ycpti03 process control functional description(1)

TECHNICAL STANDARD Process Control Functional Description

Standard YCPTI03

The electronic version is current, or when printed and stamped with the green controlled document stamp. All other copies are uncontrolled.

Published Date: 110 February 2014 Rev: 1.1 Next Review Date: 30 March 2015 of 48

Process Control Functional Description Standard

Yabulu Refinery Technical Standard

YCPTI03

DOCUMENT INFORMATION

Description Technical Standard

Document Owner Engineering Superintendent

DOCUMENT HISTORY and APPROVAL

Rev Date Revision Description Originator Reviewed Approved

1.1 10 Feb 2014 Review date changed to 5 yearly reviews

Rohan O’Farrell

Rohan O’Farrell

David Moloney


Standard YCPTI03


Published Date: 18 March 2010 Rev: 1.0 Next Review Date: 30 March 2012 of 48

CONTENTS

1. INTRODUCTION ............................................................................................ 3

2. DELIVERABLES ............................................................................................ 3

2.1 QN Yabulu Refinery Safety Requirements ............................................................................... 3

2.2 Document Delivery .................................................................................................................... 3

3. VENDOR PACKAGE EQUIPMENT ............................................................... 4

4. APPLICABLE PROJECTS ............................................................................ 4

5. OBJECTIVES ................................................................................................. 4

6. Exclusions ..................................................................................................... 5

7. LIMIT OF DOCUMENTATION ........................................................................ 5

8. ASSUMPTIONS ............................................................................................. 5

9. DATABASE COMMON TABLES ................................................................... 5

10. BUILDING AN AUTOMATED SOLUTION ..................................................... 5

10.1 Plant Design and Allocation ...................................................................................................... 5

10.2 Engineering Workflow ............................................................................................................... 7

11. REVISION CONTROL .................................................................................... 9

12. ABBREVIATIONS USED IN THIS DOCUMENT .......................................... 10

13. TERMINOLOGY USED IN THIS DOCUMENT ............................................. 10

14. TYPICAL FUNCTIONAL DESCRIPTION ..................................................... 12

15. APPENDIXES AND REFERENCES ............................................................ 48

15.1 Technical Standards ............................................................................................................... 48

15.2 Standards Drawings ................................................................................................................ 48


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1. INTRODUCTION

The Functional Description Standard shall be used to ensure quality and uniformity in the functional descriptions produced by the project process control team, packaged plant suppliers and consultants and contractors, for each plant area and sub-areas. Process control functional descriptions are a project deliverable.

This document shall be used by EPCM contractors, vendor package plant suppliers and any project implementing control systems, as the standard to which process control functional descriptions shall be written. The functional descriptions shall be reviewed and accepted by the client project team, prior to moving to software production.

Once accepted, the produced functional description will become a contractual document. The project process control team, comprising the client, system supplier, EPCM contractor or packaged plant vendor, shall undertake a Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) where the performance shall be measured against the process control functional description, written as outlined in this document.

2. DELIVERABLES

The functional descriptions are a project deliverable. They are created and maintained by the EPCM contractor, package plant vendors, or process control engineers assigned to the project. The Engineering Superintendent – Instrumentation & Control shall approve all functional descriptions.

A Plant Area may be described by several functional descriptions, including core process, vendor packages and auxiliary processes. The breakdown of the Plant Area functional descriptions shall be based around the System Hierarchy, i.e. Plant Area, System, Sub-system and Equipment. Refer to the standard document Operation and Control Philosophy, YCPTI02, System Hierarchy and Level of Automation. The breakdown shall also be at the discretion of the project lead process control engineer.

2.1 QN Yabulu Refinery Safety Requirements The QN Yabulu Refinery Safety Requirements apply to all QN Yabulu controlled sites and activities, and to all QN Yabulu employees, contractors and visitors when involved in any activity.

These requirements can be achieved by actively assessing risks and determining and implementing appropriate control measures using a risk based management system.

2.2 Document Delivery An electronic softcopy of the functional description and its attachments are to be delivered. This includes, but is not limited to the items below. The documents must be capable of manipulation by others, such as manipulating spreadsheet data for engineering purposes. A hardcopy shall also be submitted in addition to the electronic softcopy:

Word documents

Spreadsheets

Functional Logic diagrams

Sequence charts and descriptions

Loop drawings

Process and Instrument Diagrams


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3. VENDOR PACKAGE EQUIPMENT

Vendors supplying package mechanical equipment shall supply a functional description for the package being supplied. The vendor functional description shall fulfil the requirements described in this document.

The vendor shall be responsible for delivery and maintenance of the package functional description up to completion of the Site Acceptance Testing (SAT) and Client Sign Off.

Vendor functional descriptions shall be reviewed and accepted by the client project team.

The vendor shall attend FAT and SAT, and review and approve software completed to the functional description.

4. APPLICABLE PROJECTS

There are a number of different QN Yabulu projects to be undertaken, with different control solutions being presented. These include:

Upgrade of existing plant areas to the Industrial IT Control and HMI system

Installation of new plant equipment to the Industrial IT Control and HMI system

Integration of existing PLC’s to the Industrial IT HMI system

Installation of new PLC’s which shall integrate to the Industrial IT HMI system

This functional description standard shall be applicable for all the above project types presented. Some of the sections may not be relevant to some projects, e.g. defining controller configuration details does not apply for the “Integration of Conductor NT HMI system to Industrial IT HMI system”, since the controllers are not intended to be upgraded.

Sections not relevant can be noted with a “Not applicable” note by document users.

5. OBJECTIVES

The document will specify all requirements for functional descriptions, to ensure that:

A consistent approach is undertaken to software implementation for all areas of the Yabulu refinery.

There is sufficient detail to allow software configuration by an integrated process control team (e.g., package plant vendors supplying a functional description in this format will enable programming to be done by others).

The client is provided with a document describing the software functionality of the control system operations.

The client project team, using the produced functional description as a contractual document, is able to assess the performance of the process control system in accordance with the documented specification(s)

The information is provided in a consistent format allowing the process control system software team to undertake software production.

The functional description is sufficiently detailed and consistent to allow a standard testing methodology to be used during FAT, SAT, commissioning and control system maintenance.


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6. EXCLUSIONS

This technical standard specification does not cover Safety Instrumented Systems (SIS)’s. These systems are detailed in the project standard document “Safety Instrumented Systems (SIS) Standard”, no. YCPTI01.

7. LIMIT OF DOCUMENTATION

The functional description shall not describe common software functionality. Standards exist for drive logic, valve logic, duty / standby drive operation, control loops and algorithms, graphic symbols, colours, navigation and indication, alarm conventions, etc. This is documented in the project standard document “Control System Software Configuration Standard”, no. YCPTI04.

When the process area requires functionality, which is not documented by the existing standards, it shall be included in the respective functional description.

8. ASSUMPTIONS

The Bentley I&W System is the central database including tools for the YEP Project, for all instrumentation loop diagrams, terminations, instrument indexes, IO lists etc.

Data provided in the functional description shall be imported into the Bentley I&W Plant Design System, which will generate Excel Worksheets containing the data to then be utilised to perform the control system configuration.

9. DATABASE COMMON TABLES

In order to improve efficiencies related to documentation, controller configuration and online documentation, design data shall be captured into common Microsoft Excel Spreadsheets. Much of the tabled information shall be exported from the Bentley I&W Plant Design System to give a central point of information access. Once received by the Control System Supplier via the functional description, the data shall be used as DCS bulk data configuration wherever possible. The functional description document shall be retained as the master configuration document.

Examples for the capture of design information using project common tables are as follows:

Loop Listings

I/O Listings

Alarming

Fail Safety

Modes of operation

Document References

10. BUILDING AN AUTOMATED SOLUTION

10.1 Plant Design and Allocation The AUABBTools suite of tools shall be used as the bulk engineering data tool for the configuration of Control Builder M application software. These tools are designed to automate applications built using the BMI library Object Types and the associated additional Object Types created by ABB.


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The data shall be entered into the Bentley I & W System by QN Yabulu, and then exported from in the correct Excel spreadsheet format (this output forms part of the Functional Description) for use by the BentleyToODS tool. Should the Bentley I & W System not be used the data shall be manually entered in the correct Excel spreadsheet format. The format is outlined in section 0 5.10. I/O Listings and examples are shown in Appendices B, and C.

The output of the BentleyToODS tool will be Object Definition Sheets (ODS), refer to Appendix K for ODS examples. Further data will be manually entered into the ODS’s by ABB, on completion the ODS’s will be submitted to the QN Yabulu Project team for authorization, authorization is required before programming may commence.

The ODS’s are the input to the ODSToCBM tool. This latter tool is used to create the hardware and I/O allocation structures in the controller(s), as well as the Control Builder M application code (mainly in the form of Control Modules) for the objects, as well as most of their connections.


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10.2 Engineering Workflow The engineering workflow is important for a successful and efficient design. Engineering tools like AUABBTools may be a big help for the engineering process, but only if everybody understands the data and workflow. The table below gives a general description of the steps that form the engineering workflow:

1 Ensure that the required data has been entered into the Bentley system (if used) for all I/O. This includes address allocation for both I/O and ProfiBus connected devices.

2 Export the data from the Bentley system in the required format, or (if Bentley has not been used), create workbooks with the required format and let the customer enter the data.

