Professional Documents
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Table of Contents
Introduction.................................................................. 6
Selection......................................................................15
Design..........................................................................35
Configuration ..............................................................67
Implementation ...........................................................93
Operation...................................................................106
1-Introduction
Introduction
Purpose
The goal of this System Technical Guide (STG) is to provide recommendations,
guidelines, and examples to help develop a process control application.
This guide proposes a methodology to implement a process control application
using SoCollaborative Engineering with Unity Application Generator (UAG) as a
system engineering project tool.
Moreover, the STG suggests best practices to take advantage of system openness
while reducing the risks of misuse and misunderstanding.
The recommendations and guidelines provided in the following chapters of this STG
are generic and are targeted at process applications such as water treatment, mining,
oil and gas, and so on. We will, however, use the specific example of a cement plant
with an automation project based on a Collaborative Control System Architecture to
illustrate a process application developed with the UAG system engineering tool.
Starting from the process analysis, a top-down approach is used to develop the
project.
1-Introduction
1-Introduction
Document Overview
The document provides a step-by-step methodology to create an application with the
UAG system engineering tool. Here is an overview of the document:
Chapter 2, Selection. The P&ID of the plant process is used as the starting point
for this analysis. This chapter includes the following four topics to help you select
the most appropriate solution for your application:
1. Functional analysis: From this analysis and the process description,
the proposed methodology allows you to divide your factory into Units
(according to ISA-S88) and to establish the physical model using a
top/down design.
2. Customer standards: This analysis includes naming rules and others
customizations.
3. Operator requirements: Lean how to categorize, prioritize, and filter
your information according to its criticality.
4. Library requirements: from the process needs, establish the objects
library. List the necessary modules and devices following the P&ID
conception.
Chapter 3, Design. This chapter includes three topics to help you build the core
application:
1. Library definition: Build the project objects library based on the UAG
process library, adding your customized objects (in terms of control
and/or HMI, and develop the UAG library objects (SCoDs).
2. UAG project preparation: Customize the UAG project to meet the
project constraints and requirements.
3.
Chapter 4, Configuration. This chapter explains the different elements that you
have to set up in the UAG project:
1. UAG project organization
2. topological model
3. physical model
4. link between the these models
1-Introduction
Chapter 6, Operation. This chapter summarizes what the operator can do with the
final SCADA application:
1. process visualization and navigation
2.
alarms
3.
trends
Project Requirements
The project must comply with the following specific requirements:
1-Introduction
2) raw mill: This function obtains the right composition of raw material to optimize the
combustion in the kiln. It includes three sub-functions:
3
10
1-Introduction
3) Clinker: This function is the heart of the cement plant. It performs transformation of
the blended material with a temperature treatment. It includes four sub-functions:
3-1) A pre-heater with 4 cyclones pre-heats the
blended material and manages the
de-carbonation rate by flow steering.3-2) A kiln
brings the blended material up to 1500C and
includes temperaturealarms and flame
monitoring.
3-3) A cooler reduces the temperature of the
resulting Clinker.
3-4) Three Clinker silos store the cooled clinker. This unit manages the silo levels
according to the Clinker temperature and performs quality control of the clinker.
4) A Cement mill recovers the Clinker from the kiln output to deliver the finished
product. It contains three main sub-functions:
4-1) Two silos add pouzzolane to the clinker,
giving the cement the correct properties
according to the recipe.
4-2) A cement mill grinds the Clinker and its
additives to provide the finished cement.
4-3) Finally, three cement silos store the
finished product.
11
1-Introduction
Customer Standards
To standardize the design according to customer specifications, the project has been
developed with the UAG system engineering tool.
The use of UAG respects the following customer standards:
naming rules
operation rules
operating modes
process constraints
The model of the process application is designed using customized objects, variables,
and pictures in order to fit as closely as possible to project requirements and
standards. The integration of standards with object-oriented developments facilitates
the reuse of previous work, such as
(pictures and HMI), and objects. Implementing UAG in a single database provides for
the handling of data between SCADA and PLC systems during different phases of the
project (design, configuration, implementation, etc.)
