20180e00

0 ISSUE TM STIN STIN DEC. 94

REV. DESCRIPTION PREP'D CHK'D APPR'D DATE

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.

FUNCTIONAL SPECIFICATION

ELECTRIC NETWORK CONTROL SYSTEM WITH PROGRAMMABLE LOGICCONTROLLERS

20180.EQP.ELE.FUN

Rev. 0

December 1994

20180.EQP.ELE.FUNRev. 0 December 94Sheet 2


FOREWORD

Rev. 0 Total Number of pages 34December 1994Issued to comply with the EEC directives



INDEX

1. GENERAL

1.1. Scope

1.2. Normative references1.2.1. European normative references

2. FUNCTIONAL NORMATIVE REQUIREMENTS

2.1. Definitions

2.2. Symbols and abbreviations

2.3. Operating Environment

2.4. Functional Requirements2.4.1. Basic design data2.4.2. Operating conditions2.4.3. System composition2.4.4. Operation characteristics2.4.5. Construction characteristics2.4.6. Packing for transport

2.5. Boundaries, limits and exclusions2.5.1. Limits and exclusions

2.6. Ergonomics

2.7. Safety2.7.1. General rules

2.8. Requirement for Quality Management and Assurance

2.9. Additional Requirements for Review2.9.1. Type Test2.9.2. Acceptance Test (individual)2.9.3. Special Test

2.10. Documentation2.10.1. Bid documentation2.10.2. Documentation subjected to Approval2.10.3 Documentation used by the Company for the system design2.10.4. Test documents2.10.5. Final technical documentation



1. GENERAL

1.1. Scope

This specification defines the minimum requirements and the inspection plan for thesupply of "Electric network control system with programmable logic controllers (PLC).For any other additional information not covered by this specification see theapplicable Normative References and Publications as well as the project technicaldocumentation, in particular:

Technical Data Sheet(T.D.S.); Inspection Data Sheet (I.D.S.); Required Documentation Data Sheet (R.D.D.S.).

The technicaI requirements of this Functional Specification are based uponconsiderations of performances and functionality, therefore the instructions containedin this document are not meant to be discriminatory.Any alternative suggestions will be considered, provided that they comply with therequirements of this document from both a functional and a performance point of view.

1.2. Normative References

The Normative References and the Publications that define the entirety of the variablespeed electric drives are listed below.When applicable, references will be made to the European Normative References ENand to the CENELEC Harmonisation Documents or, in their absence, to the CEI/CEIUNEL Normative References and the IEC Publications.In any case, the plants shall comply with the requirements of the Legislation andRegulation issued by Local Authorities and Organisations under whose jurisdiction theplants shall be installed.

1.2.1. European Normative References

EUROPEANCENELEC

INTERNATIONALIEC

NATIONALCEI/CEI UNEL

TITLE( NOTE 1 )

--- 60 - 1 () 42 - 4High voltage test techniques - General definitionsand test requirements

---60 - 3 ()60 - 4 ()

42 - 5High voltage test techniques - Measuring devicesand application guide for measuring devices

EN 60068-2-1/2 ()

68-2-1/2 ()

68-2-3 () Environmental testing -HD 323 () 68-2-14/28 () 50 - 3 Temperature and damp heat tests

68-2-30/33 ()68-3-1 ()

EN 60073 () 73 16 - 3 Coding of indicating devices and actuators bycolours and supplementary means

--- 255 41 - 1 Electrical relays



follows " European Normative References "

EUROPEANCENELEC

INTERNATIONALIEC

NATIONALCEI/CEI UNEL

TITLE( NOTE 1 )

EN 60546 1 () 546 - 1 ---Controllers with analogue signals for use inindustrial process control systems.Part 1: Methods of evaluating the performance

EN 60546-2 () 546 - 2 ---Controllers with analogue signals for use inindustrial process systems.Part 2: Guidance for inspection and routinetesting

--- 617 - 2 3 - 14Graphical symbols for diagrams. Part 2: Symbolelements, qualifying symbols and other symbolshaving general application

--- 654 ---Operating conditions for industrial-processmeasurement and control equipment

HD 481 . 1 () 801 - 1 () 65 - 5 Electromagnetic compatibility for industrial-EN 6081-2 () 801 - 2 () 65 - 6 -process measurement and control equipment

HD 481 . 3 S1 () 801 - 3 () 65 - 7

--- 902 65Industrial-process measurement and control.Terms and definitions

--- 1131 - 1--- 1131 - 2 --- Programmable controllers

EN 61131-3 () 1131 - 3

-- 50 --- International Electrotechnical Vocabulary

Notes for reading the table in paragraph 1.2.1.:

1) Titles of IEC publications, when common to CEI rules and CENELEC, aretranslated from the original relevant texts.

2) The Normative References and Publications with () have completecorrespondence with the CEI or UNI National ones. In the other cases the subjectis the same but the requirements are not entirely the same.



2. FUNCTIONAL NORMATIVE REQUIREMENTS

2.1. Definitions

As to definitions and terminology reference shall be made to Normative Referenceslisted in paragraph 1.2.

2.2. Symbols and abbreviations

As to symbols and abbreviations reference shall be made to the NormativeReferences listed in paragraph 1.2.

2.3. Operating environment

The entirety of the system shall be designed and built according to the environmentalconditions of the installation site specified in the Data Sheet.

When H2S is detected in the atmosphere, unless otherwise specified, the followingconcentrations shall be considered:

0,10 ppm of H2S continuously. 5 ppm of H2S and 2 ppm of SO2 occasionally and for short periods.

The Supplier shall adopt suitable protective measures and prove their validity with testcertificates for the components.



2.4. Functional requirements

2.4.1. Basic design data

The system design shall be the Suppliers specific responsibility. He shall comply withthe requirements of this specification, of the Data Sheet and of the NormativeReferences listed in section 1.2.In particular, the Supplier shall verify the data laid out in the Data Sheet, suggestingany variations or changes he may deem necessary.

The entirety of the PLC electric network control system shall be designed in order tooperate in the environmental conditions of the installation site defined in the DataSheet.

