OV 141113 FDS JR Comments - Revision - 1

FUNCTIONAL DESIGN SPECIFICATION
Ref # : OV-141113-FDS
Rev # : A
Date : 12-Feb-2015
Project Title : Expansion of Modicon PCS and ESD PLC

for MOL Bijel 1
Customer : OilServ
End User : MOL-Iraq
INTECH Process Automation Inc.

4903 W Sam Houston Parkway N, Suite A100, Houston, Texas 77041, USA
Tel: +1 713 849 1000 Fax: +1 713 856 0785
Email: info@intechww.com URL: www.intechww.com
Project Title
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provide Project Title, here>
Customer
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provide Customer Name, here>
End User
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provide End Use Name, here>
Project Title : Expansion of PCS and ESD PLC for MOL Bijel 1
INTECH Project Code : OV-141113
Customer : OilServ
Customer Project # : 714002
End User : MOL-Iraq
End User Project # :
Ref # : OV-141113-FDS
Rev # : A
Date : 12-02-2015
REVISION HISTORY
Rev #
12-Feb-2015
Date
Issued For Approval
Description
HS
JR
BF
WRT
By
RVW
By
APP
By
INTECH
FRM # : OPS-WI-06-FD (15)

Issue # : 01
Date of Issue: 30-Jan-2014
APP
By
CUST
APP
By
END
USER
Comments
Page 2 of 56
Customer : OilServ
End User : MOL-Iraq
Ref # : OV-141113-FDS
Rev # : A
Date : 12-02-2015
NOTICES, COPYRIGHTS AND TRADEMARKS

Electronic controlled copy is available to all corresponding, on the corporate intranet with secure
access controls and respective rights. This Document contains proprietary information of INTECH
Process Automation.
Information contained herein is for the sole use of the customer receiving this document. Acceptance of
the document by the customer constitutes agreement by the customer that they shall not disclose
proprietary information by INTECH Process Automation to any third party and shall not transmit any
documents or copies thereof containing proprietary information of INTECH Process Automation to any
third party except as may by authorized in writing by INTECH Process Automation.
No part of this document may be used, translated into another language, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or
otherwise, without the prior written consent of INTECH Process Automation.
While every effort has been made to ensure the accuracy of this document, INTECH Process
Automation assumes no responsibility for omissions and errors. Neither is any liability assumed for
damages resulting from the use of information contained herein.
Questions or comment regarding this document or the product to which it relates should be directed to:
INTECH Process Automation Inc.
4903 W Sam Houston Parkway N, Suite A100
Houston, Texas 77041, USA
Tel: +1 713 849 1000
Fax: +1 713 856 0785
Email: info@intechww.com
URL: www.intechww.com
INTECH, TAP and FPM are registered logotypes and trademarks of INTECH Process Automation.
Copyright 2004 INTECH Process Automation Inc. All Rights Reserved.
All other logotypes, trademarks, brands and product names in this document are acknowledged as
properties of their respective companies/owners.

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Ref # : OV-141113-FDS
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Date : 12-02-2015
TABLE OF CONTENTS
1.
INTRODUCTION................................................................................................8
1.1.
1.2.
1.3.
1.4.
2.
SCOPE OF WORK..........................................................................................12
2.1.
2.2.
3.
HARDWARE SCOPE OF SUPPLY......................................................................................... 12

SOFTWARE SCOPE OF SUPPLY..........................................................................................13
HMI SOFTWARE DESIGN..............................................................................14

3.1.
3.2.
3.3.
4.
INTRODUCTION..................................................................................................................... 14
SOFTWARE VERSION........................................................................................................... 14
HMI SYSTEM CONFIGURATION........................................................................................... 14
OPERATOR INTERACTION...........................................................................15
4.1.
4.2.
5.
HMI SCREENS LIST............................................................................................................... 15

4.1.1.
HMI SCREEN.......................................................................................................... 16
4.1.1.1. OVERVIEW_3.............................................................................................. 16
4.1.1.2. OVERVIEW_4.............................................................................................. 17
ALARM SUMMARY................................................................................................................. 18
PLC SOFTWARE DESIGN GUIDELINES.......................................................19

5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
6.
INTRODUCTION..................................................................................................................... 19
SOFTWARE ENVIRONMENT SETTINGS..............................................................................19
APPLICATION STRUCTURE.................................................................................................. 20
5.3.1.
PROCESS PLC APPLICATION STRUCTURE........................................................20
5.3.2.
ESD PLC APPLICATION STRUCTURE..................................................................21
REMOTE IO HARDWARE CONFIGURAION..........................................................................22
5.4.1.
PROCESS PLC....................................................................................................... 22
5.4.2.
ESD PLC................................................................................................................. 23
5.4.3.
MAST (MASTER TASKS)........................................................................................24
5.4.4.
SECTIONS.............................................................................................................. 24
PLC OBJECT FUNCTIONALITY.............................................................................................26
5.5.1.
INTRODUCTION..................................................................................................... 26
5.5.2.
ANALOG INPUT SCALING BLOCK........................................................................26
5.5.3.
PID CONTROLLER BLOCK....................................................................................28
5.5.4.
PUMP OBJECT....................................................................................................... 30
CONTROLLER TAGS............................................................................................................. 30
5.6.1.
PROCESS PLC....................................................................................................... 30
5.6.2.
ESD PLC................................................................................................................. 30
HMI OBJECT FUNCTIONALITY.....................................................................31