3 Ensure that you know the Process Unit(s) for the area(s) that you are working with - BentleyToODS will need this.

4 Use the BentleyToODS to create Excel workbooks. One will be created for each Process Unit.

5 Study the log file from the BentleyToODS tool for problems that relate to the input data.

6 Establish if the input data needs updating/correcting. If so, have all such data corrected and run BentleyToODS again.

7 If all data that can come from the input file is there and correct, study each Object Definition Sheet (ODS), correct incorrect data (e.g. too long descriptions), and add other information required. This activity includes defining interlocks and interlock texts, as well as start warnings etc.

8 Submit output to QN Yabulu Project team for review and approval

9 Study feedback and update sheets.

10 Make sure that the workbooks only contains objects for one controller only. If not, split the workbooks.

11 Get hold of the system(s) that are to be configured, including controllers, and prepare it for programming.


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12 Install the ODSToCBM tool on the Engineering node(s) that are to be used for the configuration.

13 Create a Control Builder M Project and create the required applications.

14 Create all control networks required. Add all required I/O stations, S800 Modules and Profibus nodes.

15 Select one node and run the ODSToCBM tool to create single control modules within the application and populate the I/O and ProfiBus devices.

16 Select one group and download it. Check the result in CB M and save the project.

17 Do the detail programming group by group, following the rules and guidelines in this document. Complete all the interlocks for the process object and associated external code on the group level.

18 Add MMS variables to the project specific MMS Data Type library whenever you require a signal from another controller.

19 Add the required system supervision code.

20 Assign the application to a controller, compile and download.

21 Test the software according to the ABB application software test protocol.

Engineering Workflow


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11. REVISION CONTROL

Revision control is an aspect of document control whereby changes to documents are identified by incrementing an associated number or letter code termed the revision level, or simply revision. It has been a standard practice in the maintenance of engineering documents.

It shall be common for updated revisions of the functional descriptions and their associated documents to be supplied as the project proceeds. The necessity for all proceeding versions of documents will hence clearly identify changes.

Changes to Word Documents must be performed with “Tracking Function On” to indicate:

o Content of the document modified

o Person implementing document modification

o Date of modification

o Comment detailing reason for modification

o Modified content to be in red underlined format

Changes to Excel Spreadsheets must be clearly highlighted on the spreadsheet cells, as per example below:

o Added cells to be highlighted in green, with red text

o Deleted cells to be highlighted in red, with black text strikethrough

o Modified cells to be highlighted in yellow, with red text

Added Added this revision

Deleted Deleted this revision

Modified Modified this revision

o Modification date to be provided in the “Mod.” column of the spreadsheet

o Initials of the individual undertaking the modification to be inserted in the “Mod By” column of the spreadsheet

Where a new document revision is issued, all tracking details, highlighted cells, and modification date and initials are to be cleared. This will ensure only most recent changes relevant to the newly revised document are clearly indicated.


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12. ABBREVIATIONS USED IN THIS DOCUMENT

Abbreviations used in this document are as follows:

ABB ABB Australia Pty Ltd AS Australian Standards DCS Distributed Control System LCS Local Control Station MPR Motor Protection Relay FAT Factory Acceptance Test I & C Instrumentation & Control FD Functional Description HMI Human Machine Interface SIS Safety Instrumented System CCTV Closed Circuit Television IEC International Electro technical Commission I/O Input/Output MCC Motor Control Centre PPA Process Portal A P&ID Process and Instrumentation Diagram SIL Safety Integrity Level SFC Sequential Function Chart VSD Variable Speed Drive UPS Uninterruptible Power Supply OOS Out of Service OS Operator Station

13. TERMINOLOGY USED IN THIS DOCUMENT

The list contains terms used in the document:

Term Description

Alarm An alarm is an abnormal state of a condition associated with an Aspect Object. An alarm is active as long as the abnormal state of the corresponding condition persists. An alarm is unacknowledged until a user has acknowledged it.

Alarm acknowledgement A user action to confirm the recognition of an alarm. Acknowledgement changes the state of an alarm from unacknowledged to acknowledged.

Aspect Objects A computer representation of a real world entity like a pump, a valve, an order or a virtual object like a service. This computer representation is implemented by the 800xA System. An Aspect Object works like an information container for its aspects.

Authentication The process by which the system validates the user's logon information. A user's name and password are compared against an authorized list. If the system detects a match, access is granted to the extent specified in the permissions list for that user.

AUABBTools A suite of engineering tools created by ABB specific to the QN Yabulu Projects to assist the engineering workflow, the tools include and are not limited to; BentleyToODS ODSToCBM

BentleyToODS An Excel spreadsheet generated by the Bentley I & W System is converted to Object Definition Sheets using the BentleyToODS Tool.

ODSToCBM Data from Object Definition Sheets is converted to Control Builder M application using the ODSToCBM Tool.

ODS Object Definition Sheet. There is an ODS type for each object in the application program, the ODS contains the user configurable data for


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Term Description

the object.

Context Menu A menu that appears when you right-click on an Aspect Object or an aspect. The context menu lists aspect operations, actions, aspects, and global operations.

Event An event is a detectable occurrence, which is of significance to an Aspect Object. An event may or may not be associated with a condition. For example, the transitions into High Alarm and Normal conditions are events, which are associated with conditions. However, operator actions, system configuration changes, and system errors are examples of events, which are not related to specific conditions. OPC Clients may subscribe to be notified of the occurrence of specified events.

Faceplate A faceplate is an aspect that provides a graphical representation of a certain Aspect Object, with presentation of certain properties related to the object, and mechanisms for operator interaction such as on/off, increase/decrease, etc. Aspect Object types often include several different faceplate aspects, providing different presentation and interaction possibilities.

Graphic Display A graphic display is an aspect that provides a visual presentation. It consists of static graphics representing for example tanks, pipes, etc., and graphic elements that present dynamic information. Graphic displays are often used to present the state of a process or a part of a process, but are useful in any context where dynamic graphical information needs to be presented. Examples of predefined graphic display categories are Graphic Display, Overview Display, Navigation Display, Status Display, etc.

Industrial IT (IIT) ABB’s vision for enterprise automation.

Industrial IT system An arrangement of Industrial IT products, which work together as a system, implementing (part of) the Industrial IT vision.

Re-authentication The process of re-identifying an individual previously identified through authentication. Re-authentication serves two purposes It verifies that the individual trying to perform a certain operation is identical with the user that is currently logged on. It means that the user electronically signs that he or she is performing the operation.

Security Security controls a user’s authority to perform different operations on Aspect Objects, depending on several parameters: The user’s credentials, as provided by Windows The node where the user is logged in. This makes it possible to give a user different authority depending on where he or she is located, e.g. close to the process equipment, in a control room, or at home accessing the system through Internet The operation the user wants to perform The Aspect Object that the user wants to perform the operation on


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14. TYPICAL FUNCTIONAL DESCRIPTION

Table of Contents

1. INTRODUCTION 2. SAFETY

2.1. Hazardous Area Classification 2.2. Hazardous Area Equipment 2.3. Safety Integrity Systems 2.4. Hazardous Products and Corrosive Substances 2.5. Equipment and Process Start-up Warning 2.6. Emergency Stops 2.7. Emergency Power 2.8. Environmental Monitoring

3. GENERAL 3.1. Glossary 3.2. Standards

4. PROCESS OVERVIEW 4.1. Process Model 4.2. Process Description 4.3. Operating Equipment 4.4. Process Sequences 4.5. Process Operating Conditions 4.6. Process Equipment Descriptions 4.7. Process Operating Strategy 4.8. Process Operating Modes 4.9. Process Operating Locations 4.10. Requirements for Operation 4.11. Process Operation Scenarios 4.12. Process Upstream Requirements 4.13. Process Performance Indicators

5. INSTRUMENTATION AND CONTROL 5.1. Plant Control Systems 5.2. Human Machine Interface Graphic Displays

5.2.1. Listing of HMI Graphic Displays 5.2.2. Graphic Display Conceptual Drawings 5.2.3. Security 5.2.4. Other Special Requirements

5.3. Analogue Control and Discrete Interlocking Logic 5.4. Alarms

5.4.1. Alarming of Analogue Loops 5.4.2. Alarming of Digital Loops 5.4.3. Alarming Logic

5.5. Fail Safety 5.5.1. Fail Safe States 5.5.2. Fail Safe Modes (on controller restart) 5.5.3. I/O Error Handling

5.6. Scan Times 5.7. Sequencing

5.7.1. Sequential Function Charts - GRAFSET 5.7.1.1. Graphical Representation of Sequential Structures 5.7.1.2. Simplified Representations

5.7.2. Sequence Logic Diagrams 5.8. Loop Diagrams 5.9. P&ID’s 5.10. I/O Listings

5.10.1. Analogue I/O Listing 5.10.2. Discrete (Digital) I/O Listing

5.11. Trending


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5.12. Reporting 5.12.1. Totalisers 5.12.2. Costing Reports 5.12.3. Other Reports

5.13. Critical Operation Authentication 6. REFERENCE DOCUMENTS


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1. INTRODUCTION

This is a brief introduction to the plant area or equipment that the Functional Description is describing, as well as the objectives of the functional description document.

2. SAFETY

2.1. Hazardous Area Classification

A summary of hazardous area classifications within the scope of work for the functional description as per AS2430 (Classification of Hazardous Areas) and AS60079 (Electrical Apparatus for Explosive Gas Atmospheres). This includes the regulatory acts and standards that the area classifications have developed.

