Modernization of the TELEPERM Control Level (OS520) for ... · TELEPERM Control Level (OS520) for Chemical Production Processes Example 11 May 2009 ... (Visual Basic, VB-Script, C)

Informations-, Prozess- und Kommunikations-Systeme GmbH

Modernization of the TELEPERM Control Level (OS520)

for Chemical Production Processes Example

11 May 2009

IPKS GmbH Dresdner Bank Erlangen D-91058 Erlangen D-47051 Duisburg Geschäftsführer: [email protected] Kto.: 554 574 200 Am Weichselgarten 36 Salvatorweg 22 Bernd Kinnen, Hubert Pflug www.ipks.de BLZ: 760 800 40 Tel.: +49 (0) 91 31/6 95 88-0 Tel.: +49 (0) 2 03/4 10 96-60 Amtsgericht Fürth HRB 3079 Fax: +49 (0) 91 31/6 95 88-25 Fax: +49 (0) 2 03/4 10 96 -80 USt.-Idnr.: DE 132 498 074

Example Modernization of the TELEPERM OS520 System

Publisher

IPKS Prozess-Software-Entwicklungs GmbH Am Weichselgarten 36 D - 91058 Erlangen Tel.: +49 (0)9131/69588-0 Fax.: +49 (0)9131/69588-25 Email: [email protected]

Contact person: Mr. Bernd Kinnen

Copyright © 2009 IPKS GmbH

The content of this document is the sole property of IPKS. No part of this publication may be reproduced or distributed in any form or by any means, without the prior written permission of IPKS GmbH. Any person who does any unauthorized act in relation to this publication may be liable to criminal prosecution and civil claims for damages.

Limitation of Liabilities

While every precaution has been taken in the preparation of these specifications, the publisher assumes no responsibility for errors or omissions, or for damages resulting from the use of the information contained herein. Subject to change without notice.

Trademarks

Trademarks or patents generally protect all references to software or hardware used in this document.

© IPKS GmbH 2009. All rights reserved.

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Contents

1 Introduction .................................................................................................................... 5 1.1 Subject of the Example .................................................................................................................. 5

The Starting Point (Current State)....................................................................................... 6 1.2 Process Control Level .................................................................................................................... 6

2 The Tasks ........................................................................................................................ 7 2.1 Objective of the Modernization Project ......................................................................................... 7

3 The Proposed Solution ................................................................................................... 8 3.1 General Objectives......................................................................................................................... 8 3.2 Architecture of the Proposed System............................................................................................. 8 3.3 The "Soft Migration" Concept ....................................................................................................... 9

3.3.1 General................................................................................................................... 9 3.4 New Process Control Technology................................................................................................ 10

3.4.1 Hardware ............................................................................................................. 10 3.4.2 Software................................................................................................................ 10 3.4.3 Operator Control Interface .................................................................................. 11 3.4.4 Representation of the OS Functions..................................................................... 15 3.4.5 Operator Control in Multi-Monitor Mode ........................................................... 15 3.4.6 Messages .............................................................................................................. 16 3.4.7 Reports, Analyses ................................................................................................. 16

3.5 Connection CS 275 ↔ New Process Control System.................................................................. 16 3.6 Installation of the System Devices............................................................................................... 18


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

List of Tables


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1 Introduction

1.1 Subject of the Example This example provides solutions for the future-oriented modernization and expansion of the control level for the plant's production processes. The approach outlined in this example incorporates the existing TELEPERM M/ME system (AS controllers and CS275 automation bus) and the existing SIMATIC S5 control equipment, which remain unchanged. With the connection of the existing equipment to the new visualization system, all I/O assignments and structure data of the legacy system will be preserved and ported to the new platform. Presently the process control level consists of the Siemens TELEPERM OS (Operator Communication Systems). The table lists the subsystems with the components to be modernized and the data to be taken into account:

• Computers of the process control level:

OS Host systems for process control and monitoring (OS525 computers) HP-UX BES Batch X System

• Operator control equipment in the control room:

OS525 terminals

• Process data: Automation level with six AS488 controllers SIMATIC S5 controllers

• Interfaces, bus systems: CS275 automation bus Hardware of the Process Control Level The proprietary hardware components of the process control level (OS525 host systems and terminals) are discontinued by the supplier (Siemens). Future provision of replacement parts cannot be guaranteed as the required hardware components will no longer be available on the market. Also, the use of aging stock parts increases the risk of a plant standstill. Functional Scope of the Process Control System The functional scopes of the plant's OS systems and Batch system meet the current requirements so that these systems are not necessarily in need of replacement. The introduction of a modern visualization system offers the possibility to bring the existing operator control concept in line with today's standards of efficient and ergonomic plant control and open it for future expansion. Operator Control Level I/O equipment such as workstations communicates with the OS systems via bus connections and is distributed over several workplaces. Automation Level The plant's automation level consists of Siemens AS488 controllers connected to the process control level via the CS275 bus, and SIMATIC S5 controllers. The automation level with CS275 bus remains untouched.