6.1.
6.2.
7.
INTRODUCTION..................................................................................................................... 31
OBJECT TYPES...................................................................................................................... 31
ANALOG INPUT..............................................................................................32
7.1.
7.2.
8.
SCOPE OF DOCUMENT.......................................................................................................... 8
REFERENCE DOCUMENTS.................................................................................................... 9
ACRONYM USED IN THIS DOCUMENT................................................................................10
SYSTEM ARCHITECTURE..................................................................................................... 11
OBJECT OVERVIEW.............................................................................................................. 32
VARIABLE NAMING NOMENCLATURE.................................................................................32
PID CONTROL VALVE....................................................................................34

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8.1.
8.2.
8.3.
8.4.
9.
Date : 12-02-2015
PID OBJECT OVERVIEW....................................................................................................... 34

GRAPHICAL REPRESENTATION........................................................................................... 34
CONTROLLER IO & VARIABLE NOMENCLATURE...............................................................35
PCV ANIMATION DETAILS..................................................................................................... 35
DISCRETE INPUT...........................................................................................36
9.1.
9.2.
9.3.
9.4.
10.
OBJECT OVERVIEW.............................................................................................................. 36
CONTROLLER I/O & VARIABLE NOMENCLATURE..............................................................36
ANIMATION DETAILS............................................................................................................. 37
PUMP WITH COMMAND AND FEEDBACK...................................................38
10.1. PUMP P-170A/B OBJECT OVERVIEW................................................................................38

10.2. ANIMATION DETAILS............................................................................................................. 38
11.
11.1.
11.2.
11.3.
11.4.
11.5.
1.
SHUTDOWN VALVE OBJECT........................................................................40

OBJECT OVERVIEW.............................................................................................................. 40
IMPLEMENTATION TABLE..................................................................................................... 40
DETAILED SPECIFICATIONS.................................................................................................42
INTRODUCTION................................................................................................8
1.1.
1.2.
1.3.
1.4.
2.
SCOPE OF WORK..........................................................................................12
2.1.
2.2.
3.
HARDWARE SCOPE OF SUPPLY......................................................................................... 12

SOFTWARE SCOPE OF SUPPLY..........................................................................................13
HMI SOFTWARE DESIGN..............................................................................14

3.1.
3.2.
3.3.
4.
INTRODUCTION..................................................................................................................... 14
SOFTWARE VERSION........................................................................................................... 14
HMI SYSTEM CONFIGURATION........................................................................................... 14
4.1.
4.2.
5.
HMI SCREENS LIST............................................................................................................... 15

4.1.1.
HMI SCREEN.......................................................................................................... 16
4.1.1.1. OVERVIEW_3.............................................................................................. 16
4.1.1.2. OVERVIEW_4.............................................................................................. 17
ALARM SUMMARY................................................................................................................. 18

5.1.
5.2.
5.3.
5.4.
5.5.
INTRODUCTION..................................................................................................................... 19
APPLICATION STRUCTURE.................................................................................................. 20
5.3.1.
PROCESS PLC APPLICATION STRUCTURE........................................................20
5.3.2.
ESD PLC APPLICATION STRUCTURE..................................................................21
REMOTE IO HARDWARE CONFIGURAION..........................................................................22
5.4.1.
PROCESS PLC....................................................................................................... 22
5.4.2.
ESD PLC................................................................................................................. 23
5.4.3.
MAST (MASTER TASKS)........................................................................................24
5.4.4.
SECTIONS.............................................................................................................. 24
PLC OBJECT FUNCTIONALITY.............................................................................................26

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5.6.
6.
Date : 12-02-2015
5.5.1.
INTRODUCTION..................................................................................................... 26
5.5.2.
ANALOG INPUT SCALING BLOCK........................................................................26
5.5.3.
PID CONTROLLER BLOCK....................................................................................28
CONTROLLER TAGS............................................................................................................. 30
5.6.1.
PROCESS PLC....................................................................................................... 30
5.6.2.
ESD PLC................................................................................................................. 30

6.1.
6.2.
7.
INTRODUCTION..................................................................................................................... 31
OBJECT TYPES...................................................................................................................... 31
ANALOG INPUT..............................................................................................32
7.1.
7.2.
8.
oBJECT OVERVIEW............................................................................................................... 32
VARIABLE NAMING NOMENCLATURE.................................................................................32

8.1.
8.2.
8.3.
8.4.
9.
pid - OBJECT OVERVIEW...................................................................................................... 34

CONTROLLER IO & VARIABLE NOMENCLATURE...............................................................35
PCV ANIMATION DETAILS..................................................................................................... 35
DISCRETE INPUT...........................................................................................36
9.1.
9.2.
9.3.
9.4.
10.
OBJECT OVERVIEW.............................................................................................................. 36
CONTROLLER I/O & VARIABLE NOMENCLATURE..............................................................36
10.1. PUMP P-170A/B OBJECT OVERVIEW................................................................................38

10.2. ANIMATION DETAILS............................................................................................................. 38
11.
11.1.
11.2.
11.3.
11.4.
11.5.
1.
DISCRETE OUTPUT OBJECTS.....................................................................40

s OBJECT OVERVIEW........................................................................................................... 40
IMPLEMENTATION TABLE..................................................................................................... 40
DETAILED SPECIFICATIONS.................................................................................................42
INTRODUCTION................................................................................................8
1.1.
1.2.
1.3.
1.4.
2.
SCOPE OF WORK..........................................................................................12
2.1.
2.2.
3.
HARDWARE SCOPE OF SUPPLY.........................................................................................12