2.2. Hazardous Area Equipment

A description of the explosion protection techniques used for each hazardous area zone classification within the scope of the Functional Description as per AS2380 (Electrical Equipment for Explosive Atmospheres – Explosion Protection Techniques) and AS2381 (Electrical Equipment for Explosive Atmospheres – Selection, Installation and Maintenance).

2.3. Safety Integrity Systems

A list of systems within the scope of the functional description that require a safety integrity level (SIL) higher than zero. The list shall include the SIL rating for each system and a SIL study to justify the ratings.

Refer to AS61508 (Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems) and AS61511 (Functional Safety – Safety Instrumented Systems for the Process industry).

Refer to project standard document “Safety Instrumented Systems” no. YCPTI01 for the project general and technical standards, related to all aspects of safety instrumented systems.

2.4. Hazardous Products and Corrosive Substances

Identify all hazardous products and corrosive substances associated with the process and area within the project scope.

A Material Safety Data Sheet shall be provided for each hazardous or corrosive product.

2.5. Equipment and Process Start-up Warning

Identify all start-up warnings in the form of sirens and flashing beacons used to warn personnel of equipment about to start.

Identify location, quantity, alarm intervals, alarm tones and flash frequencies.

2.6. Emergency Stops

Identify any process or equipment specific emergency stop requirements within the project scope.

2.7. Emergency Power

Identify any equipment to be maintained on emergency power.

Identify requirements for equipment to be supplied by an “Uninterruptible Power Supply”, including the reasons for the requirement and the duration required of the backup power.

2.8. Environmental Monitoring

A description of safety related environmental conditions such as gas, heat and dust, and the methods used to safeguard against those conditions. For each environmental condition identified:

Identify the potential or existing hazard


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Assess the risk associated with the hazard

Identify the control measures used for safeguarding against the hazard

Document any project HAZOP studies or risk assessments that the above may be based on.

3. GENERAL

3.1. Glossary

A list of all abbreviations, acronyms, and their definitions relating to the Functional Description. This can be shown in a table in the functional description.

3.2. Standards

This section lists all relevant Australian, Queensland and project standards (YCPT Documents) that shall be complied with in the design and engineering of the project.

4. PROCESS OVERVIEW

The process overview is a brief description of the process plant operation. The operating functionality for the plant shall be described and the relationship between the various plant areas and sub-areas shall be detailed.

The process overview describes the battery limits of the document and the breakdown of the areas and process cells covered in the document or related process areas and process cells that are covered in another document.

4.1. Process Model

A figure should be used to illustrate the relation between the various sections of the Plant Area.

The operation of the plant is based on a hierarchical system of Plant Areas, Systems, Sub-systems and Equipment. Refer to the description detailed in the project standard document “Operation and Control Philosophy Standard” no. YCPTI02 (“System Hierarchy and Level of Automation”). The breakdown of the Plant Areas into Systems, which contain the individual pieces of equipment are considered “Units” of the Plant Area.

The boundary of the functional description are to be bound to an individual Unit, and possibly to more than one unit. This ensures that the functional description is both effective and manageable. The boundary of the functional description must be clearly identified on the process model. An example is shown in Figure 1 below:

Figure 1: Example of diagram depicting Plant Areas, Systems, Sub-systems and Equipment

4.2. Process Description

This section contains a generic description of all process and equipment contained within the scope of work for the Functional Description.

4.3. Operating Equipment

This section describes the proposed operator interface hardware including:

List of conceptual Human Machine Interfaces (HMI) screens

List of Closed Circuit Television’s (CCTV)’s

Plant Area

System (Unit) System (Unit) System (Unit)


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o Details of their purpose, location and operational impact. Refer to project standard document Operation and Control Philosophy, no. YCPTI02 for further details

List of Local Control Desks (as defined in project standard document Operation and Control Philosophy, no. YCPTI02)

Other operational hardware necessary for operating the plant

4.4. Process Sequences

Process Plant Areas are broken down into Systems and Sub-systems (refer Section 0 above - 4.1. Process Model). A sequence is the software parent responsible for the operation of a distinct plant function. Sequences are arranged to provide the simplest operating groups by process.

The sequences shall be listed briefly in this section in a tabular format as per example below. The listing shall be used to provide a basis for understanding the remaining the remaining functional description. The detailed analysis of sequences shall be documented later in Section 0 below -.

The listing of sequences include the following:

Area

o Physical plant area number

o Plant area is at the highest level of system hierarchy. The breakdown of the system hierarchy is defined in the project standard document “Operation and Control Philosophy” no. YCPTI02, under the section labelled “System Hierarchy and Level of Automation”

System or Sub-system Name

o Plant Area is broken down into Systems and Sub-systems

o Name of this System or Sub-system is required

Sequence Name

o Descriptive name of the Sequence

Sequence Description

o Description of the Sequence

P&ID Numbers

o P&ID numbers related to the Sequence, for reference

Faceplate Access

o Indicates that sequence requires interaction by operator through an operator interface

o Y(es) or N(o) answer required

Recovers

o Sequence auto recovers from cold start or power failure

Area System or Sub-system Name

Sequence Name Sequence

Description PID

Numbers Faceplate Access

Recovers

340 CCD Thickeners Yes No

340 Thickeners Sump Yes No

340 Thickeners Tunnel No Yes

340 Thickeners Overflow Recycle

No No

340 Thickener Overflow Column

Yes No


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4.5. Process Operating Conditions

This section describes the key Operating Parameters and the expected Operating Conditions.

Examples:

Process Temperature Conditions:

Description Range

H2S Reactor Heater 443 - 454C

H2S Reactor Vessel Bottom 443 - 454C

H2S Reactor Vessel Middle 443 - 454C

H2S Reactor Vessel Top 443 - 454C

Quench Tower Top 145 - 154C

H2S Gas Product 43 - 54C

Sulphur Cooler Shell 128C

Sulphur Exit Sulphur Cooler 138C

Cooling Water exit Reflux Condenser 45C

Cooling Water Supply 35C

H2S Cooler exit Cooling Water 45C

Process Pressure Conditions:

Description Range

SynGas Supply (before PV2502A) To 1740 kPag Max

SynGas Feed to Reactor (after PV2502A) 860 kPag

H2S Reactor Pressure 758 kPag

H2S from Quench Tower Pressure 689 kPag

H2S Gas from H2S Coolers Pressure 551 – 689 kPag

Sulphur Cooler Shell Pressure 200 kPag normal (138kPag -241kPag)

Sulphur Reflux Condenser Cooling Water Temperature

35C

Sulphur Make-up Pump discharge Pressure

1103 -1241 kPag

Sulphur Re-circulation Pump discharge Pressure

1103 -1241 kPag

Nitrogen Supply (before PCV-2502L) 1700 kPag

Nitrogen supply to reactor (after PCV-2502L)

1063 kPag

4.6. Process Equipment Descriptions

This section lists and describes:

Types of process equipment within scope of work

General description of specialised equipment

The operating windows and constraints of the process equipment (min, max, turn down ratio, ramp rates etc)

The equipment arrangement and configuration to allow different operation scenarios based on raw material, operating and maintenance changes. The insertion of a drawing may be necessary for explanation.

4.7. Process Operating Strategy

An explanation of the strategy to operate this area or process cell, focussing on the steady state operation. This section should include details on how the control system can influence the operation to achieve the process objectives.

4.8. Process Operating Modes

This section describes the operations in each mode. The operator may have to choose product types or feed sources that may have an impact on the automatic controls.


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These selections should be identified as modes and used to characterise the operation and control.

4.9. Process Operating Locations

Used to identify the primary Operator Station(s) where control and monitoring will normally take place as well as any local or other operating facilities. Refer to project standard document “Operation and Control Philosophy”, no. YCPTI02 for further details regarding possible control room locations and other operational control locations.

Examples:

420 Gas Plant control room

420 Local Control Desk

370-380 Final Nickel Plant control room

370-380 Final Nickel Plant local control stations etc.

4.10. Requirements for Operation

The functional description shall discuss normal operator interaction for start-up, stand-by, operation and shutdown. This section should provide a guide as to manning and supervisory demands on personnel to operate the plant, and provide a background for configuration engineers as to plant operating methods.

All sequences shall operate in fully automatic mode wherever possible. This shall provide for start-up, operation and shutdown, with set points cascaded from related process areas. Where operators are required to specify operating parameters or carry out manual actions in the field or at the DCS, these actions and operating modes shall be documented.

Equipment which does not have any automatic function shall be specifically described in this section, e.g. Start Agitators on Melting Pits, 330MC15021A, 330MC15022, 330MC15023 etc.