The Starting Point (Current State)

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

Figure 1: Current state of the production process control level based on TELEPERM

OS Systems

SSV 104SSV 104 SSV 104SSV 104

Industrial EthernetIndustrial Ethernet

HPHP--UXUXBES BES BatchBatch X X

OS525OS525Terminal 2 Terminal 2

OS525OS525Terminal 3 Terminal 3

OS525OS525Terminal 1Terminal 1

ES500ES500Engineering Station Engineering Station

ASASBedienplatz Bedienplatz

AS AllgemeinAS AllgemeinBATA 0/1BATA 0/1AS488AS488

AS AS AnsatzvorAnsatzvor..BATA 0/2BATA 0/2AS488AS488

AS Linie 1AS Linie 1BATA 0/3BATA 0/3AS488AS488



ProzeßbusProzeßbus CS275 CS275

TELERPERM MTELERPERM M

OS 525OS 525

EG183UEG183U

ET100ET100

ET100ET100

EG183UEG183U

ET100ET100

S5S5--115U115U

S5S5--115U115U

EG183UEG183U

EG183UEG183U

S5S5--115U115U

EG183UEG183U EG183UEG183U

EG183UEG183U S5S5--115U115U EG183UEG183U S5S5--115U115U

ET2ET2

OS 525OS 525

WaageWaage

WaageWaage

Automation Automation conceptconcept

ET100ET100 ET100ET100 ET100ET100

Host 1Host 1 Host 2Host 2

ET100ET100

ET100ET100

ET100ET100

ET 200MET 200M

ET 200MET 200M S5S5--115U115U

SimovertSimovert FUFU


OS525OS525Terminal 4Terminal 4

WaageWaage

SiwarexSiwarex PP SiwarexSiwarex MM

• Two (2) OS525 Host systems as productive systems • One (1) HP-UX Batch x system

CS275 Automation Bus The OS Host systems are connected to a CS275 bus system by means of interface modules. The CS275 bus system is the interface to the automation level which remains unchanged. Automation Level The automation level is based on the Siemens AS488 automation system and SIMATIC S5 control equipment.

I/O Equipment The I/O equipment of the OS Host systems consists of four (4) OS525 video display terminals which communicate with the OS HOST systems via bus connections. Test and Structuring An ES500 Engineering Station with PROGRAF AS and BIPRO is used for the OS/AS system structuring.

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2 The Tasks

2.1 Objective of the Modernization Project The aim of this project is the future-oriented modernization and expansion of the plant's process control level. All structure parameters and I/O allocations of the 'old' system shall be safely and consistently ported to the new system to avoid the high error rate and considerable engineering expenditure that would be involved in reprogramming or entering the information from scratch. The core of the project is the systematic reengineering of the process and operator control level and the data and systems involved on the basis of new nonproprietary hardware and modern operating systems on the one hand, and the connection of the existing automation concept to the new visualization system on the other hand. The conversion and reorganization work is conducted without having to interrupt the running operation of the plant.

Proprietary components of the "old" system

The starting point: Block control with TELEPERM M/ME

Proprietary graphic display screens and video terminals located in the block control room

Siemens computers running the OS 525 process control systems

CS275 automation bus

ASxxx automation equipment

Sustainable re-engineering based on open standard technologies Standard Windows workstations for operator control in the block control room.

Redundant commercial off-the-shelf servers with Windows operating system, SQL database and modern SCADA system.

TCP/IP-LAN network ensures open system architecture.

'Transparent' gateway black box handles the CS 275 <->TCP/IP message transmission. No programming required!

The automation level with Asxxx controllers, CS275 bus and all wiring remains untouched.