Making sure that the system is perfectly functional and compatible with the controlledelectrical components (e.g. switchboards) shall also be responsibility of Supplier. Forthis purpose the Supplier shall send (or send for in time) all the data, information,documents recommendations, even if not specifically required, to the Manufacturers ofthe electric switchboards, for the design and execution of all which is theirresponsibility so as to make sure that the entire Control system and controlledswitchboards form a single constructively integrated and functionally homogeneousunit.

The system design shall be carried out considering the following as fundamental:

easy command and regulation manoeuvre; easy alarm reading; separation of the equipment of different circuits or systems to avoid manoeuvre

and/or reading errors; correct and immediate localisation of emergency equipment as well as their

protection to avoid manoeuvre problems; easy intervention for maintenance and replacement of components.

The PLC electric network control system shall be designed for the followingoperations and for the reasons indicated on the project documentation:

Control and management of the electric network; Data acquisition from the field; Alarm processing; Communication with external units (supervisors, DCS, SCADA, etc.); Remote control processing; Management and/or functional calculations (load shedding, load sharing, user

change, etc.); Autodiagnostic; Visual display of the plant; Historical file processing; Maintenance management.

The system structure and the location of the components shall generally beestablished by the Company in the Data Sheet. The quantity of the equipment shall bedefined in relation to the Companys requests and the system functional needs.Defining the quantity of equipment shall be responsibility of the Supplier, even if it isnot specifically indicated in the Data Sheet.



2.4.2. Operating conditions

2.4.2.1 Environmental conditions

The system equipment shall be suitable for operation in the environmental conditionsindicated in the Data Sheet, with the minimum requirements shown in TABLE 1:

TABLE 1

ENVIRONMENTAL CONDITIONS OPERATION LIMITS

Operation temperature (inside the switchboard) + 5C Errore. Ilsegnalibro non definito.

Storage temperature (outside the switchboard) - 25C Errore. Ilsegnalibro non definito.

Hygrometry (without condensation) 30% Errore. Il segnalibronon definito. Errore. Il

Altitude 0m Errore. Il segnalibronon definito. Errore. Il

Depending on the ambient temperature, great attention shall be paid to the coolingsystem in order to allow the release of the heat produced inside the switchboard bythe equipment in operation, so as to keep temperature below 50C. Ventilation can benatural or forced.

Whenever necessary, prearranging equipment for the temperature check inside theelectric switchboard shall be responsibility of the Supplier.

The entirety of the system and the individual components shall not be affected byharmonic vibrations and heavy impacts that may occur during transport and routineoperations within the limits indicated in the relevant Normative References.



2.4.2.2. Power supply system

The electric power supply distribution shall comply with the Data Sheet and theenclosed documents.Each power supply shall have an input switch-breaker.

The power supply to the logic component shall be provided according to the followingoutline:

Equipment code reading:

Q - Switch-Breaker with fuse KM - On-line contactor TF - Insulation transformer KM01 KMn - Contactors for power supply to LCU unit racks and the inputs KS01 KSn - Contactors for power supply to outputs LCU - Local Control Unit

Any re-start after a shutdown caused by a blackout or an emergency stop shall beallowed by the appointed personnel in compliance with the safety rules.



The equipment feeder shall be compatible with the values of TABLE 2:

TABLE 2

TYPICAL VALUESFUNCTIONS 24V D.C. 110-127V A.C. 220-240V A.C.

Operation field19,2 Errore. Il

segnalibro non definito. 30 V

90 Errore. Ilsegnalibro non

definito. 140 V

180 Errore. Ilsegnalibro non

definito. 264 V

Limit frequency --- 47 Errore. Ilsegnalibro non definito. 63 Hz

47 Errore. Ilsegnalibro non definito. 63 Hz

Micro-interruptions(typical values)

duration 10msrepetition 1Hz



Harmonic factor - 10% 10%

Included residualwaviness 5% max. --- ---

2.4.3. System composition

The control system, in its entirety, shall consist of the following interconnected parts,in accordance with the requirements of the project documentation:

a) Conventional component (Hard Wired);b) Logic component.

The two main components, Hard Wired and Logic components shall be strictlyinterdependent. The Supplier shall guarantee their complete and perfect compatibilitylooking for alternatives, if necessary, in order to obtain a symbiosis between HardWired and Logic components. Since this specification defines the characteristics ofthe Logic component, the Supplier shall check these characteristics with the HardWired Component (e.g. if the analogue input cards are standardised at 0-20mA, themeasure convertors shall operate according to the analogue card characteristics).

2.4.3.1. Conventional component (Hard Wired)

The conventional component shall carry out the operation, protection and shutdownfunctions. It typically consists of electric switchboards and related internal componentswhose definition shall be found in the relevant Functional Specifications.

2.4.3.2. Logic component

The logic component shall carry out functions of command, control and supervision ofinternal, external and in-between-switchboard automations. It shall control andcommand all switchboard hard wired components.

The logic component generally consists of:

Local Control Unit (LCU) with related application programme; Connection local network; Video terminals or keyboards with display; Supervision system (VDU); Software.



A LCU shall be normally provided for each section of the plant, switchboard or area,as established in the Data Sheet. The Supplier, in agreement with the Company, shalldecide whether to add any further LCUs, when necessary for functional needs, and inrelation to their costs.

a) Local Control Unit (LCU)

It generally is a PLC consisting of the following parts:

1) Rack

It shall made of material suitable for its application (e.g. self-extinguishing),with 8 card slots, unless otherwise specified.Should operation needs require a ventilation system on the rack, it shall besupplied with the same voltage foreseen for the main .feeder.If necessary, expansion racks shall be provided with the samecharacteristics as those of the main rack although they shall not beinterchangeable.A mechanic and/or electronic protection shall be provided to avoid theincorrect connection or the exchange between modules in case ofreplacement.

2) Power supply module

It shall be able to supply all the cards foreseen in the LCU (even if notinstalled), and, if necessary, it shall also supply the expansion rack.

The input power supply can be one of the following:

110 V 50/60 Hz; 220 V 50/60 Hz; 24 V D.C.

The module shall be suitable to bear a voltage and frequency variation aspreviously shown in table 2; however, an internal protection shall beprovided to limit damages during a variation exceeding the operation limits.

Suitable pilot lights on the module shall indicate:

Input voltage included, or not included, within the operation limits; Error detected in the power supply circuit.

An exchange contact shall be required to indicate the failure of the moduleand/or an incorrect power supply.