The general requirements for operation are not required for DCS bulk editing. The format of presentation of this section shall be at the discretion of the process control engineer. A written description or an abbreviated table are possible presentations. Refer to the following abbreviated table for example:

Field Operator Control Room Operator Plant Control System

1 Confirm line up: flush lines closed drain valves closed area cleared

2 Start Sequence for Condensate Return. Start Sequence for HP Seal Water.

3 Request Power Station 50T/Hr and 65bar

4 Start Preheat Sequence

5 Advise Preheat Sequence Completed

6 Start Feed Sequence. Start Acid Addition.

7 Feed Sequence starts. Acid Sequence waits until operating

8 Set to production mode with auto set point, or cascade/balance.


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4.11. Process Operation Scenarios

This section contains a description of all the applicable operation scenarios for the plant area covered by the Functional Description including the following:

Manual operation

Normal start (empty)

Resume start (under load)

Mode transfer (local / remote)

Stop (normally orderly shutdown of the process)

Maintenance shutdown (empty and stop)

Emergency stop

Fault sequences

Power recovery

Equipment specific

For each of the above scenarios, the following shall be covered:

Initial conditions

Operator pre-operational verification

Specific equipment configuration

Procedure description (control system sequence)

Clear distinction of manual and automatic functions

Clear distinction of control system function and operator action

4.12. Process Upstream Requirements

This section shall list the requirements upstream from the process being described to achieve the required Process Indicators detailed in Section 0 below - 4.13. Process Performance Indicators.

Example:

The H2S Plant feed streams at nameplate capacity are as follows:

SynGas – supply 5.95 T/day (658Nm3/h) @ 791kPa and 29C. (This is on the basis of a SynGas composition of 79.2% H2 and 18.0% N2 using design data from the existing plant. Normal operation is 74.62% H2 and 24.4% N2)

Molten Sulphur, as make-up of 17.47 T/day at 138C.

4.13. Process Performance Indicators

This section lists the key performance indicators (e.g. quality control variables) that are needed to monitor operation performance against the process objectives for normal process conditions. KPI’s shall document:

Normal operating rates for the sequences in the process area

Process performance goals for control and consistency

Equipment availability

Minimum process downtime

Example:

The H2S Plant is expected to operate to the following KPI’s:

Nameplate capacity of 18.1 T/day H2S, as supplied to the Aqueous Ammonium Hydrosulphide Plant

Plant capacity factor of 94%. This is inclusive of:

o Availability 98.0%

o Utilisation 97.5%


Standard YCPTI03



o Effectiveness 98.5%

5. INSTRUMENTATION AND CONTROL

5.1. Plant Control Systems

This section describes the proposed control system and shall include the items below. A simple control system logical block diagram should be shown if applicable. An example has been provided below in Figure 2. The diagram will be useful for identifying existing control equipment, instrumentation to be retained, and the expected integration to new controls

Figure 2: Logical Block Diagram of proposed control system

The following points are to be detailed:

General description of how control components will be implemented on the plant control system

General description of specialized control system equipment

Specific requirements

Any interfaces with special equipment, controllers, or instruments

5.2. Human Machine Interface Graphic Displays

Definition: A graphic display provides a visual representation. It consists of static graphics representing for example tanks, pipes etc., and graphic elements that present dynamic information. Graphic displays are often used to present the state of a process or a part of a process, but are useful in any context where dynamic graphical information is needed.

This below sub-sections of Section 5.2 shall detail the conceptual Human Machine Interface (HMI) graphic displays. These requirements shall be applicable for all possible project implementations including:

Upgrade of existing plant areas to the Industrial IT Control and HMI system

Installation of new plant equipment to the Industrial IT Control and HMI system

Integration of Conductor NT HMI system to the Industrial IT HMI system

Integration of existing PLC’s to the Industrial IT HMI system

AC800M Controller

AB Control Logix PLC

Profibus-PA Adapter

30 Existing VSD’s (Profibus-DP/V1 comms)

Profibus-DP/V1

50 New Instruments

200 Existing IO Points (S800 I/O)

Modbus

150 Existing IO Points


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Installation of new PLC’s which shall integrate to the Industrial IT HMI system

5.2.1. Listing of HMI Graphic Displays

This section shall list for reference, all graphic display drawings to be attached to the functional description.

The listing of graphic displays to be submitted shall be in a tabular format:

Graphics Ref.

o Reference number of graphic so that attached graphic drawing can be referenced

System Name

o Descriptive name of the System

o Plant area is subdivided into one or more systems. The breakdown of the system hierarchy is defined in the project standard document “Operation and Control Philosophy” no. YCPTI02, under the section labelled “System Hierarchy and Level of Automation”. It is also detailed in this document, Section 0 above - 4.1. Process Model

Graphic Title

o Descriptive title of the graphic drawing

o Shall be used when constructing the control system graphic pages

Graphic Description

o Brief description of the graphic diagram

o Shall be used when constructing the control system graphic pages

Graphic Type

o Include drawings related to the process equipment covered by this functional description for the following:

o Plant Overview

o Process Graphic Displays

o Interlocking Help Displays

o Calculation Help Displays

o Trend Page Link Displays

o Table Data Entry Pages

P&ID ref.

o Process and Instrument Diagram document reference number

o If applicable, the relevant P&ID number should be referenced


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Refer to the following table for the format of data required.

Graphic Ref.

System Name Graphic Title Graphic Type P&ID Ref.

1 450 Gas Plant H2S Plant Process Overview Plant Overview

2 450 Gas Plant H2S Plant Trend Links Trend Page Link Display

3 450 Gas Plant H2S Reactor and Quench Tower

Process Graphic Display

4 450 Gas Plant H2S Reactor Interlock Overlap

Interlocking Help Display

5 450 Gas Plant H2S Coolers Process Graphic Display

6 450 Gas Plant H2S Sulphur Cooler and Reflux Condenser

Process Graphic Display

7 450 Gas Plant H2S Reflux Condenser Cooling Calc Overlap

Calculation Help Display

5.2.2. Graphic Display Conceptual Drawings

Graphic display concept drawings shall be attached as part of the functional description.

The programming engineers shall use the drawings to build the control system HMI graphic displays. Refer to Appendix A for examples of graphic drawings.

The drawings provided as part of this functional description, shall adhere to the following guidelines:

Computer software (e.g. Microsoft Visio, Microsoft Excel, Microsoft Power Point, AutoCAD etc.), shall be used to construct the drawings

All detail must be clear, concise and accurate

Both static equipment and dynamic points must be shown

All static equipment and dynamic points must be identified with the tag name which will correspond the P&ID drawings

Any process lines coming in or going out from process displays must be identified with their corresponding alternate page link locations

5.2.3. Security

Some displays may require security, for example, an application engineer is only permitted to view and change tuning parameters on tuning graphical display. These requirements shall be listed in this section. Refer to project standard document “Operation and Control Philosophy”, no. YCPTI02 for further details on the Security Structure.

5.2.4. Other Special Requirements

Any other special graphic requirements are to be listed in this section.

Examples:

Washing sequence consisting of multiple selectors on graphics may require additional description, which shall be listed in this section.

Specific colour requirements to fulfil safety standards for particular plant equipment may be listed in this section if the scheme falls outside the bounds of the standard colour scheme employed in the project.

5.3. Analogue Control and Discrete Interlocking Logic

This section describes the process through the associated process interlocks, safety interlocks, logic, and equipment controls. Object Definition Sheets shall be used to describe the majority of the logic for plant equipment and systems within the scope of the functional description, this is described in section 10 BUILDING AN AUTOMATED


Standard YCPTI03



SOLUTION. Functional Logic Diagrams may be provided to clarification on the interlock or glue logic surrounding each object.

A definition of the Interlocks and Permissives are required to effectively specify the process through Functional Logic Diagrams. Refer to project standard document “Operation and Control Philosophy”, no. YCPTI02, Section titled “Interlocks and Permissives”. The definitions have also been provided in abbreviated form in the following:

Interlocks and Permissives

There are three (3) different interlock types to consider. These are defined in the proceeding sections.

Safety Interlock

o Interlock that prevents a device from operating in order to prevent a hazardous situation from occurring. The DCS shall act on a safety interlock, by stopping the equipment and preventing start of equipment whilst the Safety Interlock exists. An alarm condition will be generated. Safety Interlock must also be hardwired to control circuits.

o Safety Interlock applies in all modes of operation, and cannot be overridden for safety reasons.

Process Interlock

o Interlock based on limits or constraints that are applied by other equipment surrounding the object that is interlocked. The DCS shall act on the Process Interlock by stopping the equipment, and preventing start of equipment whilst interlock exists. An event condition is to be generated only. The object is permitted to start again once the Process Interlock condition is released.

o Process Interlocks do not apply when object is being controlled locally in Test Mode.

o Some Process Interlocks can be blocked by the operator in modes other than Test Mode, i.e. Auto or Manual. This requirement is to be specified as part of the Functional Description.

Permissive (Start Interlock)

o Start Interlock based on limits or constraints that are applied by other equipment surrounding the object that is interlocked. The DCS shall act on the Start Interlock by preventing the equipment to start whilst the interlock exists. Once the Start Interlock is lifted and the equipment is running the Start Interlock does not have any effect on the object.

o Start Interlocks do not apply when object is being controlled locally in Test Mode.

o Some Start Interlocks can be blocked by the operator in modes other than Test Mode, i.e. Auto or Manual. This requirement is to be specified as part of the Functional Description.

Functional Logic Library Sheets

The Functional Logic Diagrams are an extremely effective method for providing a description of the plant to allow programming engineers to efficiently develop software for the plant automation, and leaves minimal scope for misinterpretation.