SOFTWARE SCOPE OF SUPPLY.......................................................................................... 12
HMI SOFTWARE DESIGN GUIDELINES.......................................................13

3.1.
3.2.
3.3.
4.
INTRODUCTION..................................................................................................................... 13
HMI SYSTEM CONFIGURATION...........................................................................................13
4.1.
HMI SCREENS LIST............................................................................................................... 14

4.1.1.
HMI SCREEN.......................................................................................................... 14
4.1.1.1. OVERVIEW_3.............................................................................................. 15
4.1.1.2. OVERVIEW_4.............................................................................................. 16

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4.2.
5.
Date : 12-02-2015
ALARM SUMMARY................................................................................................................ 16

5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
6.
INTRODUCTION..................................................................................................................... 17
APPLICATION STRUCTURE.................................................................................................18
5.3.1.
PROCESS PLC APPLICATION STRUCTURE.......................................................18
5.3.2.
ESD PLC APPLICATION STRUCTURE.................................................................19
HARDWARE CONFIGURAION.............................................................................................. 20
5.4.1.
PROCESS PLC...................................................................................................... 20
5.4.2.
ESD PLC................................................................................................................. 21
5.4.3.
MAST (MASTER TASKS).......................................................................................22
5.4.4.
SECTIONS.............................................................................................................. 22
PLC OBJECT FUNCTIONALITY............................................................................................23
5.5.1.
INTRODUCTION..................................................................................................... 23
5.5.2.
ANALOG INPUT SCALING BLOCK......................................................................23
5.5.3.
PID CONTROLLER BLOCK...................................................................................25
CONTROLLER TAGS............................................................................................................. 27
5.6.1.
PROCESS PLC...................................................................................................... 27
5.6.2.
ESD PLC................................................................................................................. 27

6.1.
6.2.
7.
INTRODUCTION..................................................................................................................... 28
OBJECT TYPES..................................................................................................................... 28
ANALOG INPUT..............................................................................................29
7.1.
7.2.
7.3.
8.
FIT-0013 OBJECT OVERVIEW..............................................................................................29

VARIABLE NAMING NOMENCLATURE................................................................................29
ALARM MANAGEMENT CYCLE...........................................................................................30

8.1.
8.2.
8.3.
8.4.
9.
PIT-0010 - OBJECT OVERVIEW............................................................................................31

GRAPHICAL REPRESENTATION..........................................................................................31
CONTROLLER IO & VARIABLE NOMENCLATURE..............................................................32
ANIMATION DETAILS............................................................................................................ 32
DISCRETE INPUT...........................................................................................33
9.1.
9.2.
9.3.
9.4.
10.
OBJECT OVERVIEW.............................................................................................................. 33
CONTROLLER I/O & VARIABLE NOMENCLATURE.............................................................33
10.1. PUMP P-170A/B OBJECT OVERVIEW...............................................................................35

10.2. ANIMATION DETAILS............................................................................................................ 35
11.
11.1.
11.2.
11.3.
11.4.
11.5.
DISCRETE OUTPUT OBJECTS.....................................................................37

ESD-9002 OBJECT OVERVIEW............................................................................................ 37
IMPLEMENTATION TABLE.................................................................................................... 37
DETAILED SPECIFICATIONS................................................................................................39

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LIST OF FIGURES
Figure 1: System Architecture................................................................................................................ 11
Figure 2: Overview_3 Screen................................................................................................................ 16
Figure 4: Alarm Summary Screen.......................................................................................................... 18
Figure 5: Process PLC Application Structure.........................................................................................20
Figure 6: ESD PLC Application Structure............................................................................................... 21
Figure 7: Process PLC Expansion Rack................................................................................................22
Figure 8: ESD PLC Expansion Rack...................................................................................................... 23
Figure 9: Process PLC Sections Structure............................................................................................. 24
Figure 10: ESD PLC Sections Structure................................................................................................ 25
Figure 11: AI Scaling Formula................................................................................................................ 26
Figure 12: AI Scaling Block.................................................................................................................... 26
Figure 13: PID Control Block................................................................................................................. 28
Figure 14: Controller Tag Name ............................................................................................................ 32
Figure 15: Graphical representation(s) of analog Object.......................................................................32
Figure 16: Graphical Representation of PIT-0010 Controlling PID.........................................................34
Figure 17: Controller Tag Name............................................................................................................. 35
Figure 18: Graphical Representation of DI_01.......................................................................................36
Figure 20: ESD/SDV Object (Typical).................................................................................................... 40
Figure 9: ESD PLC Sections Structure.................................................................................................. 25
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Figure 9: ESD PLC Sections Structure.................................................................................................. 23