12
1-Introduction
Safety Notice
The standards and level of safety you apply to your system is determined by its
design and the extent to which your system may be a hazard to people and
equipment. Building a system based on the architectures introduced in this document
does not relieve the user from adhering to the relevant national and international
safety laws and regulations.
Read these instructions carefully, and look at the equipment to become familiar with
the device before trying to install, operate, or maintain it. The following special
messages may appear in this documentation or on the equipment to warn of potential
hazards or to call attention to information that clarifies or simplifies a procedure.
13
1-Introduction
14
2-Selection
Selection ________________________________________________________ 16
Functional Analysis ____________________________________________________ 17
Description of the Process ______________________________________________________ 17
Customer Standards __________________________________________________________ 29
Operator Requirements ________________________________________________________ 31
Library Requirements __________________________________________________________ 33
15
2-Selection
Selection
This chapter describes how to perform the functional analysis of the process. It gives
the user a methodology for:
16
2-Selection
To follow correctly this methodology, the user has to gather information from different
sources:
functional specifications
operator requirements
company standards
This information helps you either to choose the most appropriate objects in the project
libraries or to build new ones.
For more details about process libraries, please refer to the next chapter, Design.
Functional Analysis
Description of the Process
To perform functional analysis, the ISA-S88 international standard is used. . It
consists of terminology and models for structuring the production process and
establishing equipment control. Although this standard was developed for batch
processes, it can also be applied to continuous processes. These models describe
the process: recipe, procedural, and physical models.
Recipe Model
In this project, the process transforms only one product. Consequently, a recipe
model is not needed. Nevertheless, some formulas are required to define the cement
composition and the appropriate proportions of additives.
17
2-Selection
Physical Model
The aim of the physical model is to structure the process in terms of functions. This
model defines six levels.
Note: The ISA-S88 model does not define a continuous approach. The levels of this
standard have been adapted to this project.
This diagram explains the different levels of the ISA-S88 physical model and their
potential interaction:
The Enterprise, the highest level, answers
three questions related to the final product:
What is it? How is it performed? Which site
is concerned?
The site is a physical or geographical group
determined by the enterprise.
The Area level describes the main parts of
the site. An area can be composed of
several tasks. Each task is associated with a
Process Cell.
The Process Cell level contains all of the
production and supporting equipment (Unit,
Equipment, and Control Module) necessary
to make a product.
Each Production Unit has several equipment
modules. Each one performs a simple
process
function. For a complex function, the ISAS88 standard allows you to divide it into
organization
2-Selection
The design must take into account the potential extensions with more process lines.
Applied to the current cement plant project, we identify different levels coming from
ISA-S88.
Each process line is identified as an Area. Four Process Cells compose the line.
These Process cells are named SHOP: Quarry, Raw Material, Clinker, and Cement
Mill. Every piece of equipment in a SHOP is linked by a unique SEQUENCE of
operating modes.
This illustration shows a process line that has been spilt into four SHOPs:
Clinker
Cement Mill
Quarry
Raw Material
Line 1
The process P&ID describes the components inside a SHOP.
The process control industry describes the plant process and their instrumentation by
a P&ID. It shows the plants process flow, including the actuators and sensors. This
representation gives a tag (name) to each device along with additional functional
parameters.
19
2-Selection
This illustration gives details about the different representations used for the elements
from the ISA5 standard. (For more information, please refer to the ISA standard.):
The Raw Material SHOP is an example of this methodology. Four main functions
(Production Units in the ISA-S88 model) can be isolated: the Homogenizer,
Additives, Raw Mill, and Blending Silos. These functions are linked through a
sequence called SEQUENCE.
20
2-Selection
This illustration shows the division in the Raw Material SHOP and its four main
functions (SEQUENCE) using the P&ID representation:
21
2-Selection
This illustration isolates the Additive SEQUENCE:
3) The Raw Mill SEQUENCE has two PARTs: a Raw Mill and a Conveyor.
The Raw Mill PART includes the following CONTROL MODULEs: a Level
Indicator, an Analog Motor and a Speed Indicator.
The Conveyor PART has only one CONTROL MODULE: a Digital Motor.
4) The Blending Silo SEQUENCE has a Silo PART with the following CONTROL
MODULEs: two Analog Transmitters.