3) CPU - Processing unit

The module shall be suitable for all the functions foreseen in the Data Sheetand it shall be programmable and technologically up to date.If necessary, the module shall be able to contain one or more memoriesaimed at expanding its processing capacity; if the memory is of RAM type alithium battery shall supply it with power in case of power loss.On the same module, indicators shall be provided with the purpose ofsignalling:

Module being supplied; Module in RUN (programme on running); Errors of the module or in the running of the programme.



The CPU shall be provided with a relevant connector for connection to theprogramming unit, and if foreseen it shall be able to contain the networkcard, connected in the network.If the project requires the use of more than one LCU, CPUs shouldpreferably be always of the same type in order to minimise the sparematerial and uniform their structure and programming.

4) Input/output cards

The input and output cards can be digital and analogue. Both shall have thefollowing characteristics:

High reliability STD dimensions and possibility of being fitted in any rack slot Terminal block that can be disconnected (replacing one card shall not

result into having to re-do the wiring harness); Signalling the input or output state.

The operation characteristics shall be included among the following:

Digital inputs : 24 -110 V.D.C. / 110-220 V.A.C.; Analogue inputs : 0 -10 V / 0-20 mA / 4-20 mA / 5V; Digital outputs : 20-110 V.c.c. / 110-220 V.A.C.; Analogue outputs : 0 -10 V / 0-20 mA / 4-20 mA / 5V.

In particular the cards shall have the following characteristics:

- Digital inputs

Galvanic insulation for each input; Protection filter against induced signals; Permissible modularity not higher than 4; State-change acquisition time not longer than 25 ms; Number of inputs that can be connected 16/24/32, and, anyway, in

compliance with the requests.

- Digital outputs

Protection against induced overvoltages; Protection against polarity reversals (downstream connection of

external diode to the output, if necessary); Minimum reply time not longer than 10 ms; Number of outputs that can be connected 8/16/24/, and, anyway, in

compliance with the requests.

- Analogue inputs

Galvanic insulation for each input; Max. permissible error



In particular cases, a single card/module including inputs and outputs can beprovided.All cards shall be provided with a simplified system for determining errors ineach input and output.

5) Communication module

It shall be of module STD size and it can be fitted in any rack slot.Network connections shall be carried out with a simple and highly effectivetechnique in order to simplify all replacement and maintenance operations.

6) Compact PLCs

Some applications might require the use of a compact PLC which, althoughbeing of reduced size, shall fit the following into a single module:

Feeder; Processor; Minimum 16 digital I/Os; Pre-setting for analogue I/Os; Pre-setting for connection into network.

7) Remote unit

It is an additional component to the LCU and it increases the processingcapacity of the latter (further increase of I/Os resident in the LCU).Comprising of a rack and the I/O cards, it can be supplied separately orthrough connection to the main LCU. The remote unit can be used as LCUlocal extension, therefore fitted in the same switchboard, or it can be used asunit subjected to the control of another switchboard. In this case, theSupplier shall decide and agree with the Company upon a suitableconnection system which, in any case, shall guarantee a distance of at least25 m between main rack and remote one.

An indicator signalling the correct communication between LCU and remoteunit shall be provided. Furthermore, the remote unit disconnection shall notinterfere in the operation of the cards fitted in the LCU.

8) Intelligent terminal blocks

Systems which cover very large areas might require the use of intelligentterminal blocks in order to set inputs and outputs as remote using equipmentcapable of minimise the usage of field wiring harnesses.Intelligent terminal blocks are an integral part of the LCU; they shall beconnected to the latter by means of a specific bus.

In general, they shall have the following characteristics:

minimum number of I/Os for each terminal block: 16; configuration of the individual terminal block as digital inputs, digital

outputs, and digital inputs and outputs mixed; minimum number of terminal blocks that can be connected to the bus not

lower than 32; possibility to set a terminal block as remote at 500 m. from the LCU at

least;



the break of the bus (physical cut), shall guarantee the operation of theterminal blocks connected upstream to the fault;

the fault of one terminal block shall not jeopardise the correct operation ofthe others.

The wiring of I/Os shall be carried out with the same mechanism foreseen forthe LCU I/O cards.

b) Communication networks

1) Local network of connection between LCUs

It is the hardware support (typically it is a cable with 4 wires or coaxial) and itlinks the system components. It is able to transport information between LCUand other components such as the supervisor.

The communication network shall be placed onto a or specific conduit. Itshall follow a different route than the one used for the power cables in orderto avoid induced disturbances.The communication modules fitted into the LCU are an integral part of thecommunication network. The modules can be connected to thecommunication network directly or indirectly through cable sections (Tjoints); in any case, the communication network output and/or input to theswitchboard shall be connected through a different route from all otherconnections (I/O, power supplies etc.), so as to allow an easy control of thenetwork cables.

The communication system shall guarantee control procedures of theinformation in network so as to avoid unwanted manipulations of theinformation passing through; a checksum shall be typically required for allthe information passing through the network.

It is important that each station recognise the state of the connection in thenetwork; such state shall have to be signalled locally and to the remotecontrol system, if there is any.

In accordance with the indications of the Data Sheet, and considering thetypology of the system checked, the communication network can be built onthe basis of the following typical architectures:

Master/Slave network

In this case, one of the LCUs forming the system shall be regarded asMaster and the remaining ones as Slaves. The Master is the networkinformation manager and administrator; it carries out a continuous pollingof all the network components, if a network component is to sendinformation to another component, the Master shall grant such request.This architecture creates a convergence of information towards theMaster. The absence of the Master prevents any exchange of information.A configuration like the one described above can be provided, but theMaster shall be floating; this architecture shall allow one or more Slavesforming the network to be reset as Master, ensuring the exchange ofinformation even when the main Master is out of order.

Open network

In this case all the connected components shall be independent, thenetwork traffic shall be managed by a "token" (network traffic signal) thatcyclically moves from one network component to another. The network



component which has the token is enabled to send information to theother components. The token is released when a component does nothave any information to send through network or when the maximum levelof information that can be sent through network has been reached.

In both architectures described above, each network component shall becoded with a one-way address.

If indicated in the Data Sheet, the network and/or LCU redundancy shall beprovided.