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LIST OF TABLES
Table 1: Reference Documents................................................................................................................ 9
Table 2: Acronym List............................................................................................................................. 10
Table 3: HMI Software Environment Settings......................................................................................... 14
Table 4: HMI System Configuration....................................................................................................... 14
Table 5: HMI Screen List........................................................................................................................ 15
Table 6: PLC Software Environment Settings........................................................................................19
Table 7: Process IO Rack Hardware Configuration................................................................................22
Table 9: AI Scaling Block IO Elements................................................................................................... 27
Table 10: PID Control Block Intput Element...........................................................................................29
Table 11: PID Control Block Output Element......................................................................................... 29
Table 12: Process Controller Tags......................................................................................................... 30
Table 13: ESD Controller Tags............................................................................................................... 30
Table 14: HMI Object details.................................................................................................................. 31
Table 15: Variable Naming Nomenclature..............................................................................................32
Table 16: I/O Variable Name.................................................................................................................. 35
Table 17: Animation Details for Object PIT-0010....................................................................................35
Table 19: Pump P-170A States Indications............................................................................................ 39
Table 20: ESD/SDV implementation table..............................................................................................40
Table 21: SDV States Indications........................................................................................................... 41
Table 22: SDV/BDV Object Detailed Specification.................................................................................42
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Ref # : OV-141113-FDS
Rev # : A
1.
Date : 12-02-2015
INTRODUCTION
Current Beijell-1 facility is equipped with Schneider Electric M340 PLC as Process Control PLC and
Quantum PLC as safety Control PLC. An expansion in system is required due to addition of new
Instruments in the field, toC.To aAccommodate new addition of instruments it is required to add new IO
racks for both PCS and Safety PLC systems because there is no more space for new IOs in existing
PLC racks.
facility an expansion IO rack has to be installed that shall communicate with existing system.
Keeping in view the space limitations at control room INTECH is providing a combined enclosure* for
both PCS and safety PLCs. In addition of the enclosure INTECH will be providing a EWS and an OWS
station also which will provide monitoring and control of system.
INTECH is also responsible of integration of following 3 rd party systems with SCADA system:
VRU PLC
Nitrogen Generator PLC
Generator Control System
Loading Controller Station
2. SCOPE OF DOCUMENT
This document details the minimum hardware and software requirements for the design, procurement,
implementation, documentation and testing of the PLC/HMI based system for expansion of Modicon
ESD Safety and PCS system for MOL Bijel1.
.It will be used as a basis for the development and implementation work.
. It covers the following aspects:
System Aarchitecture
PCS and ESD Logic Ddesign Ddetails
HMI Screen List
HMI Object Ffunctionality
HMI Screen lList
Note: Combined Enclosure in this document will refer to INTECH provided control panel cabinet.

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3. REFERENCE DOCUMENTS
Sr.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Reference Documents
Revision
Document Number
Bijell-1B EWT Facility Upgrade Functional

Requirements
Flowline ESD Skid P&ID
00
64-16-02-1200
Slug Catcher V-100 P&ID
00
64-16-02-1201
Basket Strainers ST-100A/B P&ID
00
64-16-02-1201A
Flare Knockout Drum V-170 P&ID
00
64-16-02-1202
Flare Knockout Drum Recycle Pumps P-170A/B

P&ID
00
64-16-02-1203
HP Flare Stack FS-810 P&ID
00
64-16-02-1204
Instrument Index with IO List
02
0714002-3650-001
ESD IO Wiring
00
OV-141113-ESD-IO
PCS IO Wiring
00
OV-141113-PCS-IO
General Assembly Drawings
00
OV-141113-GA
AC and DC Power Distribution
00
OV-141113-PD
Control philosphy
00
0714002-3620-003
System Architecture
OV-141113-SAR-001
Table 1: Reference Documents

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4. ACRONYM USED IN THIS DOCUMENT

Acronym
Word/Phrase Represented by Acronym
AI
Analog Input
AO
Analog Output
DI
Digital Input
DO
Digital Output
BOM
Bill of Materials
FAT
Factory Acceptance Test
FT
Factory Talk
HH
High High
HMI
Human Machine Interface
I/O
Input / Output
LP
Low Pressure
MCC
Motor Control Center
PCS
Process Control System
PID
Proportional Integral Derivative
PLC
Programmable Logic Controller
PV
Process Value
SDV
Shutdown Valve
SP
Set point
Table 2: Acronym List

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5. SYSTEM ARCHITECTURE

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Figure 1: System Architecture

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6.
Date : 12-02-2015
SCOPE OF WORK
The scope of work can be divided in two main areas:
Hardware scope of supply
Software scope of supply
7. HARDWARE SCOPE OF SUPPLY

INTECH is providing a combined enclosure for both PCS and Safety systems due to space constraints.
PLC racks in INTECH provided control panel cabinet dont include any PLC controller but only IO
Cards and rack expansion modules.
Hardware Scope of supply can be divided as follow:
Combined Enclosure for PCS and Safety Remote IO Racks
Remote IO Drop Module for Quantum PLC (will be installed on existing Quantum PLC rack)
Rack Expansion module for M340 PLC (will be installed on existing M340 PLC rack)
Protocol Converters
o
CAN to Modbus RTU for Generator Control System (will be installed in Generator
Control System Cabinet)
Modbus RTU to Modbus TCP the 3 rd Party systems (will be installed in combined
enclosure)
Engineering and Operator Workstations
UPS to provide backup power to workstations
Armored Communication Cable for Serial communication of 3rd Party systems

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INTECTH is supposed to supply remote IO racks for newly created facility for MOL Iraq.IO racks shall
contain Schneider M340 and Quantum IO cards to accommodate newly created IOs.Intech is also
supposed to provide platform for third party communications with new facility.
8. SOFTWARE SCOPE OF SUPPLY