22
2-Selection
23
2-Selection
Procedural Model
The procedural model defines the control that enables the equipment (SEQUENCE)
in the physical model to perform a task. This model allows up to four levels.
This illustration shows the four levels of the ISA-S88 Procedural Model and their
descriptions:
24
2-Selection
The following illustration shows the link between the Physical and Procedural Models
of ISA-S88:
25
2-Selection
For a cement application, the Start and Stop Sequences between different pieces of
equipment are among the most important functions. For each Production Unit, a
specific sequence (that can be split into sub-sequences) is defined.
For instance, the following illustration describes the start sequence for the Raw
Material Unit Procedure:
Note: These four levels are linked to the Sequence described in the physical model.
Note: To respect state-of-the-art cement production, the highest-powered equipment
must stop only on internal detected fault and must be the last to start and stop.
Consequently, the highest-powered actuator of the installation is linked to the first pin
of the sequencer.
Note: The procedural model is not directly managed by UAG. Nevertheless, its
analysis helps the design of the library and the associated control sequence.
26
2-Selection
Topological Model
The topological model results from the procedural model. It describes the hardware
architecture in terms of controllers, I/Os, and operator workstations.
To design the topological model, observe these criteria:
plant size
criticality of parts
availability needed
CCS architecture proposes simulating the plant automation. The proposed CCS
architecture intentionally mixes different ranges of PLCs and different fieldbuses
technologies. The aim is to cover the most important types of hardware architectures
to facilitate its use in a large number of projects. In this application, one PLC
configuration is allocated for each Production Unit. According to the process criticality,
a high-availability configuration is defined for the main functions (such as the Kiln
management) with redundant controllers.
Power
Management
SCADA
server
Instrumentation
Motor
control
Collaborative
control
Plant
information
management
The goal is to implement and offer a variety of configurations, making the installation
adaptable to future needs. Only those motors that are discussed in the following
examples are represented in the diagram.
27
2-Selection
These illustrations describe each functional unit with their corresponding hardware:
Raw Mill
An HBSY TSX Premium configuration represents the unit core.
An Ethernet-based network is used for the control. The additive silos
are managed through a Tesys U connected to an Advantys STB
island. An ATV71 drives the additives conveyor. The Raw Mill
Contactors control the Raw Mill. A PM750 performs electric
measurements.
Clinker
The core unit is composed by an HSBY Quantum configuration
with Quantum RIO and Profibus DP devices.
The temperature regulation of this unit is a key feature. A
temperature sensor connects to Profibus PA. Consequently, a
contactor and TeSys T starter controller manage the kiln through a
Profibus-based network. An ATV71 drives the Cooler. Contactors
control the Blending Silos.
Cement Mill
The core unit is an HSBY Quantum configuration with a quantum
RIO and Ethernet devices.
An Ethernet-based network is used for the control. The additive
silos are managed through Tesys U linked to an Advantys STB
island. An ATV71 drive controls the additive conveyor and the
Cement Mill. Contactors control the Blending Silos.
28
2-Selection
Customer Standards
Each project is unique, and each customer has uniquely defined standards. In this
phase of the project, it is important to listen to customer expectations in term of
engineering design (such as naming rules). In the same way, the operation of the
plant must also follow rules in terms of operator areas and access rights.
Naming convention
A naming convention is defined to aid in design and maintenance. To identify the
elements, common rules are based on the ISA5 standard, or they can be adapted
from customer standards.
Here, we define our own standard to differentiate the main types of module. For
example, the SHOP is defined by two letters: QU for Quarry, RM for Raw Mill, and so
on.
The identification of each component uses the following structure:
AA
SHOP
AAA
SEQUENCE
AA 11
PART
AA 11
CONTROL
VarName
VARIABLE
MODULE
2 letters
3 letters
2 letters +
2 digits
2 letters +
2 digits +
1 name
29
2-Selection
PART
FU: Function
BC: Belt
CR: Crusher
HO:
Homogenizer
AD: Additive
CONTROL MODULES
Actuators
Controllers
Analog I/O
PID: PID
SI: Silo
proportional)
Controller
MI: Mill
VA: Proportionnel
ON:
CR: Crusher
valve
Sequencer
Conveyor
SP: Speed
FL: Flow
TC:
MI: Mill
FA: Fan
BLS: Blending
DP: Damper
PR: Pressure
GT: Gate
RT: Rate
CY: Cyclone
(percent)
Silo
PH: Pre-Heater
KI: Kiln
CO: Cooler
RO: Roller
Temperature
ME:
Measurement
BU: Burner
CMS: Cement
Silo
CKS: Clinker
Silo
30
2-Selection
Operator Requirements
Every piece of information that the process returns does not have the same criticality.