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A set of predefined logic library sheets have been provided in Appendix D. Refer to Appendix E for examples of Functional Logic Diagrams that can be used as a basis for the standard of information to be provided. The library sheets include symbols and descriptions for the following:

Operator interface

o Refer to library template in Appendix D – “Predefined Functional Logic Library Sheets”, sheet 1

o Refer to example diagram in Appendix E – “Sample format of Functional Logic Diagrams for Analogue Control”, sheets 1 to 4

o Refer to example diagram in Appendix F – “Sample format of Functional Logic Diagrams for Discrete (Digital) Control”, sheets 3 to 7

Basic elementary logic functions


o Refer to example diagram in Appendix F – “Sample format of Functional Logic Diagrams for Discrete (Digital) Control”, namely sheets 1 and 2, and in addition sheets 3 to 7

Basic function blocks

o Refer to library template in Appendix D – “Predefined Functional Logic Library Sheets”, sheets 3 to 7

o Refer to example diagram in Appendix E – “Sample format of Functional Logic Diagrams for Analogue Control”, sheets 3 and 4

Calculation function blocks


o Refer to example diagram in Appendix E – “Sample format of Functional Logic Diagrams for Analogue Control”, sheet 1

Sequence diagram blocks

o Refer to library template in Appendix F – “Predefined Functional Logic Library Sheets”, sheet 16

o Sequences are discussed in detail in Sections 0 below -

Measurement function block


o Refer to example diagram in Appendix E – “Sample format of Functional Logic Diagrams for Analogue Control”, sheet 2

Object oriented templates including:

o PIDCtrl (PID Controller) – PID function block type


o Refer to example diagram in Appendix E – “Sample format of Functional Logic Diagrams for Analogue Control”, sheets 3 and 4

VLV1 (Valve 1) - on-off valve control function block type

o Refer to library template in Appendix F – “Predefined Functional Logic Library Sheets”, sheet 11

o Refer to example diagram in Appendix F – “Sample format of Functional Logic Diagrams for Discrete (Digital) Control”, sheet 3


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MOT1 (Motor 1) - motor control single direction/speed function block type



MOT1_VVVF (Motor Variable Speed Drive) - motor control for frequency converters function block type



MOT2 (Motor 2) - motor control bi-direction/speed function block type



MOTP (Motorised Valve with Position) - motorised valve or damper control function block type



Alternative Specification

Where existing systems exist at Queensland Nickel, the generation of Functional Logic Diagrams may not be required. The DCS or PLC code of existing controllers may be submitted as a substitute. This must be on the basis of the following:

DCS or PLC code system must be a current printout of the existing controller(s)

Date of retrieval of code is to be provided

Assembly language format of code is not acceptable

Structured text format of code is not acceptable

DCS or PLC code is to be submitted for review by both QN Yabulu engineering and the software engineering programming group

There must be agreement between QN Yabulu engineering and software engineering group that code submitted is of suitable standard for software development

A description of library components shall be provided

5.4. Alarms

This section lists alarming requirements for equipment within the scope of the functional description.

5.4.1. Alarming of Analogue Loops

The alarming of Analogue Loops shall be detailed in the Analogue IO listing, Appendix B. A description of the spreadsheet columns has been provided Section 0 5.10.1. Analog I/O Listing.

The Alarm Priorities are detailed in the project standard document “Operation and Control Philosophy”, no. YCPTI02


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The following must be considered when defining alarming of Analogue Loops and I/O:

Wherever a higher level object exists, e.g. PIDCtrl, then the alarming shall be applied to this higher level object (i.e. PIDCtrl is alarmed instead of measured variable I/O point)

The alarming functionality for Analogue Loops and I/O is integrated into the software objects, hence no further configuration is required

To prevent nuisance alarms, alarm masking shall be defined to prevent alarms during conditions when the alarm is deemed unnecessary

5.4.2. Alarming of Digital Loops

The alarming of Discrete (Digital) IO shall be detailed in the Digital IO listing, Appendix C. A description of the spreadsheet columns has been provided Section 0 5.10.2. Discrete (Digital) I/O Listing.

The Alarm Priorities are detailed in the project standard document “Operation and Control Philosophy”, no. YCPTI02

The following must be considered when defining alarming of Digital Loops and I/O:

Wherever a higher-level object exists, e.g. MOT1, then the alarming shall be applied to this higher-level object (i.e. MOT1 is alarmed for motor “Ready” instead of ready signal I/O variable).

The alarming functionality for Digital Loops and I/O is integrated into the software objects; hence no further configuration is required.

To prevent nuisance alarms, alarm masking shall be defined to prevent alarms during conditions when the alarm is deemed unnecessary

5.4.3. Alarming Logic

There may be other requirements for alarming based on specific logic conditions. This logic will require additional definition, and shall be in the form of Object Definition Sheets or Functional Logic Diagrams defined in Section 0 above - 5.3. Analogue Control and Discrete Interlocking Logic.

5.5. Fail Safety

The following fail safety information is required to implement the safety requirements of the plant into the control system. This includes a listing of the fail-safe states, fail safe modes and I/O error handling.

5.5.1. Fail Safe States

This section refers to process equipment fail-safe states that are deemed necessary for safe operation of the plant. Loss of loop signal and air is to be considered.

The fail safe states shall be detailed in the “Fail Safe State” and “Fail Safe State Description” columns of the Analogue and Digital IO spreadsheet listings, Appendix B and C respectively. Refer to the following table for example of data requiring definition in the relevant columns of Appendix B and C:

Equipment Tag Equipment Description Fail Safe State

Description Fail Safe

State

352HIC15101A Inlet Valve No.1 Loss of air / signal Fail Closed

352HIC15102B Inlet Valve No.2 Loss of air / signal Fail Closed

420PIC16005A Dryer Steam Outlet Pressure Loss of air / signal Fail Opened

5.5.2. Fail Safe Modes (on controller restart)

This section refers to process equipment fail safe modes that are deemed necessary for safe operation of the plant when controller restart occurs due to a power failure, software reload etc. This is referred to as the “Restart Mode”.


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The control modes of operation are defined in the project standard document “Operation and Control Philosophy”, no. YCPTI02, in the “Control” section.

The failsafe mode will normally be manual for most loops; however some loops will have alternative requirements.

The fail safe modes shall be detailed in the “Fail Safe Mode (controller restart)” columns of the Analogue and Digital IO spreadsheet listings, Appendix B and C respectively. Refer to the following table for example of data requiring definition in the relevant columns of Appendix B and C:

Equipment Tag Equipment Description Fail Safe Mode

(controller restart)

352HIC15101A Inlet Valve No.1 Auto

352HIC15102B Inlet Valve No.2 Auto

514PIC16121A Dryer Steam Inlet Pressure Manual

514PIC16005A Dryer Steam Outlet Pressure Manual

5.5.3. I/O Error Handling

This section refers to I/O output fail-safe states that are deemed necessary for safe operation of the plant. When the I/O enters this fail-safe state, this is referred to as OSP-control.

OSP-control (Output Set as Predetermined) describes the error handling for outputs, when there is an error in the communication between the I/O device and the controller.

The different types of error handling which can be set for the outputs are as follows:

OSP-control: defines how the output channel operates during OSP-control. There are two possible settings:

o Keep current value: the Output I/O channel maintains the current output value

o Set OSP value: the output I/O channel will be set to the value specified by OSP-value

OSP-value: a pre-defined value for an output I/O channel, when “Set OSP-value” is selected. This will be true / false for digital output channels, and a value set in % of the output range between 0 and 100% for analogue output channels

By default, I/O channels are configured to enter the off or zero state during OSP-control, hence the following default OSP settings:

OSP-control: Set OSP-value

OSP-value: False (for digital output channels), or

0% (for analogue output channels)

The OSP requirements shall be detailed in the “OSP control” and “OSP value” columns of the Analogue and Digital I/O spreadsheet listings, Appendix B and C respectively. Refer to the following table for example of data required:

I/O Tag Description OSP-control (outputs only)

OSP-value (outputs only)

340MC15125A_MSTR Fan Pump Start Set OSP value False

340MC15028A Bleaching Agitator Start Set OSP value False

340HCV33020A Feed Valve Open Set OSP value False

514MC15800A_MSTR Main Steam Pump Start Keep current value n/a

514PIC16121A Dryer Steam Inlet Pressure Set OSP value 0 %

514PIC16005A Dryer Steam Outlet Pressure

Keep current value n/a


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5.6. Scan Times

In general, loops shall be configured in programs with the following scan times:

Flow and Pressure Controls, scan of 500msec

Level Controls, scan of 1000msec

Motors, scan of 500msec

The above scan times shall apply to the majority of loops. Analog and Digital Loops with scan times faster than the above values (or different to) are to be specified in the “Scan Time” column of the Analog and Digital I/O listings. Refer to Appendix B and C respectively. The scan times for individual loops will serve as a guide to software programmers when allocating task intervals to the programs. Scan times considered to be excessively fast by the software programming engineers, may request that these values be assessed and approved by the I&C Group Leader.

5.7. Sequencing

The sequenced automation of equipment operation is described in the proceeding sections, using two possible methods: Sequential Function Chart (SFC) Grafcet, or Sequencing Logic Diagram.

5.7.1. Sequential Function Charts – GRAFSET

A Sequential Function Chart (SFC) is a transition system consisting of steps and transitions. For every SFC there exists exactly one initial step. The sequence permissives will be defined at this initial step. The sequence will not be permitted to start until the permissives are met. Thereafter, the sequence will be permitted to start by operator action or automatically by the application program. The point of control for starting and stopping the sequence will need to be detailed as part of the functional description.