The software scope of supply includes the design, PLC hardware configuration, PLC and HMI software
implementation, integration and testing.
These modifications will include addition of new instruments logic and hardware configuration of
remote IO racks to existing PLC applications for both Safety and PCS controllers. INTECH will only be
performing addition of new logic; previous logic will not be modified or changed
Since PLC application was previously developed in modular routine where multiple routines were
created, INTECH will be following the same application structure to add necessary PLC logic. INTECH
will perform PLC application additions in new routines which will have no impact on previous logic.
The software scope of supply includes the design, PLC hardware configuration, PLC and HMI software
implementation, integration and testing. SSoftware design can be divided in three main areas:
1. HMI Software Design

o
List of HMI Screens added to existing Application
Existing HMI Software Environment
Existing HMI System Configuration Guidelines
Software Environment Settings

HMI System Configuration
Screen List
2. PLC Software Design Guidelines

o
Existing PLC Software Environment
Existing PLC Application Structure
Addition of new IO Modules to the H/W configuration of Existing Applications
Software Environment Settings.
Application Structure.
Addition of new routines in existing Application
Controller Tags
3. HMI Object Functionality

o

Issue # : 01
Detailed functionality of each HMI Object used in new HMI screens as per existing HMI
Application
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PLC Object Functionality

o

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Detailed functionality of each PLC Object used in new PLC logic as per existing PLC
Application
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9.
Date : 12-02-2015
HMI SOFTWARE DESIGN GUIDELINES
10. INTRODUCTION
The HMI provides a monitoring and control window for both the Safety and Process systems. It will
enable the operator to view the data being gathered by the PLCs and provide limited control. of the
process. This section of the document defines the operational requirement and design basis followed
as per existing application. for the project.
11. SOFTWARE ENVIRONMENT VERSIONSETTINGS

HMI Development Software Name & Version
Vijeo Citect Scada
Firmware Version
7.3
Table 3: HMI Software Environment Settings
12. HMI SYSTEM CONFIGURATION

Resolution
640 x 480
800 x 600
1024 x 768
1280 x 1024
1600 x 1200
Others _____________
Font Size
Small
Medium
Large
Color Palette
256
32768
65536
1152 x 864
True Color (16 bit)
Others _____________
Screen
Background
Color
Cyan
Table 4: HMI System Configuration

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13. OPERATOR INTERACTION

Operators shall interact with new created facility for MOL bijell-1 through HMIs on Engineering work
stations. Real time process control shall be provided through run time Graphics
14. HMI SCREENS LIST

Based on P&IDs and RFQ provided by the customer, the following table shows the list of screens
identified for Expansion of Modicon PCS and ESD PLC Bijel 1.
Sr.#
P&ID/Screen Name
Overview_3
Overview_4
Table 5: HMI Screen List

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Date : 12-02-2015
HMI SCREEN
The following are the static graphics screens developed for Expansion of Bijel1.

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OVERVIEW_3
Figure 2: Overview_3 Screen

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OVERVIEW_4
Figure 3: Overview_4 Screen

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ALARM SUMMARY
It should be noted that new created alarm summary shall be included in existing alarm summary
graphic page to keep consistency with existing system.
Figure 4: Overview_4Alarm Summary Screen

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19. PLC SOFTWARE DESIGN GUIDELINES

20. INTRODUCTION
NTECH received the existing Unity Pro PLC applications from client for both PCS and Safety systems.
INTECH will be performing the desired additions to existing logic on both controllers
This section outlines the basis on which the new logic will be added to existing Controller Application
will be modified. . It includes the structure and naming convention to be used for modifying the
application. It will ensure that the program structure and tagging convention being used remains
consistent throughout the application and previous settings has been followed.
This document also describes the Object Oriented Approach used by INTECH for implementation of
the Process Control requirements.
21. SOFTWARE ENVIRONMENT SETTINGS

Software Environment
Operating System
Windows 7
Controller Application Development

Software
Unity Pro XLS 7.0
Process Controller Type
Quantum BMX P34 2020
ESD Controller Type
Quantum Safety CPU 140 651 60S
Process Application Name
PLC501
ESD Application Name
PLC500
Process Controller Slot
Existing Rack 0, Slot 0
ESD Controller Slot
Existing Rack 1, Slot 2
Programming Language
Ladder Logic
Table 6: PLC Software Environment Settings

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22. APPLICATION STRUCTURE

We have received Unity Pro logic applications from client for both PCS and Safety systems. We will be
adding our progam sections to existing logic applications.
On the Unity Pro XLS 7.0 platform, the basic element of an application is a TASK. There are different
types of task like MAST (Master Task) and FAST (Fast Task) which in turn comprise of different
Sections and Sub-routines. We will only explain MAST and Sections topic will be only discussed here
as thesewe are only being using thatused in existing and newour application.
Application Structure for both PLCs is shown below:
23.

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PROCESS PLC APPLICATION STRUCTURE
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Figure 5: Process PLC Application Structure

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ESD PLC APPLICATION STRUCTURE
Figure 6: ESD PLC Application Structure

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25. REMOTE IO HARDWARE CONFIGURAION

Hardware configuration for the Expansion racks of both Process and SAFETYESD systems are as
follows:
26.
PROCESS PLC
Expansion hardware configuration is shown at Rack 2 in figure below:
Figure 7: Process PLC Expansion Rack
AREA
PROCESS PLC
STATION
PROCESS PLC
STATION
PROCESS PLC
STATION
PROCESS PLC
STATION
PROCESS PLC
STATION
PROCESS PLC
STATION
Rack
Number
Slot
Module
BMX DDI 3202K
BMX DRA 1605
BMX AMI 0810
BMX AMI 0810
BMX AMI 0810
BMX AMO 0410
Table 7: Process IO Rack Hardware Configuration

