date Modification AutorV 1.0 30.11.2007 First release created during the E-workshop

in Nov 2007 in Novi Popovac on the basis of a draft release V6.6 from NP personnel

APPENDIX "Typical IO wiring" has been revised by the NP plant personnel.

This release will be frozen in HGRS as internal Report.

NP PersonnelR. Stingelin HGRS



Content

1. General Standards..............................................................................................................6

1.1 Automation System......................................................................................................6

1.2 HAC..............................................................................................................................6

1.3 Cabling concept............................................................................................................6

1.4 Documentation.............................................................................................................6

1.5 Voltage levels...............................................................................................................7

2. Local Controls...................................................................................................................8

2.1 Types of local commands.............................................................................................8

2.2 Code definition for local commands to use in HDRS.................................................102.2.1 Code for the buttons............................................................................................102.2.2 Codes for command box type.............................................................................102.2.3 Code example for local controls in HDRS...........................................................11

3. Local Isolators.................................................................................................................12

4. Cabling.............................................................................................................................12

4.1 Standard for cables....................................................................................................124.1.1 Color abbreviations DIN IEC 757........................................................................124.1.2 Colors of power cables (IEC / DIN VDE 293).....................................................124.1.3 Standard control cables (DIN 47100)..................................................................134.1.4 Direct wiring........................................................................................................144.1.5 Cross sections for power cables.........................................................................144.1.6 Typical cable definition in HDRS (Field F4A)......................................................14

5. DMC Standard..................................................................................................................15

5.1 General DMC Design.................................................................................................15

5.2 Mechanical DMC module design................................................................................155.2.1 Wiring and cabling for DMC................................................................................165.2.2 Typical wiring for a 230V single phase consumer control...................................195.2.3 Typical wiring for a 24V consumer control..........................................................22

5.3 Code definition for MCC treatment in HDRS..............................................................235.3.1 List for voltages...................................................................................................235.3.2 Code for supply location......................................................................................235.3.3 List for DMC-types..............................................................................................245.3.4 List for DMC standard power ranges..................................................................245.3.5 Examples for DMC-Code....................................................................................24

6. Subsystems.....................................................................................................................25



7. Control room concept.....................................................................................................26

7.1 CCR, Engineering and Production meeting Room.....................................................26

7.2 PLC and PC & Server Room......................................................................................27

8. UPS concept....................................................................................................................28

9. PCS / HMI Concept and Layout......................................................................................29

10. PCS IO Box design......................................................................................................30

10.1 Concept for the DMC and DIO box............................................................................30

10.2 Typical DIO module design........................................................................................3110.2.1 Typical wiring for field IO Box (DIO)....................................................................31

11. Standard wiring............................................................................................................32

11.1 Standard wiring of local motor control........................................................................32

11.2 Standard wiring of local valve control.........................................................................32

11.3 Typical wiring of DMC interface signals for Motors/Valves........................................33

11.4 Standard wiring of MCC interface signals for valves and single phase consumers...3811.4.1 Typical wiring for a 24V consumer control..........................................................39

11.5 Typical wiring of analog devices.................................................................................41

11.6 Typical wiring of digital devices..................................................................................43

11.7 Wiring for rope switches.............................................................................................44

12. Other engineering standards......................................................................................46

12.1 List of used standard record sets in HDRS................................................................46

12.2 List of used formal records sets in HDRS..................................................................47

12.3 Definitions in HDRS for direct wiring in DMC.............................................................48

13. Appendix Action list...................................................................................................49



14. Appendix Typical IO wiring (as example).................................................................50

14.1 IO-wiring ET200S.......................................................................................................5014.1.1 Digital Input 24V 2 wire.......................................................................................5014.1.2 Digital Input 24V 3 wire.......................................................................................5114.1.3 Digital Output 24V...............................................................................................5114.1.4 Analog Input 24V 2 wire......................................................................................5214.1.5 Analog Input 24V 4 wire......................................................................................5214.1.6 RTD Input 2 wire.................................................................................................5314.1.7 RTD Input 3 wire.................................................................................................5314.1.8 RTD Input 4 wire.................................................................................................5414.1.9 Analog Output current.........................................................................................54



1. GENERAL STANDARDS

1.1 Automation System The PCS standard will be made from Standard-Hardware and also from Standard software as following: PCS software standard is Siemens (CEMAT – Holcim) based on Holcim

design criteria and on process control system SIMATIC PCS 7. Process stations shall be S7-416. IO modules for DMC and Field IO (DIO) will

be ET200S. The engineering will be done with the HDRS database

1.2 HAC The HAC is currently used and will be applied for all new projects and PCS upgrade. HAC coding and Electrical flow sheets (E-Flow sheets) shall be updated before each control system implementation.