Following the initial step, are a series of steps, and one or more actions will be associated to each step. Every transition is labelled by a corresponding transition condition, which when satisfied, will allow the sequence to carry forward to the next step.

An SFC does not necessarily have to be a single sequence of steps and transitions. SFC’s can be identified by a number of different transition types:

Simple Transitions between two steps

Sequence Selection, i.e., the choice between several transitions

Divergence into Parallel Sequences also known as Simultaneous Sequences, i.e., a parallel branching from one step into a set of parallel steps

Convergence from Parallel Sequences which denotes a synchronization of several parallel steps into a single step

The International Standard (IEC 60848 Ed. 2.0) GRAFCET specification language can be used for the functional description of the behaviour of the sequential part of a control system.

The standard specifies the symbols and the rules for the graphical representation of this language, as well as for interpretation, and has been prepared for automated production systems of industrial applications.

The GRAFCET specification language enables a Grafcet to be created showing the expected behaviour of a given sequential system. The language is characterised mainly by its graphic elements, which, associated with an expression of variables, provides a synthetic representation of the behaviour, based on an indirect description of the situation of the system.


Standard YCPTI03



The specification language GRAFCET is particularly related to the specific programming language SFC (Sequential Function Chart) for IEC 61131-3 that forms the basis of the Industrial IT control system sequences.

IEC 60848 Ed. 2.0 and IEC 61131-3 have each a specific domain of application:

A behaviour specification language GRAFCET is independent of any specific technology of implementation, hence its usefulness for functional descriptions

A specific programming language SFC for IEC 61131-3, allows the user to implement the sequential behaviour of the control program graphically

For reasons of convenience, the behaviour description is based on steps called GRAFCET. In the GRAFCET, several steps may be active simultaneously, the situation being then characterised by the set of active steps at the considered moment. The evolution of one set of steps to another are translated by one or several transitions, each characterised by:

Its preceding steps

Its succeeding steps

Its associated transition condition

5.7.1.1. Graphical Representation of Sequential Structures

The designer can construct Grafcet charts using different distinctive structures, subject to strict application of the syntax rule concerning the step/transition alternation. The structures are diagrammatically and descriptively depicted in the following:

Sequence

A sequence is a succession of steps such that:

Each step, except the last one, has only one succeeding transition

Each step, except the first one, has only one preceding transition enabled by a single step of the sequence.

The sequence is said to be "active" if at least one of its steps is active. The sequence is said to be "inactive" when none of its steps is active.

Sequence may include any number of steps.

Cycle of a single sequence

The case of a looped sequence such that:

Each step has only one succeeding transition,

Each step has only one preceding transition enabled by a single step of the sequence.

A cycle of a single sequence may constitute a partial Grafcet


Standard YCPTI03



Selection of sequences

The selection of sequences shows a choice of evolution between several sequences starting from one or several steps. This structure is represented by as many simultaneously enabled transitions as possible evolutions.

Exclusive activation of a selected sequence is not guaranteed from the structure. The designer should ensure that the timing, logical or mechanical aspects of the transition-conditions are mutually exclusive.

Example 1: The exclusion between the sequences is achieved by the logical exclusion of the two receptivities. If “a” and “b” are simultaneously true when step 5 is active, no transition may be cleared.

Example 2: Priority sequence. In this example, a priority is given to the transition 5/6, which is cleared when “a” is true.

Example 3: Selection of sequences following synchronization of two preceding sequences. The selection of the succeeding sequences, by g and h, is possible only when the two transitions are cleared by the simultaneous activity of the steps 8 and 9.


Standard YCPTI03



Step skip

Particular case of selection of sequences, which allows a complete sequence or one or several steps of the sequence to be skipped, when, for example, the actions associated to these steps become unnecessary.

Backward Sequence Skip

Particular case of selection of sequences, which enables a sequence to be repeated until, for example, an established condition is satisfied.


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Activation of parallel sequences

The synchronisation symbol is used in this structure to indicate the simultaneous activity of several sequences from one or several steps.

After their simultaneous activation, the evolution of the active steps in each of the parallel sequences thus becomes independent

Synchronisation of sequences

The synchronisation symbol 9 is used in this structure to indicate the delay before preceding sequences end before the activation of the succeeding sequence.

The transition is only enabled when all the preceding steps are active.

Synchronisation and activation of parallel sequences

The synchronisation symbol is used twice in this structure to indicate the delay before preceding sequences end before the simultaneous activation of the succeeding sequences.


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Starting of a sequence by a source step

A source step is a step that does not have any preceding transition.

To allow the activation of the source step, at least one of the following conditions, shall be satisfied:

The source step is initial,

The source step is required by a forcing order from a partial Grafcet of the higher level

The source step is one of the activated steps of an enclosure

Example 1: Initial source step:

The initial source step 1 is only active at the initialisation time, the steps 2, 3, and 4 form a cycle of a single sequence.

5.7.1.2. Simplified Representation

When designing functional descriptions using GRAFCET specification language, the full interpretation may or may not be used (i.e. Full set of symbols and notations). This will depend on the design engineer’s knowledge and experience using the language. A more general specification of the sequence is possible, as per example in Figure 3.

Note that initial step is designated Step Index 00, and steps thereafter are incremented in the decades, e.g. 20, 30, 40 etc.

The alternate branch will be denoted with incremental alpha character, e.g. 30a, 30b, 30c etc. wherever alternative branching is present.

5.7.2. Sequence Logic Diagrams

Sequence Logic Diagrams (SLD)’s are another method for describing the functional description of the behaviour of the sequential part of the control system.

The SLD utilises the Sequence Diagram Blocks and the General Functions/Function Blocks found in the Functional Logic Library sheets in Appendix D

Refer to “Appendix H – Sample format of Sequence Logic Diagrams for Sequences” sheets 1 to 6, for examples of Sequence Logic diagrams that can be used as a basis for the standard of information required.


Standard YCPTI03



5.8. Loop Diagrams

Loop diagrams are essential in providing a schematic visualisation of each control loop. The loop diagrams shall be generated by the Bentley I&W Plant Design system, and shall be provided by the QN Yabulu project team.

Loop diagram numbers are to be detailed on the Loop and I/O listings, as per Appendix B, C, D and E, in the “Schematic or Loop Diagram” column.

The diagrams shall detail (but not be limited to):

Functional unit of the loop (e.g. valve, transmitter etc.)

Loop tag name(s)

Field junction terminations

Cable numbers

Cable cores

Address of the I/O module relevant to the control system including the channel number. Refer to project standard document “Control System Software Configuration Standard” no. YCPTI04 for details on addressing of controller modules and channels.

5.9. P&ID’s

P&ID’s are essential in providing a schematic visualisation of the process including the equipment and loops.

The final P&ID’s shall be generated by the Bentley I&W Plant Design system, and shall be provided by the QN Yabulu project team to the programming engineers.

Where Vendor supplied packages are applicable, the Vendor P&ID’s shall be provided to the QN Yabulu project team, who will incorporate the diagrams into the Bentley I&W Plant Design system. The final P&ID’s produced by the Bentley system shall incorporate the Century Tag Numbering to loops as per QN Yabulu standards.

P&ID numbers are to be detailed on the Loop and I/O listings, as per Appendix B, C, D and E, in the “P&ID reference” column. P&ID’s do not need to be attached to the functional description; only the references to the documents are required.

5.10. I/O Listings

Each I/O will be documented in a Microsoft Excel spreadsheet format, along with relevant properties to enable bulk data configuration of the DCS. Separate spreadsheet listing will be provided for Analog and Discrete (Digital) I/O as detailed in the following sections.

Once the spreadsheets are received, the data will be incorporated into the Bentley I&W Plant Design System, giving a central point of information access. The data will then be exported and provided for DCS bulk data configuration.

5.10.1. Analog I/O Listing

Format of the data spreadsheet for Analog I/O Loops are provided in Appendix B. At a minimum, the properties to be included in the columns of the Analog I/O listing are:

Plant Area



Plant Area Name

o Descriptive name of the plant area


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Process Unit

o Descriptive name of the section of the Plant Area, e.g.: Blowers

System Name

o Descriptive name of the system name


Loop Tag

o Unique loop identifier based on the Yabulu Century Tag system. Refer to the project standard document “QN Yabulu Equipment Tagging Standard”, no. YCPTG04 for further details

o For vendor supplied package equipment, a general identifier can be supplied, final identifier shall be provided by QN Yabulu from the Bentley Plant Design system

I/O Tag

o Unique I/O loop identifier based on Yabulu Century Tag system


Description

o Short description of the loop tag (equipment)

I/O Type

o Intrinsically Safe IO to be prefixed with IS. E.g.: IS-AI

o Analog input / output to be specified for normal I/O

Power

o Loop powered when analogue instrument circuit is supplied with power from the control system I/O modules

o Field powered when analogue instrument circuit is supplied from external power source in the field

Low range

o Scaling parameter Range Minimum, in engineering units (e.g. 0kg for minimum input signal 4mA)

High range

o Scaling parameter Range Maximum, in engineering units (e.g. 10kg for maximum input signal 20mA)

Units

o The signal unit in engineering unit (e.g. kg)

o Documents must use SI and metric units

o Refer to project standard document “Control System Software Configuration Standard” no. YCPTI04 for a full list of project approved units and symbols

Dec


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o The number of decimals for measured value and its alarm limits, for set points and their limits, and for Low and High Range

Input Type

o Type of analogue input signal

o For traditional hardwired I/O loops, e.g. 0.20mA, 4..20mA, 0..10V, 2..10V

o Communication protocol is to be detailed for devices communicating to control system via serial or other communication. Mostly this will be Profibus-PA or Profibus-DP/V1

OSP control

o Output set as predetermined

o Will define how the output channel operates during OSP-control. Refer to Section 0 above -

o 5.5.3. I/O Error Handling for further details

OSP-value

o A pre-defined value for an output I/O channel when I/O enters fail-safe state. Refer to Section 0 above -


Processor

o Processor name to be detailed to which the physical I/O will be allocated

o Processor name forms the highest part of an address in locating the I/O point

Bus

o Bus number to be detailed to which the physical I/O will be allocated

o Bus number forms part of an address in locating the I/O point

Station

o Field communication interface (FCI) station number to be detailed to which the physical I/O will be allocated

o Station number forms part of an address in locating the I/O point

Pos

o Module position number to be detailed to which the physical I/O will be allocated

o Module position name forms part of an address in locating the I/O point

Channel

o Channel number to be detailed for the module the I/O will be allocated

o Channel number name forms the lowest part of an address in locating the I/O point

P&ID reference


Schematic or Loop Diagram

o Schematic or loop diagram document reference number. Refer to Section 0 - 5.8. Loop Diagrams for further details.