Modernized system based on open standard technologies

Migration concept

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3 The Proposed Solution

3.1 General Objectives The proposed modernization of the existing systems is guided by the following targets and requirements: • The proposed solution is based on state-of-the-art technologies and recognized

standards, both operator control and automation level are future-oriented and open for further development and expansion.

• The proposed solution is based on nonproprietary concepts both for the process control system and the employed hardware components.

• The proposed solution is scalable and can be easily adapted to future expansion of the quantity structure.

• The proposed solution can be adapted to changed requirements, such as modifications to the structure and operational mode of the overall system.

• The proposed solution is based on open interfaces: - Open interfaces to the automation level with OPC (OLE for Process Control) - Open interfaces for programming tasks (Visual Basic, VB-Script, C) - Open interfaces for data management tasks (SQL, ODBC) - Open interfaces for data archiving and data backup

• Both the computer system and the security system concept with its high degree of availability are future-proof, easy to maintain and based on nonproprietary standard hardware and software components.

• The operator control concept is future-proof, easy to maintain and independent of modifications to the network structure (Intranet) or operator terminal designs.

• The proposed solution allows the integration of the process control system in companywide applications and the company's information technology.

3.2 Architecture of the Proposed System The system architecture shown in the figure below meets the specified criteria.

The existing automation system with the CS 275 automation bus remains unchanged. Gateways connect the automation system to the TCP/IP network - opening the system to new standards in computer and process control technology.


Figure 2: Proposed system with Windows computers

The OS525 Host systems will be replaced by a redundant WinCC Server system. The OS525 Terminals are replaced by WinCC Client PCs.

The functions of the Batch x system are implemented in the WinCC Server system. A separate Client PC is used for operating the new batch functions.

3.3 The "Soft Migration" Concept

3.3.1 General

As the existing automation system with its structure data and the CS 275 automation bus shall continue to run unaffected by the modernization process, we recommend our method of "soft migration": the 'old' system continues to operate without interruption while it is being replaced step by step by the new SCADA system In order to preserve and secure the structure data of the existing OS systems and avoid reprogramming or entering the information from scratch, the 'old' system shall be safely and consistently ported to the new system. All structure information and I/O addressing of measuring values, analog and binary values, arithmetic values, etc., is migrated from the old systems to Windows files. New process graphics are created for the new process control scheme, but there will be no need for a reconfiguration of the basic "wiring".

This also applies to the existing batch and recipe data. The UNIX / ORACLE system migrates all recipes to the new batch system.

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3.4 New Process Control Technology

3.4.1 Hardware

All discontinued hardware components of the process control level are replaced by commercial off-the-shelf hardware based on standard operating systems.

This applies to the following components:

OS systems • Replacement of the computer hardware old: 2x OS525 Host systems new: redundant WinCC Server (2x Windows Server)

• Replacement of the operator stations old: 4x OS525 Terminals new: 4x WinCC Client (4x Windows computer)

Batch X systems • Replacement of the computer hardware old: HP-UX new: no longer used, will be integrated in the WinCC Server

• Replacement of the operator station new: additional WinCC Client computer

A new process control system based on WinCC is installed in parallel to the existing OS systems.

The new process control system consists of highly available WinCC server systems (2x Windows Server) in a redundant arrangement.

The time synchronization of the new systems (WinCC servers, terminal computers) is based on a LAN network and an NTP Time Server with integrated highly accurate DCF-77 radio clock.

The system is operated by means of three (3) terminal computers which communicate with the WinCC master computers over the LAN.

An additional terminal computer is used for recipe management and control.

Using a MultiVGA card it is possible to connect up to two (2) modern TFT screens to one terminal computer. The process diagrams on the terminal computer's video screens are operated with mouse device and keyboard. The connection of a large screen projection is possible.

The two servers and the terminal computers communicate with each other over a redundant local fiber optic LAN (control room LAN).

It is possible to connect network printers to the control room LAN with the terminal computers.

All systems are designed to allow expansion of both the hardware components (processor performance, storage capacity, ....) and the software components (quantity structure, Web functions, ....).

3.4.2 Software

The new process control and visualization concept is based on the SCADA system WinCC.

WinCC offers the benefits that fit your specific needs:

Process control and visualization based on latest technology Not a proprietary system restricted to specific industries


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Established SCADA system for control rooms and centers in many industries, including power stations

Future-proof system, well-established on the market Open for other bus systems, such as Profibus, field bus, etc. and automation systems

(e.g., Siemens, ABB, OPC interface)

PM Control is used as the new system for batch / recipe management and control.