1.3 Cabling concept Following cabling basics has been agreed: The two wire concept will be applied:

2 wires = 1 signal = 1 data record1 wire = 1 terminal

If the shield has to be electrically connected, this should be done on the field IO box side

Decentralized MCC (DMC) and Field I/O will be applied The field bus will be a redundant with fiber optic ring combined with copper

bus segments (Profibus)

1.4 Documentation HDRS is the engineering and documentation database of HGRS. It contains all mechanical, electrical and signal information, required for programming and serving the PCS. HDRS03 will be applied for project execution and maintenance including the

documentation E-Flowsheets will be done as per Holcim’s standards with standards symbols

linked to HAC.



1.5 Voltage levels

Voltage level Voltage RemarkHigh Voltage MV 110'000 MV Incoming

Medium Voltage distribution MV 6000 MV Distribution

Low Voltage (VSD) 690 Used for VSD

Low Voltage LV (3 phase) 400 LV Drives (MCC)Low Voltage LV (single phase) 230 Low power consumers

(Instruments, valves etc)

Control Voltage 24 PCS IO devices, Transmitters etc.



2. LOCAL CONTROLS

2.1 Types of local commands

If a motor has no DMC (e.g. big mill motor) these local command arrangements will be placed on the door of a field IO box or on a separate box near the drive (very seldom).



For bucket elevators two DMC circuits will be built together in one box. Due to safety rules both motors have to be local isolated and locked with separated isolators.Existing DMC will be modified accordingly.

Actual existing two position switches for valves will be replaced by push button pairs or by spring-returned switches during the PCS upgrade



2.2 Code definition for local commands to use in HDRS

2.2.1 Code for the buttons

Code Type command button LabelG Button GO STARTS Button STOP STOPF Button FORWARD NAPREDR Button REVERSE NAZADO Button OPEN OTVARANJEC Button CLOSE ZATVARANJEI Button INCREMENT POVEĆAVANJED Button DECREMENT SMANJIVANJEX Start to X position (Open) POZICIONER ZATVORENY Start to Y position (Close) POZICIONER OTVORENZ Start to Z position (middle position) POZICIONER SREDINAU Button UP GORED Button Down DOLE

2.2.2 Codes for command box type

Code Number of command button1B 1 Button 2B 2 Button 3B 3 Button 4B 4 Button 5B 5 Button

2S 2 Position Switch (for valves only)

Code Location of command buttonD On DMC boxF On Field IO box (DIO)L On Local command box (seldom used)



2.2.3 Code example for local controls in HDRS

Code Description2BD-GS 2 button / GO STOP3BD-FRS 3 buttons / FORWARD, REVERSE4BD-GSID 4 buttons / GO, STOP, INCREMENT, DECREMENT2SD-OC 2 position switch Open / Close (for valves only)

3B How much buttons usede.g. 3B = 3 buttons

..D D = button in DMC integratedF = Buttons in Filed IO box (DIO)L = Local command box

.. - delimiter -FRS Type of buttons applied



3. LOCAL ISOLATORS In the DMC's the motor circuit breakers can also be switched manually. Therefore they will be applied also as local isolators. In the exceptional case of use of a separated local isolator, the isolator type will be written direct to the assigned field in HDRS.

4. CABLING

4.1 Standard for cables

4.1.1 Color abbreviations DIN IEC 757

English abbrev.DIN IEC 757(DIN VDE 0293)

Color Abbrev

black BKbrown BNred RDorange OGyellow YEgreen GNblue BUviolet VTgrey GYwhite WHpink PKturquoise TQ

4.1.2 Colors of power cables (IEC / DIN VDE 293)

CableType

ColorL1

ColorL2

ColorL3

ColorN

ColorPE

HACcode

New application L N PE BN BU YE/GN P03New application L1 L2 L3 PE BN BK GY YE/GN P04

Most of these existing power cables match these definitions.In case of old cables they will be changed during the PCS upgrade



4.1.3 Standard control cables (DIN 47100) Colors of control cable (DIN 47 100)

Wire No Cable4 wires(H04)

1 WH2 BN3 GN4 YE

Cross section is 0.5mm2. The cable has a shield with shield wire

Actual several already installed control cables have no shield.In future only control cables with shield will be applied



4.1.4 Direct wiring For direct wiring in the MCC panels and IO field boxes wire pairs with color combination as following will be used:

Wire ColorDI signal wire + GY

DI signal wire - PK

DO signal wire + BK

DO signal wire - PK

Ana signal wire + OR

Ana signal wire - PK

24V Supply wire + RD

24V Supply wire - BU

4.1.5 Cross sections for power cables

Current[A]

Cross section[mm2]

<= 8 001.5

<= 16 002.5

<= 20 004

<= 25 006

<= 40 010

Cross section for cables longer than the indicated max length has to be calculated manually

4.1.6 Typical cable definition in HDRS (Field F4A)

Example HDR Field F4A DescriptionP03-001.5 Power cable 3 x 1.5 mm2

P04-004 Power cable 3 x 10 mm2

H04 Control cable



5. DMC STANDARD

5.1 General DMC Design Generally, the following topics have to be treated:

Types of DMC modules Standard DMC drawings

5.2 Mechanical DMC module design Following two typical examples for DMC as they have been already applied and will be applied also in the future



5.2.1 Wiring and cabling for DMC The already existing wiring and cabling for the DMC will be applied with a minimum of modification for future applications.The main design for the infrastructure for DMC and field IO boxes (DIO) will be similar.(See also the description for the field IO boxes below in this document)

Following the actual used example for a normal drive and a reversible drive:

Motor normal



Motor reversible

Motor with VSD and soft starterPTC's will be connected direct to the VSD or soft starter. Its signal will be defined in HDRS as virtual objects with a HAC like @@@-@@@.TM

Temperature measurements on the drive windings have to be done as individual measurement fore every PT100 with ET200 RTD modules.

Direct supplied consumers with breaker protection.For direct supplied 400V consumers (e.g. actuators, subsystems etc) the DMC will be reduced to the breaker/isolator. As standard signals only the signal :K and :DK will be applied.

Based on the examples above, standard drawings have to be created for the following types of 3 phase LV consumers:- DMC for normal drive (3ph)- DMC for reversible drive (3ph)- DMC for LV VSD normal drive (3ph)- DMC for LV VSD reversible drive (3ph)- DMC for LV Soft starter normal drive (3ph)- DMC for Damper drive (3ph)- DMC for Bucket elevator with main and auxiliary drive (3ph)- DMC for Direct Breaker Load (3ph)



The wires for standardized signals in the DMC will be labeled as following

Signal Wire Wire labelM1:D + D+

- D-M1:DX + DX+

- DX-M1:DY + DY+

- DY-M1:DK + DK+

- DK-M1:K + K+

- K-M1:R + R+

- R-M1:RX + RX+

- RX-M1:RY + RY+

- RY-M1:S + S+

- S-M1:G + G+

- G-M1:GX + GX+

- GX-M1:GY + GY+

- GY-M1:INC + INC+

- INC-M1:DEC + DEC+

- DEC-

In the HDRS the color information will be defined as combination of the wire color and the wire label.(e.g.)

Signal Wire HDRS color definition in field F4B2 / F4C2M1:R + GY/D+

- PK/D-



5.2.2 Typical wiring for a 230V single phase consumer control The following types for single phase consumers will be applied:

Type of 230V consumer Applied forDirect supplied non switched consumers protected by a common breaker

Digital and analog sensors and transmitters etc

Direct supplied relays switched consumers protected by a common breaker

Valves, warning devices etc

Direct supplied non switched consumers protected by it own common breaker with auxiliary contact (signal :K)

e.g. 230 V actuator

seldom usedDirect supplied relays switched consumers protected by it own common breaker with auxiliary contact (signal :K) and with a relays contact feedback (signal .R)

e.g. heating's etc

The signal wiring of all these four typicals will be done by direct signal connection to the hardware terminals the equipment:

Following the four typicals:



5.2.3 Typical wiring for a 24V consumer control For several 24V consumers (e.g. warning devices) the following typical wiring will be used as already applied.

Single phase consumer controls will be placed in DMC’s, in field IO Boxes or in separate panels.



5.3 Code definition for MCC treatment in HDRS This code is helpful to define MCC types in HDRS

5.3.1 List for voltages

Voltage code Description

110K 110 kV AC020K 20 kV AC6000 6 kV AC0690 690 V Ac0400 400 V Ac0230 230 V AC0024 24 V DC

In a real application only the needed types have to be defined and used

5.3.2 Code for supply location For the different supply locations the following code will be applied

Feed-Type DescriptionFB Field BoxPP Power Panel (for non process loads)DM Decentralized MCC (DMC)SS Sub Station (for MV motors)LV Low Voltage DistributionMV Medium Voltage Distribution (for MV motors)



5.3.3 List for DMC-types The following code will be applied:

DMC-Type DescriptionNOR NORmal driveNSS Normal drive SoftStartNFC Normal Frequency Converter