Consequently, the information has to be categorized, prioritized, and filtered.
31
2-Selection
The following figure gives the main criteria to be taken into account and actions to be
implemented:
the quarry
the plant (all the process steps between the quarry and the packing)
the packing
Each area such as the Quarry can only be controlled by one single dedicated
operator.
32
2-Selection
Library Requirements
The selection of the library is the most important part of the project. Obtain a detailed
analysis of process requirements and constraints (motors, sequencers, interlocks,
and so on) and a correct understanding of all the devices that require control before
the library selection phase begins.
A library consists of objects that have several parts:
standardized design
maintenance
In the UAG system engineering tool, the library includes all objects and parts required
for deployment during the different project phases (programming, development, and
operation).
This table suggests a methodology for selecting objects to include in the library:
Step
Action
Identify the control modules used following the P&ID diagram exactly.
Group the equipment into classes. The following topics define a class :
control logic
displayed information
performed actions
standardization
33
2-Selection
The following table gives the three different libraries you can use:
Library
Comments
This library fits the need for a specific cement application. Some
generic objects are not present and adaptations are required to
manage, for instance, the M340 PLC.
This library fits the need, but it involves more time to design and is
scratch
34
3-Design
Design __________________________________________________________ 36
Design Methodology____________________________________________________ 36
Design Principles ______________________________________________________ 36
Library Design_________________________________________________________ 36
Smart Control Devices Introduction _______________________________________________ 37
Requirements identification _____________________________________________________ 37
Functional analysis_____________________________________________________ 64
Definition of communication channels _____________________________________________ 64
Definition of the navigation rules linked to the plant operation (SCADA)___________________ 65
35
3-Design
Design
Design Methodology
Think before doing is the approach to take to any project. Correct preparation of a
project is a key factor of its successful completion.
Design Principles
Before defining the physical and topological models using UAG (see the
Configuration chapter) and then generating (see the Implementation chapter), you
must prepare all structuring elements during the Design Phase. Here, the goal is to
build three items in compliance with customer standards:
The UAG system-engineering tool is used to design our project. UAG is an advanced
design and generation software tool that integrates multiple PLCs and HMI/SCADA
systems to provide an automation solution.
Note: For those familiar with Schneider offers, UAG names SCADA (Vijeo Citect) as
HMI, and HMI (Magelis XBT-GT) as Net Partner, a convention observed hereafter in
this document.
UAG enables you to capture and reuse your best practices within application-specific
libraries to increase standardization and software robustness. Moreover, it includes a
single database to avoid both the duplication of effort and the errors that might
otherwise occur. To sum up, UAG significantly reduces total lifecycle costs.
Library Design
As introduced in the selection phase, the design of the library is essential.
This chapter highlights the different steps to build the library from the analysis of
requirements through the library creation.
36
3-Design
Smart Control Devices Introduction
Control applications consist of PLC programs, HMI programs, and all other system
architecture configuration considerations. As defined in the selection phase, the
process includes different Control Modules. A Control Module represents a real object
in the process environment (valves, motors, etc), The specific functionality of a
Control Module is defined in the Control Module Type, called the Smart Control
Device (SCoD).
The SCoD contains all functional aspects of the object it represents (control logic,
variable, communication with HMI system, etc.). It establishes a link between a
functional block (EFB and DFB in Unity Pro) and a graphic symbol (Genie and Super
Genie in Vijeo Citect).
SCoDs are organized in libraries that are either provided by a UAG predefined library
or created by the user with the SCoD editor. A SCoD serves as a template and can
act as a Control Module in a UAG project. For each instance, the specific functionality
can be parameterized.
The UAG single database contains all information about the SCoDs instances to
enable the Unity Pro and Vijeo Citect applications.
To learn more about SCoD building, please refer to the Methodology for SCoD
building section in this chapter and the UAG documentation.