2) Communication with higher control system

The communication with higher control system (DCS, SCADA, etc.), ifforeseen, shall be carried out through one of the following communicationnetworks:

RS485/RS422 asynchronous serial with ModBus communication protocol; Ethernet network.

The higher system shall be connected to a single LCU (mainswitchboard/interface), taking into account that sending information throughto other LCUs which form the electric network control system shall be a taskof the local network. Different methods of connection to the higher systemshall be discussed with the Company (e.g. connection to the supervisionsystem)

c) Video terminals or keyboards with display

These are additional elements to the LCU, directly controlled and commandedfrom the latter.

The keyboard shall be of membrane type or of similar construction; the display orthe monitor shall guarantee resistance to the environment in which it is placed.

d) Supervision system (VDU)

The supervision system, if any, shall be composed principally of:

Processing unit.(P.C. or something similar) Colour monitor Keyboard; HD and FD magnetic storage supports; Peripherals (e.g. printer); Communication card to LCU or local network; Alternative tracking system (e.g. mouse)

It is meant to :

visualise the state of the whole system; receive commands from the operator; process and print alarms; process and display historical files (field measure collection etc.).

It can be fitted in the front panel or in a separate place with possibility ofconnection within 500m. Unless otherwise specified in the Data Sheet, it is anelement connected to the network linking the LCUs.



e) Software

1) General

The system software shall supply all control, diagnostic and monitoringfunctions so as to provide the operator with all the means to allow acontinuous and simple operation of the systems.The software architecture shall be designed to guarantee high reliability andavailability. The fault of any component shall in no case affect thefunctionality of the entire system and it shall always be possible to replacefaulty parts without causing an out of order.The entire system shall also have an extreme flexibility to allow interfacingwith other systems and the possibility of future expansions.The choice of the optimum architecture, programming techniques andinstruments shall be made by the Supplier who shall forward his proposalbefore starting to work on the software.However, in this section there are some methods to comply with in order tooffer a product which can be best maintained and modified.

2) LCU software general structure

The software of the individual LCUs, apart from the programming language,shall consist of a modular and flexible structure that can be summarised inthe following points:

Acquisition of inputs at the start of the programme and their location ininternal variables that shall be used in the remainder of the programme forspecific processes; this solution shall be adopted to make the softwareflexible to modifications so that a change to the I/Os shall not requirefurther changes to other points in the programme.

Location of all the outputs in internal variables that shall be used by theprogramme for specific processes; physical outputs shall be sent at theend of the application programme.

Subdivision of the application programme so as to identify modularitiesinside the programme itself:

procedures for network data exchange; procedures for I/O card configuration and parameters; procedures for preparing data for supervision systems, if any; procedures for alarm detection and management; procedures for processing the system functions; Identification of the programme with clear and easily interpretable

comments.

3) I/O card parameters and configuration

I/O cards shall be set according to the following principles:

Univocal identifying of the card single channel; Utilising variables that can be modified by the operator, without

intervening on the programme parameters; Foreseeing all the diagnostic tests on the card correct operation.

These parameters shall be suitably modifiable by a function that shall beeasily manageable and sufficiently protected against involuntarymodifications (protection password for modifications).



4) Environmental data

Environmental data are all those data used in the application programmewhich depend on the field characteristics (e.g. current convertor full-scale).Environmental data shall be loaded and used in the programme with internalvariables modifiable by the operator without entering the applicationprogramme.

In case a supervision system is foreseen, a display and modification facilityfor the environmental data shall be provided. It shall include a list of all theenvironmental data with their current value; the operator, restrained by apassword system, can modify such data.



2.4.4 Operation characteristics

This section and the related subsections have the scope to describe the maximumfunctionalities that shall be guaranteed by the control system.Further functionalities not included in this specification can be requested in the DataSheet.

2.4.4.1 Logic component functions

The logic component is considered to be the main instrument for human interface.Therefore it shall guarantee reliability and dynamics in the management of displayedinformation (occurrences, alarms...) and of the operations carried out (commands,automatic sequences...).

The logic component is an instrument applied to the Hard Wired component in order toobtain the control of the electric network. For this reason it shall be necessary toforesee parallel functions to guarantee the system control even when the logiccomponent is faulty. The logic component shall control the Hard Wired one.

In its entirety the logic component shall guarantee:

Maximum flexibility; Reliability and error management (autodiagnostic); the defect of a single piece of

equipment shall not jeopardise the operation of the others (unless there aresignals/controls interconnected to the faulty piece of equipment). Should this not bethe case all the functions depending on the single pieces of equipment shall behighlighted;

Pre-setting for integration (also in future) with other pieces of equipment.

The functions carried out shall guarantee all which is required in the Data Sheet.

A table with a preliminary division of tasks between Logic and Hard Wiredcomponents follows here below:

TABLE 3

FUNCTIONS LOGIC HARD WIREDControls YES NOMeasures YES NOSignals YES NOAlarms YES NOShutdowns YES YESProtections YES YESInter-locks YES YESAutomatic sequences YES NO

The typology and quantity of controls, measures, alarms etc., necessary for themanagement of the electric network shall be described in the Data Sheet.



2.4.4.2 Ability to operate

The control system shall allow the management of the electric network from thefollowing spots (control centres) :

from the power switchboard front panels; from the traditional synoptic switchboard; from the higher system (when foreseen); from the supervision system (VDU).

The control system, in compliance with the indications of the Data Sheet, shallmanage the plant according to the following modalities:

Manned modality, that indicates the operators presence on the plant. It this casethe system operates following their indications.

Unmanned modality that indicates the operators absence from the plant. In thiscase the system takes operational decisions on the basis of the way it is set or ofindications coming from the upper control system (e.g. DCS).

In the absence of the logic component, the Hard Wired component shall guarantee theminimum functionalities in order to operate manoeuvres on the plant. Such possibilityshall be chosen by means of a selector switch.

The manoeuvres carried out in this condition shall be total responsibility of theoperator.



2.4.4.3 Logic component performances

The system performance is defined as its capacity and velocity of reaction to variouslyoriginated occurrences (alarms, controls, etc.).

The logic component shall generally have the characteristics described in TABLE 4.