REV REVersible driveRSS Reversible drive Soft StartRFC Reversible Frequency Converter

POS POSitioning drive (reversible)SUB SUBsystem

NRL Normal ReLays NRC Normal Relays with Contact feedback

DIR DIRect feed to consumer (with common breaker)DBR Direct feed with BReaker

XXX Special

5.3.4 List for DMC standard power ranges The power steps to realize different DMC module sizes will be the followings

Power code Description

015 DMC < 15 kW045 DMC < 45 kW110 DMC < 110 kW132 DMC <132 kW

5.3.5 Examples for DMC-Code

Code Description

6000-MV-NOR-2200 6 kV normal drive0400-DM-REV-015 400 V reversible drive- 15 KW0230-DM-POS-015 230 V positioning drive (damper)0230-FB-NRL 230 V Load (Valve) from IO in Field box



6. SUBSYSTEMS Subsystem should be connected standardized as described in the Holcim standard design criteria. The Interface signals are similar to e normal drive standardAlternatively, the subsystem could be connected by a bus to the PCS

Following is the typical shown in Holcim Design Criteria (Edition March 2007)



7. CONTROL ROOM CONCEPT

To plan a control room the following topics have to be taken in consideration:- Separate area for process operation- Separate areas for process analysis, system maintenance, engineering etc- Separate room for servers and PCS's- Ergonomic design for 24 h working- Air condition - Ergonomic placement of the operator stations to get an over view over all

processes

The already existing control room concept in the plant will be treated later on by NP.

7.1 CCR, Engineering and Production meeting Room



7.2 PLC and PC & Server Room



8. UPS CONCEPT Following is the typical given in Holcim Design Criteria (Edition March 2007)

The already existing UPS concept in the plant will be treated later on by NP.



9. PCS / HMI CONCEPT AND LAYOUT Actual applied layout.

The concept for the new PCS will be created in a separated Document by NP



10. PCS IO BOX DESIGN

10.1 Concept for the DMC and DIO box

One alarm signal in every DMC or DIO box, common for all breakers, will be foreseen as IO to the PCS. Its HAC will be the DIO HAC and HAC78 = .IAName example for the breaker alarm signal: 531-3S1.IA

The basic rules to name a DMC or DIO are:

HAC 78 = U1 in HDRS means always a DMC or DIO(For VSD and soft starters the HAC .C1 will be applied as before)

The DMC boxes have the HAC of the assigned motor with HAC 78 = .U1.Name example of such a DMC: 531-BC1.U1)

Additional Field IO boxes (DIO) will get a name of the next placed mech. equipment without a drive. (e.g. a silo -3S1).Name example of such a DIO: 531-3S1.U1



10.2 Typical DIO module design

10.2.1 Typical wiring for field IO Box (DIO) Drawing of an actual applied DIO.

The wiring has to be revised as following: Auxiliary contacts to the breaker have to be added. These auxiliary contacts of these breakers have to be connected in chain as

an input signal



11. STANDARD WIRING

11.1 Standard wiring of local motor control These typical for local motor commends are not foreseen to use, but there are here already prepared for future needs in very seldom cases

11.2 Standard wiring of local valve control



11.3 Typical wiring of DMC interface signals for Motors/Valves

The following standards match mostly the existing concept except the DMC for reversible drive with VSD. Actual not matching connections will be modified during the PCS upgrade



This typical drawing for reversible drive with VSD is not similar to the existing standard layout. The already existing DMC's (approx 2 – 3) will be modified according the new standard during the PCS upgrade



11.4 Standard wiring of MCC interface signals for valves and single phase consumers



11.4.1 Typical wiring for a 24V consumer control For 24V valves the following typical wiring will be applied as already done



11.5 Typical wiring of analog devices



11.6 Typical wiring of digital devices



11.7 Wiring for rope switches To follow the rules of safety NP plant will apply the HDRS recommendations from standard design criteria.Actual the rope switches have two contacts (2 x NC) but only one is wired by a 3 wire cable to the IO.All cables for rope switches will be changed to apply the recommended cabling concept as following



12. OTHER ENGINEERING STANDARDS

12.1 List of used standard record sets in HDRS

For standard record sets a HAC compliant code has to be used with the following rules:- The exact HAC structure has to be used like ###-###.###:#..- For HAC 1 – 8 every understandable code can be created.- HAC 9 – 11 has to be similar to the normally used HAC in HDRS

Using this rules the standard record sets can be used for automatic signal generationThe following code can be applied in HDRS:

Create additional other standard records as you think to need them


Code DescriptionST1-DMC.MNST1-DMC.MRST1-DMC.DAST1-DMC.V1ST1-DMC.V2ST1-DMC.H1ST1-DMC.FNST1-DMC.FRST1-ACT.Z1

Examples of object HAC for standard record set

ST1-DMC.MN:SST1-DMC.MN:K

Examples for signals in a standard record set

ST1 ST1 = STandard 1 for DMCs - Delimiter DMC FBX etc

HAC for supply location (module):DMC = Normal MCCFBX = Field IO BoxPPA = Power Panel

. Delimiter MN MR etc

HAC for object type:MN = Motor NormalMR = Motor ReversibleDA = Motor DAmper (Positioning motor)V1 = Valve 1 solenoidV2 = Valve 2 solenoidFN = Frequency converter NormalFR = Frequency converter Reversible


12.2 List of used formal records sets in HDRS As for standard record sets you can define a HAC compliant code to be used for formal records as template with a similar code structure

Formal records cannot be used for automatic signal generation

These formal records can be used as template to copy them to a real record

Code DescriptionFRM-DIG.D1 Formal records for a drift switchFRM-DIG.G1 Formal records for a start notification gong/flashFRM-DIG.R1 Formal for a rope switchFRM-DIG.SI Formal for a speed switchFRM-DIG.SN Formal for a speed switchFRM-DIG.X1FRM-DIG.Y1

Formal for a digital switch signal (e.g. pos switch)

FRM-DIG.LM Formal for a dig limit switch max signal (HH) 230V supplyFRM-DIG.TM Formal for a dig limit switch max signal (HH) no supply

FRM-ANA.S1FRM-ANA.S1:SP

Formal for a analogue signal 4 wire type (internal supplied) with set point

FRM-ANA.T1 Formal for a analogue signal 2 wire type (through signal supplied

FRM-ANA.T2 Formal for a analogue signal 4 wire type (24 V supplied)FRM-ANA.T3 Formal for a analogue signal 4 wire type (120V supplied)FRM-ANA.T4 Formal for a analogue signal 4 wire type (internal supplied)FRM-ANA.TA Formal for a analogue signal 2 wire type (RTD)FRM-ANA.TB Formal for a analogue signal 3 wire type (RTD)FRM-ANA.TC Formal for a analogue signal 4 wire type (RTD)

FRM FRM = FoRMal record for new Projects (incl. field IO) -ANA. HAC for record group:

ANA = Analogue signal examplesDIG = Digital signal examples

- .X1 HAC for object type:

Create additional other formal records as you think to need them

Remark: Formal HAC (e.g. FRM-DIG.R1) represents no real HAC.Copying formal records, a complete real HAC has top be applied.(e.g. FRM-DIG.RF to 521-BC1.R1)After copying formal records, all field content starting with the char "_" (place holder) has to be defined accordingly



12.3 Definitions in HDRS for direct wiring in DMC Related to the cable color definitions for direct wiring and to the signal definition for the standardized signals in the DMC the color code for HDRS will be applied as following:

Example for new DMC

Signal HAC HAC field Color code Field F4B2.M1:K F4B2 GY/K+

F4C2 PK/K-.M1:D F4B2 BK/D+

F4C2 PK/D-

Example for old DMC

Signal HAC HAC field Color code Field F4B2.M1:K F4B2 ../K+

F4C2 ../K-The color code will be replaced by two points (..)



13. APPENDIX Action list After finalizing this basic document the following works have to be done:

The wiring concept (A0 drawing) should by modified and finalized

All standard drawings for wiring and cabling, codes, color lists, etc, needed for the electricians (Pocket book), have to be created.

For all defined DMC types and for the DIO standrd have to be created the following documents:- The mechanical layout drawing- The electrical drawing- The item list

The HDRS database for the standard signal records has to be created or modified according the definitions in the cabling standard

The catalog file has to be revised according the applied terminal sockets

A training wall to train the electricians on the new cabling concept should be created in the electro workshop including:- All important equipment in field and MCC- All needed lists from a HDRS database for this training.

A part of the E50 training group can be used for this training project.e. g. The bucket elevator with all its sensors and additional one or two typical analog sensors. (4-20ma, PT100, etc)



14. APPENDIX Typical IO wiring applied in NP plant

14.1 IO-wiring ET200S

14.1.1 Digital Input 24V 2 wire



14.1.2 Digital Input 24V 3 wire

14.1.3 Digital Output 24V



14.1.4 Analog Input 24V 2 wire

14.1.5 Analog Input 24V 4 wire



14.1.6 RTD Input 2 wire





14.1.9 Analog Output current


np automation concept v1 0 revised by mm07!12!10

Documents