Control Method

o The BMI Library object type required, e.g.: AIS, AOS, PID, etc.

Fail Safe Mode (on controller restart)

o Defines the safe initialised mode of operation when controller restart occurs due to power failure, software reload etc., refer to Section 0 above -


Standard YCPTI03



o 5.5.2. Fail Safe Modes (on controller restart)for further details

o Will normally be manual for most discrete equipment, however, some discrete equipment will have alternative requirements

Fail Safe State

o Process equipment fail-safe states that are deemed necessary for safe operation of the plant, e.g. Loss of signal and air. Refer to Section 0 above - 5.5.1. Fail Safe States for further details

o Relevant for on-off valves and motorised valves

o Not relevant for motor drives

Fail Safe Description

o Description of condition related to fail safe state above, e.g. Loss of signal / air

Scan Time

o The scan time for individual loops

o Allowable scan times are detailed further in Section 0 above -

o

o

o 5.6. Scan Times

Set point High Limit

o High limit of set point

Set point Low Limit

o Low limit of set point

Output High Limit

High limit of output

Output Low Limit

o Low limit of output

Alarm Hi Lim2

o Alarm Limit High-High of Measured Value

Alarm Hi Lim1

o Alarm Limit High of Measured Value

High Alarm Hysteresis

o High level alarms Measured Value hysteresis

Alarm Lo Lim1

o Alarm Limit Low of Measured Value

Alarm Lo Lim2

o Alarm Limit Low-Low of Measured Value

Low Alarm Hysteresis

o Low level alarms Measured Value hysteresis

Lim 2 Alarm Priority

o Alarm limit treatment Hi Lim 2 / Low Lim 2

o Refer to Section 0 above - 5.4.1. Alarming of Analogue Loops

o -1 = no alarm and event

o 0 = event only

o 1 = Priority 1 - Not Used

o 2 = Priority 2 Warning Alarm


Standard YCPTI03



o 3 = Priority 3 Critical Alarm

Lim 1 Alarm Priority

o Alarm limit treatment Hi Lim 1 / Low Lim 1

o Refer to Section 0 above - 5.4.1. Alarming of Analogue Loops


o 0 = event only

o 1 = Priority 1 – Not Used



MV Alarm Delay

o Alarm delay in seconds

Dev Hi Lim

o Deviation high alarm limit in %

Dev Lo Lim

o Deviation low alarm limit in %

Dev Alarm Delay

o Time delay for deviation alarm limit level supervision

Dev Alarm Priority

o Alarm treatment for deviation limits


o 0 = event only




Comment 1

o Listing of any additional information

Comment 2


Mod. By

o Initials of the individual undertaking the modification to be inserted, refer to Revision details in Section 11

o for further details

Mod. Date

o Modification date, refer to Revision details in Section 11


Standard YCPTI03



REVISION CONTROL for further details

Total Analog Input Count

o Summation of the analogue inputs

Total Analog Output Count

o Summation of the analogue outputs

Total Analog Count

o Summation of the analogue inputs and outputs

5.10.2. Discrete (Digital) I/O Listing

The format of the data spreadsheet for Digital I/O Loops are provided in Appendix C. At a minimum, the properties to be included in the columns of the Digital I/O listing are:

Plant Area


o Plant area is at the highest level of system hierarchy. The breakdown of the system hierarchy is defined in the project standard document “Operation and Control Philosophy” no. YDESTSI02, under the section labelled “System Hierarchy and Level of Automation”

Plant Area Name

o Descriptive name of the plant area

o Plant area is at the highest level of system hierarchy. The breakdown of the system hierarchy is defined in the project standard document “Operation and Control Philosophy” no. YDESTSI02, under the section labelled “System Hierarchy and Level of Automation”

System Name

o Descriptive name of the system name


Loop Tag

o Unique loop identifier based on the Yabulu Century Tag system. Refer to the project standard document “QN Yabulu Equipment Tagging Standard”, no. YCPTG04 for further details


I/O Tag

o Unique I/O loop identifier based on Yabulu Century Tag system


Description

o Short description of the loop tag (equipment)

Normal I/O

o Normal I/O refers to standard I/O which is not classified intrinsically safe

o Digital input / output to be specified for normal I/O

Intrinsically Safe I/O


Standard YCPTI03



o Digital input / output to be specified for intrinsically safe I/O

Normal / Healthy State

o Normal signal value, e.g. low pressure alarm switch is normal / healthy when switch is closed (ON)

Active State

o Opposite to Normal / Healthy State above, e.g. low pressure alarm switch indicates alarm when switch is opened (OFF)

Alarm Priority

o Alarm limit treatment for conditions which cause alarms and trips to equipment

o Refer to Section 0 above - 5.4.2. Alarming of Digital Loops


o 0 = event only




Alarm Delay


OSP control

o Output set as predetermined

o Will define how the output channel operates during OSP-control. Refer to Section 0 above -


OSP-value

o A pre-defined value for an output I/O channel when I/O enters fail-safe state. Refer to Section 0 above -


Processor

o Processor name to be detailed to which the physical I/O will be allocated

o Processor name forms the highest part of an address in locating the I/O point

Bus

o Bus number to be detailed to which the physical I/O will be allocated

o Bus number forms part of an address in locating the I/O point

Station

o Field communication interface (FCI) station number to be detailed to which the physical I/O will be allocated

o Station number forms part of an address in locating the I/O point

Pos

o Module position number to be detailed to which the physical I/O will be allocated

o Module position name forms part of an address in locating the I/O point

Channel

o Channel number to be detailed for the module the I/O will be allocated

o Channel number name forms the lowest part of an address in locating the I/O point

Control Method


Standard YCPTI03



o Type of control strategy:

o MOT1 (Motor 1) - motor control single direction/speed function block type

o MOT2 (Motor 2) - motor control bi-direction/speed function block type

o MOT1_VVVF (Motor Variable Speed Drive) - motor control for frequency converters function block type

o VLV1 (Valve 1) - on-off valve control function block type

o MOTP (Motorised Valve with Position) - motorised valve or damper control function block type

o Other (to be detailed)

Local Mode

o Local control mode permitted for the equipment, refer to project standard document “Operation and Control Philosophy” no. YCPTI02 for further information on control modes

o Interlocks are active in local mode


Test Mode

o Test control mode permitted for the equipment; refer to project standard document “Operation and Control Philosophy” no. YCPTI02 for further information on control modes

o Interlocks are bypassed in test mode


Fail Safe Mode (on controller restart)

o Defines the safe initialised mode of operation when controller restart occurs due to power failure, software reload etc., refer to Section 0 above -

o 5.5.2. Fail Safe Modes (on controller restart)for further details

o Will normally be manual for most discrete equipment, however, some discrete equipment will have alternative requirements

Fail Safe State

o Process equipment fail-safe states that are deemed necessary for safe operation of the plant, e.g. Loss of signal and air. Refer to Section 0 above - 5.5.1. Fail Safe States for further details

o Relevant for on-off valves and motorised valves

o Not relevant for motor drives

Fail Safe Description

o Description of condition related to fail safe state above, e.g. Loss of signal / air

Alarm Priority

o Alarm limit treatment for conditions which cause alarms and trips to equipment

o Refer to Section 0 above - 5.4.2. Alarming of Digital Loops


o 0 = event only




P&ID reference



Standard YCPTI03



Schematic or Loop Diagram

o Schematic or loop diagram document reference number. Refer to Section 0 - 5.8. Loop Diagrams for further details.

Functional Logic Diagram

o Functional logic diagram document reference number

Comment 1


Comment 2


Mod. By

o Initials of the individual undertaking the modification to be inserted, refer to Revision details in for further details

Mod. Date

Modification date, refer to Revision details in Section 11


Standard YCPTI03



REVISION CONTROL for further details

Total Digital Input Count

o Summation of the digital inputs

Total Digital Output Count

o Summation of the digital outputs

Total Digital Count

o Summation of the digital inputs and outputs

5.11. Trending

This section will list trends displays required for analogue and digital tags.