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ESD PLC
Expansion hardware configuration is shown at Rack 2 in figure below:
Figure 8: ESD PLC Expansion Rack
AREA
ESD PLC
STATION
ESD PLC
STATION
ESD PLC
STATION
ESD PLC
STATION
Rack
Number
Slot
Module
140 SDI 953 00S
140 SDO 953 00S
140 SAI 940 00S
140 SAI 940 00S
Table 8: Process IO Rack Hardware Configuration

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MAST (MASTER TASKS)
The master task represents the main task of the application program. It is obligatory and created by
default.
The master task (MAST) is made up of sections and subroutines. Each section of the master task is
programmed in the following languages: LD, FBD, IL, ST or SFC.
You can choose the type of master task execution:
Cyclic (default selection)
Periodic (1 to 255 ms)
The master task can be controlled by program, by bits and system words.
29.
SECTIONS
Sections are autonomous programming entities.

The identification tags of the instruction lines, the contact networks, etc. are specific to each section (no
program jump to another section is possible).
These are programmed either in:
Ladder language (LD)
Functional block language (FBD)
Structured Text (ST)
Sequential Function Charting (SFC)
on condition that the language is accepted in the task.

The sections are linked to a task. The same section cannot belong simultaneously to several tasks.
The following diagram shows a task structured into sections. The new sections added in existing logic
are boxed in green.

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Figure 9: Process PLC Sections Structure

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Figure 10: ESD PLC Sections Structure

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30. PLC OBJECT FUNCTIONALITY

31.
INTRODUCTION
This section briefly describes the functionality of different blocks like AI scaling block and PID block
used in logic development.
The functionality of each object is same as in existing logic. INTECH will be following the existing
objects.
32.
ANALOG INPUT SCALING BLOCK
This function block can be used to scale the value of an analog input channel. It carries out the
following calculation:
Figure 11: AI Scaling Formula

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The figure below shows Analog Input scaling block.
Figure 12: AI Scaling Block

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The table below describes Input and Output elements of the block in above figure.
ELEMENT
EN
DATA TYPE
DESCRIPTION
BOOL
Enables the block
INT
Numerical variable to be scaled
IN_MAX
INT
Upper limit of the input scale
IN_MIN
INT
Lower limit of the input scale
OUT_MAX
REAL
Lower limit of the output scale
OUT_MIN
REAL
CLIP
BOOL
Upper limit of output scale

"1": the value of the OUT output is limited by
OUT_MIN and OUT_MAX.
ENO
BOOL
Enables Output for other blocks
OUT
REAL
IN

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Scaled output value

Table 9: AI Scaling Block IO Elements
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Date : 12-02-2015
PID CONTROLLER BLOCK
This function block produces a PID Controller. The function block has the following properties:
Real PID controller with independent gain, ti, td setting
Operating modes Manual, Halt, Automatic
Bump less changeover between manual and automatic
Manipulated variable limiting in automatic mode
Separately enabled P, I and D component
The figure below shows PID controller block:
Figure 13: PID Control Block

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The table below describes Input elements of the PID Controller block.
ELEMENT
DATA TYPE
DESCRIPTION
EN
BOOL
Enables the block
PV
REAL
Process Value
SP
REAL
Setpoint
FF
REAL
Disturbance input
RCPY
REAL
Copy of the current manipulated variable
MAN_AUTO
BOOL
Controller operating mode:

"1": Automatic mode
PARA
Para_PIDFF
"0": Manual mode

Parameter
TR_I
REAL
Initialization Input
TR_S
BOOL
Initialization Command
OUT
REAL
Absolute Value
Table 10: PID Control Block Intput Element
The table below describes Output elements of the PID Controller block.
ELEMENT
DATA TYPE
DESCRIPTION
ENO
BOOL
Enables Output for other blocks
OUT_D
REAL
Incremental value output: Difference between

the output of the current and previous cycle
Current operating mode of the function block:
MA_O
BOOL
"1": Automatic operating mode

"0": other operating mode (i.e. manual or
tracking mode)
INFO
Info_PIDFF
STATUS
WORD
OUT

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Information
Status Word
Status word
REAL
Table 11: PID Control Block Output Element
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34.
Date : 12-02-2015
PUMP OBJECT
In this expansion project there are two pumps P-170A/B. According to Control Philosophy Doc. No.
0714002-3620-003, these pumps must work in Duty/Standby Configuration. We have made the pump
logic in accordance with existing pump modules. The salient features of new pumps logic are as
follows:
Start / Stop commands to pumps will come from LIT_1700 High/Low alarms or
LSH_1701/LSL_1701 level switches.
Duty / Standby mode for pumps will be selected from field via Digital Input HS_1700A / B.
Pump will shutdown in case of emergency via ESD_1700A / B.
35. CONTROLLER TAGS

Controller tags apply to the entire controller, and can be used by all programs. In other words, the data
in a controller tag is available to every task or program within the controller application. These tags can
be seen as global variables.
Controller Tags data type, description and address types are defined in sections below:
36.
PROCESS PLC
NAME
Input Word
Integer
Analog Output
Output Word
Integer
Digital Input
Input Bit
BOOL/EBOOL
Output Bit
BOOL/EBOOL
Table 12: Process Controller Tags
ESD PLC
NAME
ADDRESS TYPE
DATA TYPE
Analog Input
Input Word
Integer
Analog Output
Output Word
Integer
Digital Input
Input Word
Integer
Digital Output