TABLE 4

FUNCTIONREQUIRED

PERFORMANCE

Minimum number of digital I/Os manageable by the singleLCU

256

Minimum number of analogue I/Os manageable by thesingle LCU

32

Pre-setting for the connection of the equipment in theNetwork (LCU etc.) Always required

Execution time for locally sent command 1 s.Execution time for command sent through network 2 s

Signalling of local occurrence on the switchboard frontpanel

0.5 s

Signalling of remote occurrence on the switchboard frontpanel 1.5 s

Maximum time of transmission of a single information intothe network (in the absence of defects in the network) 1 s

Maximum time of transmission of a single information intothe network (in the presence of defects in the network) 3 s

Minimum number of graphic pages manageable by theVDU supervision system 16

Minimum number of manageable dynamic variables for asingle graphic page (VDU) 128

Minimum number of alarms manageable by the system 1024

Signalling of local occurrence on video 1.5 s

Signalling of remote occurrence on video 2 s

Maximum time of update for a video page 5 s

Database storage capacity (with samples Errore. Ilsegnalibro non definito. 10 sec.)

200 hours

The response time of the various pieces of equipment forming the control system(LCU, Network, Video) are a basic condition for the correct management of the plantby the operator. In no case there shall be doubt; should a critical circumstances occurintervening to eliminate them with alternative "escamotage" , shall be necessary (e.g.should the video terminal show a command requiring an execution time > 5 sec., oncesuch command has been activated, the message Command being carried out.Please wait shall appear so as to avoid any doubt for the operator who has carried itout).



2.4.4.4 Signalling of occurrences

Signalling occurrences, that is displaying the state of all field users (e.g. users, circuitbreakers, disconnectors etc.), shall be carried out on the switchboard front panel andon the VDU, if foreseen, simultaneously.

Should any signal be flashing, it is compulsory for the flashing frequency to beconstant; in case this shall not be possible, the connection of an external impulsegenerator shall be preferable.

The signals shall be displayed also on the synoptic video - VDU (when foreseen). Thedisplay of the synoptic video and of the dynamic signals on it shall be carried out incompliance with the following indications:

Graphic display of the plants main diagram, as similar as possible to the traditionalsynoptic. The main signals shall be reported considering the complexity of thesynoptic and the number of signals displayed (the situation displayed shall beclearly and immediately understandable). This shall be considered as the maingraphic page.

Starting from the main graphic page, it shall be possible to recall each section indetails. In order to obtain a good manipulation of the graphic system only one levelof detail shall be preferable.

The states shall be signalled with the same colours as the traditional synoptic,considering that, further colours (of fixed type) shall be allocated to replace theflashing effect, should the graphic system not allow a constant flashing.

Whenever information makes it possible, the graphic system shall carry out furtherdisplays than the traditional synoptic (e.g. dynamic colouring of the bus-bars toidentify the voltage presence or absence).

An identification nameplate shall be placed next to the graphic display for eachpiece of equipment.

The visualisation of analogue measures shall be an integral part of the graphicdisplay. The measures shall be visualised:

in a numeric format (also decimal if necessary) in the synoptic position wherethe measure is taken;

with a bar-graph-type display (horizontal or vertical); this display shall identifythe operation limits, if any, with different colours (e.g. if measure M is to fall inbetween (X-n) and (X+m) in normal conditions, the display shall be carried outwith three different colours such as to identify the state: M < X-n; X-n < M X+m);

with dynamic trend, where according to necessities, the time axis can be that ofabscissas rather than that of ordinates (such display is described in details insection 2.4.4.8).

Should a magnetic storage peripheral unit be foreseen, a file for occurrences/statesarisen shall be provided; it shall have a 30-day historical base; it shall contain thesingle changes of state for each signal as well as the date/time in which they werenoted.

Should a printing peripheral unit be foreseen, a procedure to print every change ofstate for each signal with date/time of observation shall be devised (this shall beused by the operator to reconstruct the history of occurrences for the times theplant was not manned).



2.4.4.5 Control management

In normal operating conditions, the logic component shall guarantee all the servicecontrols required in the Data Sheet.

The controls shall be carried out in parallel by:

A. Front panel push button (cabled onto the same inlets as the LCU);B. Keyboard with display;C. Supervision system (VDU);D. Upper control system (e.g. DCS).

Checks for all shutdown sequences and control operability shall be guaranteed for allpositions; as for points B and C, a further direct control manoeuvre shall be carriedout (protected by password) to control the service excluding the operability checksand/or shutdowns to which the control is constrained (control to be utilised in the plantcommissioning stages).

A selector or a password system, when a supervision system is foreseen, shall beable to cut out all control positions.

The keyboard control procedure, when provided with a display, shall be able to showthe following information for each command given or that might be given:

Command active/non-active Command cut out (it cannot be given); Command shutdown (it cannot be given for lack of conditions);

The control manoeuvre shall be safe in order to avoid errors by the operator.

Should a magnetic storage peripheral unit be provided, all commands given shall befiled in a 30-day historical base Data Base; the filing shall be complete with date/timein which the command was given.Should a printing peripheral unit be provided, all commands given shall be printed withdate/time in which they were given.

In order to guarantee the commands, even when the feasibility conditions determinedby the field signals do not arise, the supervision systems shall have a field-signalforcing facility.These "forcing" facilities, used to cut out the control of a field sensor, shall be usefulduring maintenance in order to temporarily cut out a wrongly received signal. Accessto this facility shall be possible only through a high level password.

2.4.4.6 Alarm management

Alarms shall be controlled and displayed in parallel on:

Pilot lights on the front panel; Led or similar panel placed on the synoptic front panel; VDU system; Upper system (DCS etc.).

The alarm display procedure shall comply with the requirements of the Data Sheet.



A zero setting procedure shall be provided for alarms of particular interest andseriousness (push button on the front panel and keyboard control). In the absence ofsuch procedure, the alarm shall be considered as still present even after it has beenbrought back to normal (missing the conditions which had generated it) and it hasbeen switched off.

Should a magnetic storage peripheral unit be provided, all noted alarms shall be filedin a 30-day historical base Data Base; the filing shall be complete with date/time inwhich the alarms were noted, switched off and normalised.Should a printing peripheral unit be provided, all noted alarms shall be printedidentifying date/time in which the alarms were noted, switched off and normalised.