The trending configuration is detailed in the project standard document “Operation and Control Philosophy”, no. YCPTI02. The requirement of this functional description is to define the multipoint trend displays that will be required by Operators and Production Personnel. The three different trend display types are listed here for reference:

Trend Display

o Require application engineers privileges to be modified

o Will be used as preconfigured Trend Displays which cannot be modified by operators

Operator Trend

o Requires operator privileges to be modified

o Operators will have the ability to define and save customised trends to meet their everyday process monitoring requirements

o The Trend Displays will be accessible through page links on the OS graphics pages

Object Trend

o Require software engineer privileges to be modified

o Object trends will be available to every object using the right click context menu

By default, Object Trends will be available to every control loop object and motor loops (i.e. Motor current) using the right click context menu. It is not a requirement to provide trending specifications at an individual object level in the functional description.

The functional description must distinguish between the Trend Display and the Operator Trend. Up to eight trend traces can be defined per Display. Refer to the following table for format of data required for trend display specification:

Trend Display Name: Category:

Trace Number

Trace (Tag) Description Property (E.g.: MV, SP, OUT,

etc)

Trend Display / Operator Trend

1 345-PIC1301C CoNiS Leach Blower Outlet Pressure

MV Trend Display

2 345-PIC1301C CoNiS Leach Blower Outlet Pressure

OUT Trend Display

3 345-TI1301C CoNiS Leach Blower Outlet Temp

MV Trend Display

4 345-PI1301A Service Water Pressure MV Trend Display

5 345-TI1301A Service Water Temp MV Trend Display

6 345-TI801A Blower 1 Stage 1 Discharge Temp

MV Trend Display

7 Not Used

8 Not Used


Standard YCPTI03



The multipoint trends shall be accessed by two methods:

Defined links on the Process Graphic Displays and Trend Menu’s. The graphic layouts and links shall be defined in Section 0 above -

5.2.2. Graphic Display Conceptual Drawings

From the context menu on specified objects

5.12. Reporting

This section will detail reporting requirements.

The reporting mechanisms in the control system shall be shared between the DCS controllers and HMI, as well as the Information Manager Servers (History Servers). The use of the former and latter shall depend on the particular data and format of reporting required.

Typically for configuration, the vendor and / or process engineer shall provide an example of the completed report.

5.12.1. Totalisers

The Totalising Reporting will detail several variables in a tabular format. The vendor shall be required to follow a standard format for specifying totalised data, refer to spreadsheet in Appendix I.

Vendors and Area Process Control Engineers assigned to the project may require additional data. This data can be added to the spreadsheet by additional columns and rows as required.

Group

o Group description for subdividing totalised values on pages

o Example: Calciner Totals, Hydrogen Totals

Process Values (Tags)

o The variables requiring totalising

o If more than one variable, then a calculation shall apply in the Calculation column

Description

o Description of totalised values

Totalised Unit

o Units for totalised values

o Example: a flow in L/min shall be totalised to number of Tonnes

Current Accumulated Shift Total

o Dynamic Shift Total value for the current shift

Previous Shift Total

o Shift totalised value for the last shift

o Based on the current 12 hour shift roster for operations persons

Current Accumulated Day Total

o Dynamic Day Total value for the current day

Previous Day Total

o Day totalised value for the previous day

Current Accumulated Month Total

o Dynamic Month Total value for the current month

Previous Month Total

o Month totalised value for the previous month


Standard YCPTI03



Current Accumulated Year Total

o Dynamic Year Total value for the current year

Previous Year Total

o Year totalised value for the previous year

Calculations

o If more than one variable is to be totalised as specified in the Process Values (Tags) column, then a calculation shall apply

o Example: total flow value is to be totalised (Flow 1 + Flow 2)

o Shall be used to implement calculation in control system

Interlocking Signal

o Signal which inhibits the incremental totalising

o Example: Flow does not need to be totalised when the feed pump is stopped, hence switch a zero value

o Use appropriate tag names of interlocking devices / conditions

Comments


5.12.2. Costing Reports

The Costing Reporting will detail several variables in a tabular format. The vendor and / or process engineers shall be required to follow the format for specifying costing data, refer to spreadsheet in Appendix J.

The format of costing data in Appendix J may consist of additional columns and data if required. The additional data can be added with additional columns and rows as required.

Group

o Group description for subdividing costing values on pages

o Example: Calciner Totals, Hydrogen Totals

Process Values (Tags)

o The variables requiring costing

Description

o Description of totalised values

Budget Process Value and Budget Process Value Unit

o Process Value and Unit which budgeted cost calculation value is based on

o Example: Budgeted Alum chemical flow in 4.44 kg/T, Starch flow in 2.23 kg/T

Budget Cost and Budget Cost Unit

o Final Budget Value and Unit calculated for comparison to Actual Value (see below)

Actual Process Value and Actual Process Value Unit

o Process Value and Unit which actual cost calculation value is based on

o Example: Actual Alum chemical flow in 3.22 kg/T, Starch flow in 1.07 kg/T

Actual Cost and Actual Cost Unit

o Final Actual Value and Unit calculated for comparison to Budgeted Value

Calculations

o Details of calculations required to derive the Actual Process Value and Actual Cost

o Shall be used to implement calculation in the control system


Standard YCPTI03



Interlocking Signal

o Signal which inhibits the cost calculation

o Example: Alum kg/T does not need to b cost calculated when the Alum pump is stopped, hence retain the last value, or switch zero value

o Use appropriate tag names of interlocking devices / conditions

Alarm Priority

o Alarm treatment when actual cost value exceeds budgeted cost value

o Refer to Section 0 above - 5.4. Alarms


o 0 = event only




Alarm Delay


Comments


5.12.3. Other Reports

There may be other reports specific to the system or area of control. These reporting details are to be included in this section, along with samples or drawings of requirements to follow. No specific format is to be followed; the vendor shall decide the format and contents.

The following are examples of but not limited to, other reports:

Quality Specific Data

Managers Report

Grade or Product Reports

Production Rates

5.13. Critical Operation Authentication

This section will list the Critical Operation Authentication requirements, whereby specific objects will be required for explicit authentication before the operation can be performed. Refer to project standard document “Operation and Control Philosophy” no. YCPTI02 for details regarding Critical Operation Authentication.

The functional description must detail the following:

Loop Tag

o Tag id of the process object requiring authentication

Loop description

o Tag description

Re-authentication (RA)

o Re-authentication is required for the object

o Y(es) or N(o) answer

Double-authentication (DA)

o Double-authentication is required for the object

o Y(es) or N(o) answer

Second Approver

o For Double-authentication only


Standard YCPTI03



o Second authenticator, is the user who signs in to guarantee that the correct person performs the operation

Refer to the following table for the format of data required for authentication specification:

Loop Tag Loop Description RA DA

Second Approver (for

Double-authentication)

Reason

450FIC2502A Syngas to H2S Reactor flow

- Y Jo-bloggs Critical to H2S Plant Safety, needs confirmation

450MC15032A Sulphur Makeup Pump No.1 VSD Power Supply Feeder

Y - - Need to certain of operator controlling the drive

6. Reference Documents

This section lists the documents by name and description that have been used in the development of the Functional Description. Types of documents referenced could include the following:

Process Flow Diagrams

P&ID’s

Single Line Diagrams

Equipment Layouts

Logic Sequence Diagrams

User Manuals

Hydraulic Circuits


Standard YCPTI03



15. APPENDIXES AND REFERENCES

Appendix Details

Appendix A Examples of Graphic Display Drawings (sheets 1 to 3)

Appendix B Sample format of Analog I/O Listing

Appendix C Sample format of Discrete (Digital) I/O Listing (sheets 1 to 2)

Appendix D Examples of Functional Logic Library Sheets (Sheets 1 to 16)

Appendix E Sample format of Functional Logic Diagrams for Analogue Control (Sheets 1 to 5)

Appendix F Sample format of Functional Logic Diagrams for Discrete (Digital) Control (Sheets 1 to 5)

Appendix G Sample format of simplified Sequential Function Chart GRAFSET. (Sheets 1 to 2)

Appendix H Sample format of Sequence Logic Diagrams for Sequences (Sheets 1 to 6)

Appendix I Sample format of Totalising Report Spreadsheet

Appendix J Sample format of Costing Report Spreadsheet

Appendix K Examples of Object Definition Sheets (Sheets 1 to 10)

15.1 Technical Standards The following Technical standards shall be read in conjunction with this document.

YENS J000 Site Process Control Strategy and Projects Framework YENS J001 Instrumentation and Control Design Criteria YENS J002 Standards for Instrumentation and Control Supplied with Vendor

Packaged Plant YCPTI01 Safety Instrumented System (SIS) Standard YCPTI02 Operation & Control Philosophy YCPTI04 Control System Software Configuration Standard YCPTI05 Control System Hardware Standard YCPTI06 Fibre Optic Cables and Accessory Equipment YENS J010 Human Machine Interface Standard YCPTI07 Standard for Instrumentation and Control Installations YCPTI08 Preferred Instrumentation & Control Equipment and Suppliers

15.2 Standards Drawings 002-0002-500 Control System Network Topology Overview. 002-0002-540 Area 345 Control System Architecture. 002-0002-541 System 1 Control System Architecture 002-0002-590 Area 514 Control System Architecture.

ycpti03 process control functional description(1)

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