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DATA TYPE
Analog Input
Digital Output
37.
ADDRESS TYPE
Output Word
Integer
Table 13: ESD Controller Tags
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38. HMI OBJECT FUNCTIONALITY

39. INTRODUCTION
HMI objects will be used to visualize the functionality of the system, different animations are used to
represent the multiple states of an object.HMI applications will be developed in a modular Object
Oriented Approach. Typical functionalities have been identified, and the corresponding objects have
been defined. This approach will facilitate the development as well as further diagnostics and
troubleshooting activities.
NFurthermore newly created objects not only share consistency with existing system but also
functionality to keep system convenient to operators during runtime operations
40. OBJECT TYPES

This section describes the functionality of such objects.
Sr.
Object Descriptive Name
Brief Description
1.
Discrete Input
Object for Discrete Input
2.
Discrete outputs
Object for Discrete outputs
3.
Analog Input
Object for Analog Input
4.
SDV Valves
Object for SDV value accompanying SOV
5.
PIDPCV
Object for PID
6.
Pump

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Object for Pump with Run Status & Start/Stop

Commands
Table 14: HMI Object details
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41. ANALOG INPUT

42. OOFIT-0013 OBJECT OVERVIEW
FIT-0013 Object has been implemented in Modicon Unity XLS -programming software for
Schneider and its HMI interface has been developed in Vijeo Citect Scada V7.3. This object consists of
one Analog input only.
The raw input from transmitter (which is PV Raw) is scaled in the PLC to calculate process
value in engineering units though
Created analog object only provides provision of monitoring process analog values.
Scaling of PCS analog objects shall be done in Vijeo Citect Scada environment while ESD
Analog values shall be scaled in controller to keep consistency with existing HMI/Controller
configuration.
43. VARIABLE NAMING NOMENCLATURE

P&IDs Tag name
Controller Object Name
FIT_0013
Process_FIT_0013_Scaled
HMI Object Name

FT_0013Pipeline Pump PBE310 Suction Pressure
Table 15: Variable Naming Nomenclature
Figure 14: Controller Tag Name

Engineering Units
Device Tag Name
Process Value
Figure 15: Graphical representation(s) of analog Object

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ALARM MANAGEMENT CYCLE
Analog object relative tags in case of alarms shall be displayed in alarm summary already built. Since
existing system only provides analog objects for monitoring process in runtime environment.

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45. PID CONTROL VALVE

46. PIDPIDPIT-0010 - OBJECT OVERVIEW
LIC-0011 object has been implemented in Unity Xls - programming software for Modicon
Schneider and its HMI interface has been developed in Vijeo Citect Scada. This object consists of one
Analog input and one Analog output only.
LIC-0011 Object has analog functionality.
Set point can be configured from the Object faceplate.
PID can be put in Auto/Manual mode from Object.
In Manual mode, PID output can be set manually.
Detailed monitoring and control over PID settings are also configurable from HMI.
The percentage opening of the regulatory valve is also represented below the valve body.
47.

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GRAPHICAL REPRESENTATION
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Figure 16: Graphical Representation of PIT-0010 Controlling PID

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48. CONTROLLER IO & VARIABLE NOMENCLATURE

P&ID IO Tag
Name
Controller/HMI Object Name

Process_PITLIC_0010_SCALE
D
PICLIC-00101
Description
Slug Catcher Pressure
controller Level Controller.
Table 16: I/O Variable Name
49. PCV ANIMATION DETAILS

The animation details for the Object PIT-0010 are as follows:
Device State
Alarm text indication
Normal Operation
Green
SOV Off state
Red indication
SOV On state
Green Indication
PCV state
Green when Value lies <=98
PCV State
Red when Value lies <=100
Table 17: Animation Details for Object PIT-0010

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50. DISCRETE INPUT

51. OBJECT OVERVIEW
DI_01 object has been implemented in Modicon Unity Pro XLS programming V7.0 Software for
Schneider Electric and its HMI interface has been developed in Vijeo Citect Scada. This object consists
of one Digital input.
Digital object shall be handled in same way as done in existing HMI.
52.
GRAPHICAL REPRESENTATION
Device Alarm Status

required Device Alarm
Status
Device Tag Name
Figure 18: Graphical Representation of DI_01
53. CONTROLLER I/O & VARIABLE NOMENCLATURE

P&ID
Signal Tag
Controller/HMI Object
Name
LSH-1701
ESD_LSH_1701
Type
DI
Description
Level High High Alarm
Table 18: I/O Variable Name

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54. ANIMATION DETAILS

STATE
GRAPHICS
LSH 1701 HIGH indication
LSH -1701 normal operation

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55. PUMP WITH COMMAND AND FEEDBACK

P-170A/B object has been implemented in Unity Pro XLS V 7.0 - programming software and its HMI
interface has been developed in Vijeo Citect 7.4. This object consists of both hardwired and soft
signals.
There is one discrete input which shows pump in Duty/Standby status from field.
There is one discrete input for pump feedback status.
There a discrete output for start / stop commands.
Pump will start /stop automatically from level transmitter LIT_1700s High or Low Alarms or
from LSH_1701/LSL_1701 (level switches).
56. PUMP P-170A/B OBJECT OVERVIEW

CONDITION
STATE
Duty Mode
Mode appears in text box.
Standby Mode
Mode appears in text box.
Off or Stopped

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Motor will appear in red color.
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On or Running
Motor will appear in red color.
Transition State
Start command is given but pump hasnt start yet.
Fault
Pump will blink between red and black color when it

is in fault state like when it fails to start.
ESD State
When ESD command to stop pump is activated a

text box will appear to show pump in shutdown state.
Table 19: Pump P-170A States Indications