3.4.3 Operator Control Interface

The existing operator control concept will be reproduced with the WinCC process control software and further enhanced according to customer specifications.

The process control concept is based on the templates created in close cooperation with the customer and the existing R&I scheme. The actual number of process screens to be created will be determined in the feasibility study.

The present systems comprise the following:

• 4 lines with the following scope - 10 overview screens - 10 detail screens - 10 general screens - 10 curve group screens - 1 Alarm + Nora

• 1 AS Preparation with the following scope: - 10 overview screens - 10 detail screens - 10 general screens - 10 curve group screens - 1 Alarm + Nora

• 1 AS General with the following scope: - 10 overview screens - 10 detail screens - 10 general screens - 10 curve group screens - 1 Alarm + Nora

• 20,000 data point approx.

The figures below show examples of plant diagrams created for similar modernization projects in power plants and waste-fueled power stations. The implemented structure and control concept can in principle also be applied to the control of production processes.


Figure 3: Plant overview, visualization example

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Figure 4: Boiler overview diagram, visualization example

Figure 5: Section of the available "NOBIs", visualization example

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Figure 6: Step sequence diagram, visualization example

Figure 7: Curve diagram, visualization example

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Figure 8: Signaling diagram, visualization example

3.4.4 Representation of the OS Functions

OS functionality is determined by the existing OS systems and will be implemented in the new process control and monitoring system. Existing parameters will be migrated to the new system whenever possible.

3.4.5 Operator Control in Multi-Monitor Mode

The four WinCC workstations in the control room are equipped with one (1) video screen each (up to two video screens can be connected to each workstation). The plant diagrams can be moved across these screens and operated with one mouse device and keyboard.

Figure 9: Operator control in multi-monitor mode, visualization example

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3.4.6 Messages

Process messages and local events are recorded by the process control and monitoring system and stored in the standard WinCC message archives. The message parameters from the existing systems are migrated to the new system whenever possible. Layout and colors of the message lines will be determined in cooperation with the customer.

An example from a similar modernization project in a power plant is shown below. Here the messages are divided into alarms, warnings, states and system errors.

Figure 10: Message sequence representation, visualization example

3.4.7 Reports, Analyses

Reports and analyses are created in Excel table format for further processing.

3.5 Connection CS 275 ↔ New Process Control System The existing CS275 bus is the interface to the automation level. On the automation level, the AS488E automation devices are connected to the CS275 bus system. In the proposed system, the structure information of the AS488E automation devices is not directly connected to the superposed process control system. The existing AS488 devices are connected to the new process control system by means of gateways. These gateways have the following tasks: Conversion of the communication interface The CS275 bus is a proprietary bus system for TELEPERM M/ME systems. The CS275 gateway communicates with the CS275 bus over a local bus connection and converts the CS275 data traffic to the TCP/IP transmission standard. The CS275 automation level is thus furnished with an open, standard communication interface. Due to the use of a gateway the process data are now available on a standard communication medium (TCP/IP). User-specific control and visualization requirements can be more easily implemented. Conversion of the data and access structures The data and access structures of the AS488E automation devices are adapted to the proprietary TELEPERM M/ME process control system. The CS275 gateway converts the data and access structures of the AS488E automation devices to a general data and access structure. In the new superposed process control system, the AS488E specifications are no longer visible. The existing AS488E control systems are configured just like new standard automation devices. The figure below illustrates how the CS275 gateways are integrated in the communication structure of the process control system WinCC. The process control system communicates with the AS488E automation devices in the same way as with SIMATIC control systems or other automation systems connected via OPC.

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Figure 11: Functions of the gateways in the communication structure

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3.6 Installation of the System Devices The system devices are assembled and installed as shown below.

Devices installed in the computer room:

• Two WinCC servers

• Two gateways

• Console with KVM for the operation of the servers and gateways

• Two fiber optic switches

• One NTP Time Server with integrated highly accurate DCF-77 radio clock

Devices installed in the control room:

• Five Windows terminal computers (4x WinCC Client, 1x Batch)

• Two fiber optic switches

Figure 12: Installation of the system devices

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Notes:

Documents

Modernization of the TELEPERM Control Level (OS520) for ... · TELEPERM Control Level (OS520) for Chemical Production Processes Example 11 May 2009 ... (Visual Basic, VB-Script, C)