2.4.4.7 Historical files

The VDU system, when provided with a magnetic storage peripheral unit (HD), shallhave the task of creating and managing historical files; they shall be typically used tostore information on the basis of the time of:

Occurrences and signals Controls; Alarms; Measures (trend).

Procedures of "consulting" and "unloading of data" of historical files shall berequested in order to complete the storage function; such procedures shall allowaccess to all the information stored in the historical files according to typology andperiod of time and to download them into alternative storage units (FD) in order to beused afterwards on other equipment (e.g. for statistics...).

2.4.4.8 Trend and field measure gathering

Field measures of any nature can be displayed in trend format. The trend consists of:

Display plan: it is the static part of the trend (background), where axes, measureunits, readings, symbologies etc. are displayed;

Scribing peens: it is the dynamic part, there is one for each measure displayed onthe trend; its task shall be to scribe the measure sampling through time.

In order to make a trend, it shall be necessary to determine the sampling time for a/themeasure/s. This time shall be calculated taking into account the possible variationsthe measure might show through time in normal conditions (e.g. it is useless tosample a measure each second when such measure is being gathered from the fieldeach 10 sec.; on the other hand, very long sampling times shall not be adopted eitherwhen the measure can show very quick variations).

The trend function can be used to display:

Real measures : those which are contained in the display plan; Historical measures : those which are no longer contained in the display plan but

are filed on the 30-day Data Base.

2.4.4.9 Maintenance management

This paragraph has the scope of describing the maintenance function (when foreseenin the Design Specification) required to complete the functions of the supervisionsystem (VDU).



Such function shall not replace the maintenance system but it shall guarantee a seriesof utilities able to facilitate the task of the plant maintenance engineer.

A database shall be provided for each electric and electronic component (CPU,feeder, switches, etc.) and for each user in the plant (pumps, motors, valves, etc.).The database shall be able to:

recall automatically the user and its related data by means of entering itsnameplate, or by selecting it;

display the literal description of the service; calculate and display the operation hours and/or the moves carried out; display the LCU I/Os on which the service depends; input and process the preset values of the hours/moves after which the system

shall produce a message requesting maintenance; input data related to the last 10 years of intervention for each user, in particular:

date/hour of intervention literal description of intervention.

The above mentioned data shall all be permanently stored in a backing memorysupport, with the possibility of being printed and displayed on the operators request.

2.4.4.10 Communications between sub-systems

Sub-systems consist of all the equipment that, provided with network card, performtheir function on the basis of local information (digital and analogue signals directlycabled into the equipment) or remote information (local and other sub-systems).

The exchange modalities between sub-systems is regulated by the communicationprotocol in use, which shall guarantee the safety and the correctness of the datapassing through the network.

The choice of the modality with which to process the writing and reading of networkinformation shall be issued by the Supplier who, in any case, shall comply with thefollowing rules:

the single software functions which depend on remote information shall be enabledonly when the processing unit is certain about information updating regarding time

the input of new information into the network even after the software developmentphase, shall not result into the need of modifying the network architecture, that is,inputting new information shall be possible only by expanding the applicationsoftware

communication modalities and protocol shall be the same for all sub-units;furthermore, all LCU communication cards shall be interchangeable

should a hardware and/or software addressing system be present, all theindications needed for its modification shall be provided

branching interfaces and/or interfaces for conveying network connections, if any,shall be allowed only if they are clearly hardware components and do not needsoftware programming of any kind.



2.4.4.11 Higher system interface (DCS, SCADA, etc.)

All information necessary for the remote control of the plant shall be made available tothe higher system (when foreseen). The information can be summarised into:

state of digital and analogue inputs/outputs; state of signals used to manage the plant (manned, automatic, out of order, state of

the network, etc.).

The upper system shall be able to control the plant through remote controls; the latter,activated on the basis of procedures resident in the plant, shall be considered asparallel controls to the LCU internal sequences.

Should a supervision system be provided (VDU), each command given by the uppersystem, and its result, shall be indicated.

It shall also be necessary for the operator to be always informed about the correctconnection with the upper system through a signal lamp on the front panel or, whenthe supervision system is provided, by means of a descriptive string on the state ofthe mentioned connection.

2.4.4.12 Network redundancy

The network redundancy needs a single LCU hardware architecture for each controlswitchboard, connected to two parallel and different networks with different logisticroutes (see typical).

Given the two parallel connection networks: NETWORK 1 and NETWORK 2, thenetwork redundancy shall guarantee the communication between LCUs when theyare interconnected on any one of the two networks.

LCUs shall not change, whilst the communication network and its related modulesshall be doubled:

LCU 1 LCU2 LCU3

Network 1

Network 2

The architecture described here above foresees the network cable outline in differentlayouts.



2.4.4.13 LCU redundancy

The LCU redundancy shall be considered as an evolution of the network redundancy(two parallel LCUs for each control switchboard). This architecture, keeping thefunctional characteristics described in the previous section, shall guarantee operationeven when one of the two LCUs is out of order, whatever its cause may be (seetypical).

L C U 1A

LC U 2A

LC U 3A

LC U 1B

LC U 2B

LC U 3B

Networkcoordination

unit

The architecture described here above foresees the splitting of the entire control logicsystem, therefore it maintains the system functions unchanged even when there arefaults in the LCUs.The network co-ordination units can be another specific LCU.Any other configurations, if required, shall be identified in the Data Sheet.



2.4.5. Construction characteristics

The logic component equipment shall be built in compliance with the main nationaland international normative references concerning electronic equipment for industrialautomation.

The control system equipment, in general, shall be:

Reliable; Built with up-to-date electronic technologies; Safe in their operation; Preset for easy and quick maintenance.

2.4.5.1. Reliability

The reliability of a device shall consist in its capacity to carry out a certain functionunder conditions of use which are preset for a fixed time. Whoever the manufacturerof electronic equipment might be and notwithstanding the efforts and controls ensuredby him, the fault rate is never null. It is, therefore, a matter of foreseeing, whenstudying the control system, the necessary devices to repair the faults and limit theireffects according to the safety level required by the plant.