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58. DISCRETE OUTPUTSHUTDOWN VALVE

OBJECTS
59. ESD-9002S OBJECT OVERVIEW
ESD-9002 object has been implemented in Modicon Unity Pro XLS V7.0 programming
software for Schneider and its HMI interface has been developed in Vijeo Citect Scada. This object
consists of two Digital inputs and one Digital output.
All valve control and monitoring will be via Serial Modbus. There will be no hardwired
commands and statuses to/from any valve..
Valve open (ZSO_XXX) and close (ZSC_XXX) status will be monitored, displayed and logged
on HMI screen depending upon two discrete Inputs (as feedback signals) from Shutdown valve.
If the valve Open/ Close button is pressed while no feedback is being received, it will be in
Travel condition.
Different animations shall be applied on SDV object with subject to limit switch statuses and SOV
signal details of which are provided in section 11.4.
Object Cap shows the Digital output status and valve body shows valve status indication.
60. GRAPHICAL REPRESENTATION
SOV Status
Valve Status
Indication
Figure 20: ESD/SDV Object (Typical)
61. IMPLEMENTATION TABLE

OPEN Switch Status
1
CLOSE Switch Status

0
Close
In Travel
Mismatch

Issue # : 01
VALVE Position Interpretation

Open
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Table 20: ESD/SDV implementation table

Animation details of SDV/ESD valve are provided as under.
GRAPHICS
ESD-9002 states
ESD-9002 Closed
When Valve is in Closed State.

Valve body and cap will be Steady
in Red color.
ESD-9002 Opened
When Valve is in Opened State.

Valve body and cap both will be in
Steady Green color.
ESD -9002 transition state
When Valve goes from one state to

other untill the feedback is
received.
ESD-9002 Fault state
When Valve communication is lost.

Valve body will be in yellow and cap
will be in green color.
Table 21: SDV States Indications

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63. DETAILED SPECIFICATIONS

Parameter
HMI
Access
Implementation
Run Status Input

------Closed Limit Switch
Latched
Read Only
Controller
Open Limit Switch
Latched
Read Only
Controller
Fault
------Start Output
------Stop Output
------Open/Close Output
Latched
Read/Write
Controller/HMI
Mode
------Table 22: SDV/BDV Object Detailed Specification

Issue # : 01
Alarm
Summary
Trend
-----------------
-----------------
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FUNCTIONAL DESIGN SPECIFICATION

Project Title : Expansion of Modicon PCS and ESD PLC

INTECH Process Automation Inc.

FUNCTIONAL DESIGN SPECIFICATION

INTECH Project Code : OV-141113

Customer Project # : 714002

End User : MOL-Iraq

End User Project # :

Issued For Approval

FRM # : OPS-WI-06-FD (15)

FUNCTIONAL DESIGN SPECIFICATION

INTECH Project Code : OV-141113

Customer Project # : 714002

End User : MOL-Iraq

End User Project # :

NOTICES, COPYRIGHTS AND TRADEMARKS

FRM # : OPS-WI-06-FD (15)

FUNCTIONAL DESIGN SPECIFICATION

INTECH Project Code : OV-141113

Customer Project # : 714002

End User : MOL-Iraq

End User Project # :

HARDWARE SCOPE OF SUPPLY......................................................................................... 12

HMI SOFTWARE DESIGN..............................................................................14

HMI SCREENS LIST............................................................................................................... 15

PLC SOFTWARE DESIGN GUIDELINES.......................................................19

HMI OBJECT FUNCTIONALITY.....................................................................31

PID CONTROL VALVE....................................................................................34

FRM # : OPS-WI-06-FD (15)

FUNCTIONAL DESIGN SPECIFICATION

INTECH Project Code : OV-141113

Customer Project # : 714002

End User : MOL-Iraq

End User Project # :

PID OBJECT OVERVIEW....................................................................................................... 34

PUMP WITH COMMAND AND FEEDBACK...................................................38

10.1. PUMP P-170A/B OBJECT OVERVIEW................................................................................38

SHUTDOWN VALVE OBJECT........................................................................40

HARDWARE SCOPE OF SUPPLY......................................................................................... 12

HMI SOFTWARE DESIGN..............................................................................14

HMI SCREENS LIST............................................................................................................... 15

PLC SOFTWARE DESIGN GUIDELINES.......................................................19

FRM # : OPS-WI-06-FD (15)

FUNCTIONAL DESIGN SPECIFICATION

INTECH Project Code : OV-141113

Customer Project # : 714002

End User : MOL-Iraq

End User Project # :

HMI OBJECT FUNCTIONALITY.....................................................................31

PID CONTROL VALVE....................................................................................34

pid - OBJECT OVERVIEW...................................................................................................... 34

PUMP WITH COMMAND AND FEEDBACK...................................................38

10.1. PUMP P-170A/B OBJECT OVERVIEW................................................................................38

DISCRETE OUTPUT OBJECTS.....................................................................40

HARDWARE SCOPE OF SUPPLY.........................................................................................12

HMI SOFTWARE DESIGN GUIDELINES.......................................................13

HMI SCREENS LIST............................................................................................................... 14

FRM # : OPS-WI-06-FD (15)

FUNCTIONAL DESIGN SPECIFICATION

INTECH Project Code : OV-141113

Customer Project # : 714002

End User : MOL-Iraq

End User Project # :