2.4.5.2. Auto-test and diagnostic

LCU and VDU equipment shall be provided with auto-diagnostic functions so as toguarantee the detection of important fractions of any internal faults or any manoeuvresthat might be connected during installation and maintenance activities of theequipment itself.Depending on their nature, these tests shall be carried out either at the voltage settingor cyclically; they shall apply mainly to:

processor: control of microprogramme, RAM memories, and watch-dog processing; programme memories: checking the presence and the type of content; input/output cards: checking the presence, controlling the output short circuit and

the exchange of information with CPU.

The result of such tests shall be reported immediately to the operator.

It is important to note that part of the defects may be external to the control equipment.The use of control equipment (LCU etc.) to assist the operator in the rapid search forfaults is therefore recommended.

2.4.5.3. Safety of operation

Safety of operation for a device consists in its attitude to avoid the occurrence of faultsand to minimise their effects once they have occurred.A system is said to be of total safety if the occurrence of faults does not result intodangerous situations.

Internal faults in a system shall be of:

passive type, if they result into a cut-off output circuit (no command is given to theactuators);

active type, if they result into a closed output circuit (a command is given to theactuators).



From the point of view of safety, the latter type of fault is or is not dangerousdepending on the nature of the command carried out during routine operation. Apassive fault is dangerous if the normal command consists in an alarm operation; anactive fault is dangerous if it carries on an unwanted command.It is important to note the fundamental difference in behaviour between anelectromechanical relay and an electronic component (e.g. a transistor):

there is a great probability, about 90 out of 100 cases, that a faulty relay causes acircuit cut-off (control circuit out of voltage);

there is the same probability, 50 out of 100 cases, that a faulty transistor causesboth the cut-off and the make of a circuit.

For this reason, it is important to check thoroughly the nature and effect of the faultswhen the use of automated plants using electronic equipment is foreseen.

The Supplier of the system shall provide external devices against internal active faultsin the equipment (LCU) not signalled and considered as risky for the plant. As for thetreatment of such faults, different technological, mechanical, electromechanical,electronic etc. solutions can be adopted (e.g. direct wiring of the nearest emergencyswitch and stop on the coil of a move control contactor).To protect the plant from dangerous faults likely to affect the output circuit and the pre-actuators, the LCU treatment capacity shall be exploited, for instance the controlthrough the inputs of the good operation of the commands generated by theprogramme.

2.4.5.4. Availability

The availability of a system consists in its capacity to carry out a required function, ina precise moment and within a fixed time interval.

The availability is therefore typical of every application and it consists in thecombination of:

system architecture; reliability and durability of all its components (LCU, VDU, hardwired part etc.); maintenance logic, application software structure, fault display, spare parts

available on the spot, training of personnel for operation or maintenance.

2.4.5.5. Immunity to hits

The system shall be protected from damages to the hardware or to the memorycaused by:

transient electrical hits (radio frequencies, electric line faults, overvoltages,magnetic fields);

parasitic line signals; disturbed fields; electrostatic discharges.

Should equipment emitting magnetic fields be detected in the electric switchboard,they shall be covered in a material suitable for circumscribe the emission (e.g. softiron).



2.4.5.6. Possibility of extension of the system

The system shall be designed so as to allow the upgrading of the functionalitiescarried out.In general, the future extension shall be possible simply by adding modules andmanagement software.

A 20% backup shall always be considered, and in particular :

20% free inputs; 20% free outputs; Possibility of connecting other LCUs to the network (at least 2); Possibility of connecting video terminals and/or keypads with display, if not

foreseen in the design specification, without interfering with the system architecture(e.g. the CPU shall not be replaced);

Possibility of connecting the supervision system without intervening on the controlsystem architecture;

2.4.5.7. Installation

a) Terminal blocks and cabling

Terminal blocks shall be positioned so as to guarantee a sufficient space to fixcable terminations and to allow an easy reading of the identification marks,without running the risk of electrocution or involuntary interventions.All the I/O signals from and to the LCUs shall be wired to the terminal block.

The division of the terminal blocks shall depend on:

Output and input signals from and to the switchboard; Signal destination/origin: the terminal blocks dedicated to the wiring of the

logic units (PLC I/O cards) shall be differently located from the ones which aretotally depended on the Hard Wired component;

The terminal blocks dedicated to the wiring of the logic units shall be groupedmodularly in correspondence with the I/O cards used.

The quantity of terminals on each board shall allow the connection of only oneconductor coming from the switchboard to each terminal. The nomenclature of aterminal going to or coming from a logic component I/O card shall indicate itsunivocal location and point of connection (e.g. ID0703 identifies a digital inputaddressed to the card in position 07 and to the connection terminal 03).The same nomenclature shall be recalled to identify the conductor input or outputto/from the electric switchboard terminal strip.

The conductors shall be linked and grouped in bundles so as to group the signalscoming from or going to each single I/O card of the logic component or ofdifferent control systems. The multi-pair cable grouping can be carried out forsignals that have the same nature and an identical reference with respect to themass. The conductor colouring shall identify:

Incoming signals; Outgoing signals; Power supplies; Common.



In order to wire electronic equipment it is necessary to comply, where possible,with the following recommendations:

Digital inputs/outputs : it is advisable to separate the passage of incomingcables from that of outcoming ones and to locate them as far as possible formone another. It is therefore necessary to take these conditions into accountwhen the modules are installed in the racks. In case it were not possible toinstall them as indicated, the inputs and outputs can be clustered making sure,however, to separate the A.C. outputs from the D.C. ones.

Analogue inputs/outputs : it is advisable to separate the analogue input andoutput cables form the digital input and output ones (especially the relayoutputs).

Other modules : the cables shall be separated from one another in order toavoid confusion and interferences. Specific manuals on the cards shall beconsulted for the wiring harness of the various modules.

The I/O module cabling shall be carried out with cables having at least thefollowing characteristics:

Technical characteristics:

DATA CHARACTERISTICSCEI - UNEL tag Cable H05V-K - 1 x -- CEI-UNEL 35750Uo/U rated voltage 300/500 VConductor Red annealed flexible copper wireSection 0,75 o 1 mm2Insulation PVC (CEI 20 - 20)

Particular characteristics:

NORMATIVE REFERENCESCHARACTERISTICS EUROPEAN

CENELECINTERNATIONAL

IECNATIONAL

CEI/CEI UNELFire-retardant --- 332 - 3 20 - 22Flame-retardant HD 405. 1 S1 332 -.1 20 - 35

b) Installation of the rack in the switchboard

The installation of the system components, (e.g. LCU, expansion racks, VDU)shall be carried out inside the switchboards with a front panel made oftransparent material (external display of all components).

Depending on the configuration, it shall be necessary to respect a few rules forarranging the racks and the modules inside them.

To leave a minimum vertical room of 150 mm between one rack and the otherin order to allow access to the I/O card terminal boards and to facilitate aircirculation.

The LCU shall be installed on the lower part in order to benefit from the lowestambient temperature inside the switchboard.

to avoid installing the same switchboards (or switchboard wing) where thereare direct or indirect heat generators (transformers, feeders etc.).



to foresee sufficient room for air circulation in order to facilitate the thermalexchange with the outside.

2.4.5.8. Spare parts for start up

The system shall be provided complete with spare materials for the start up of theplant.Each drive shall be provided with the material indicated here below.The Supplier can suggest other materials on the basis of previous experience and thetypes used.

TABLE 5

POS. DESCRIPTION OF COMPONENT QUANTITY(note 1)

1 Fuses of different type and rated currentsin proportion to the installed quantities10%

(note 2)

2 Signalling lamps 10%(note 2)

3 CPU 5%(note 2)

4 Feeders 5%(note 2)

5 Conductor connection terminals of varioustypes and sections10%

(note 2)

6 Auxiliary relays like the ones installed 10%(note 2)

7 Manipulator push buttons etc. 5%(note 2)

8 Rack 5%(note 2)

9 Network cards 5%(note 2)

10 I/O digital cards 10%(note 2)

11 I/O analogue cards 10%(note 2)

NOTES:1) Round off to the upper whole number if the decimal is bigger than 5.2) Percentage quantity referring to the total number of components of the

same type installed in the system, with a minimum quantity of 1.

2.4.5.9. Protective treatments

a) Painting

Painting and the relevant protective treatments will be done in accordance withthe prescriptions contained in the Data Sheet.

b) Tropicalisation

When required in the Data Sheet, equipment and materials will be subjected totropicalisation treatments in accordance with the relevant ReferenceSpecification.



2.4.6. Packing for transport

Packing for transport shall be defined by the Supplier according to the instructionsindicated in the reference specification.

2.5. Boundary conditions, limits and exclusions

Not applicable

2.6. Ergonomics

Not applicable

2.7. Safety

2.7.1. General rules

There are no specific requirements for this topic. However, the Supplier shallguarantee that the system, subject of this Functional Specification, will have aworkmanlike manufacture in order to comply with the safety requirements contained inthe relevant Normative References.

2.8. Requirements for Quality Management and Assurance

Any additional requirements of Quality Management and/or Quality Assurance arecontained in the relevant management specification enclosed in the request for bid.



2.9. Additional Requirements for Review

When required, they will be indicated in the Inspection Data Sheet (I.D.S.) and aresubdivided in:

Type test; Acceptance test (individual); Special test.

For any inspection and test not included in the Normative References and in thisSpecification and requested in the Inspection Data Sheet (I.D.S), the executionprocedures shall be defined on a case by case basis.

2.9.1. Type Test

The purpose of the type test is to verify that specific types of materials are incompliance with the relevant Normative References and the original design.The type test shall be carried out on samples of materials used for the supply and itsexecution shall be entire responsibility of the Supplier.Acceptance of materials similar to those supplied such as prototypes are exclusiveresponsibility of the Company that is entitled to require further tests chosen amongtype tests.

Type tests for auxiliaries and accessories shall not be required if the latter comply withthe relevant Normative References and if they are installed according to theirManufacturers instructions.

The Supplier of the system shall verify the execution of the type tests for auxiliariesand accessories and shall provide the related documentation.

2.9.2. Acceptance Test (individual)

The purpose of the acceptance test is to verify that the supply complies with theoriginal project and the prototype, through both a document check, and reduced butrelevant tests and inspections. Furthermore, the test is meant to verify thecorrespondence with the Companys requirements and to detect any defects in thematerials and the construction.The inspections and acceptance checks shall be carried out both on the whole supplyand on a sample as indicated in the Inspection Data Sheet (l.D.S.).The sample shall consist of materials randomly chosen in the quantity indicated in therelevant Normative References.Should indications not be included in the Normative References, the sample shall bedefined case by case.

As to acceptance tests for auxiliaries and accessories the above indications for typetests shall be applicable, provided that they are subjected to the checks and testslisted in the Inspection Data Sheet (I.D.S.).

2.9.3. Special Test

It consists of all the tests and inspections not included in the type and acceptancetests, that the Company might require from time to time.The list of tests and inspections and any execution criteria shall be indicated in theInspection Data Sheet (I.D.S.).



2.10. Documentation

The Supplier will deliver to the Company all the documents indicated in the RequestedDocument Data Sheet (R.D.D.S.), in accordance with the agreed terms and schedule.

The technical documentation will be written in the official language indicated in theData Sheet and using the symbols indicated in the CENELEC, CEI Rules and in IECPublications.

2.10.1. Bid Documentation

The Supplier will include in his bid all the information and documentation required inthe Data Sheet (R.D.D.S.).

2.10.2. Documents Subjected to Approval

The approval of the documentation by the Company, if necessary, will refer to theformal verification of the parameters indicated in the design's documents only.

2.10.3. Documentation used by the Company for the system design

The Supplier will deliver to the Company all the documentation necessary to theexecution of the system design and to the installation of the supplied system.

2.10.4. Test Documents

The Supplier will deliver to the Company, within the schedule and in the way indicatedin the Data Sheet, all the certificates relating to the type, acceptance and specialtests.

2.10.5. Final Technical Documentation

The final technical documentation, with the only exception of the Supplier andSubsuppliers catalogues and publications will include the following references:

name of the Supplier; name of the Company; identification tag, as indicated by the Company; title of the document; details of the Company's orders.

and will consist of:

a) Design and Installation instructions;b) Operations instructions;c) Maintenance instructions.

The description and drawings can be contained in catalogues and documents of theSupplier, as long as they satisfy the following conditions:

they contain all data and information required in their final form they are relevant to the type supplied and the materials included in the supply are

clearly identified amongst those in the document.

The documentation subject to approval will be integral part of the final documentationapproved by the Company.