Requirements identification
To build the project library, you first need to identify the following items:
The four following tables present a synthesis, which can be considered as a slicing
method, of each element (SHOP):
37
3-Design
Equipment
Control/
Communication
Measurements
Command
Assigned
Function
-Current (3)
Contactor
Crusher
Quarry
-Motor Frequency
(provided by TeSys T)
CANopen
Starter Controller:
-Analog Level
TeSysT
Sequencer
hour
Speed
Belt Conveyor
CANopen
(provided by ATV31)
Homogenizer
-Recipe Number
Display
Analog Level
-Additives
Management
Starter Controller:
Digital Level
STB Island
TeSys U (4)
(2 per silos,
(Ethernet)
High and Low)
Electric
Measurement of
the Unit
Speed
Raw
Additives Conveyor
Drive: ATV71
Ethernet
Mill
(With PM750
(provided by
device) +
ATV71)
Sequencer
-Speed
(provided by
Raw Mill
Drive: ATV71
Ethernet
ATV71)
-Analog Level
Electric
Measurement of
the Unit
(With PM750
Contactor
device) +
Analog Level
Blending Silos
Temperature
Sequencer
38
3-Design
Equipment
Control/
Communication
Measurements
Command
Assigned
Function
Decarbonation
Pre-Heater
Cyclones (4),
Cyclones
analog :
status
-Temperature
(ready or not)
-Pressure
-Current (3)
Clinker
Contactor
+
Kiln
Starter
-Motor
Management
Frequency
of the kiln
(provided by
temperature
TeSys T)
through a PID
Profibus DP&PA
-Analog
Controller:
regulated valve
+
Temperature
TeSysT
(3)
Sequencer
-Number of
starts/ hour
Starter
Additives Silos
Controller:
TeSys U (2)
Additives Conveyor
Drive: ATV71
Digital Level
STB Island
(Ethernet)
(2 per silos,
High and Low)
Ethernet
Cement
Speed (provided
by ATV71)
Rcpt number,
Additives
management
Sequencer
-Speed
(provided by
Cement Mill
Drive: ATV71
Ethernet
ATV71)
Sequencer
-Analog Level
Blending Silos
Contactor
Analog Level
Note: These lists are defined according to the piping and instrumentation diagram
(P&ID). For more information, please refer to Selection chapter.
39
3-Design
motor management
measurement management
sequential control
ANAIN_P10: scale the analog input values from various hardware devices
The temperature in the kiln is managed by a regulated valve. To drive this valve, the
following objects are used:
40
3-Design
For the functionalities that are not managed by the objects included in the process
library, create new objects with the development tool SCOD Editor, provided by UAG.
For more details, please refer to the SCoDs part of this chapter.
Additional Objects
Each project is unique and therefore can require additional objects not included in the
process library.
The following part explains these topics:
building SCoDs
new devices objects that are not yet part of the library such as PM750
TeSys T: The device manages motors and carries out protection and
measurement functions. For our application, the created SCoD corresponding to
the TeSys T provides information about phase current, frequency, and the
number of starts per hour of the motor.
41
3-Design
The measurement values from the TeSys T are recovered as input. Then, they are
assigned to the HMI variable for the SCADA as output.
The following illustration shows the Vijeo Citect representation, with the displayed
values.
Power Logic PM750: This device enables the monitoring of electric network
phases (voltage, current, frequency, power, energy counting, etc.). The created
SCoD corresponding to the PM750 provides voltage, current, and frequency
measurements.
42
3-Design
The measurement values from the PM750 are recovered as input. Then, they are
assigned to the HMI variable for the SCADA as output.
Note: The DFB converts the frequency measurement from REAL to INT data type.
The following illustration shows the Vijeo Citect representation, with the displayed
values:
Entry Interface: In our process, the additive percent can be selected during the
production phase. Consequently, the SCADA must comprise a corresponding
entry as an INT data type.
This DFB consists in a Read/Write function block, for INT data type.
The following illustration shows the Vijeo Citect representation, with the
corresponding read/write value of the additive percent:
Digital Level Sensor: The created DFB gathers information from the sensor as
input. In order to avoid parasites due to the fluctuations of the measurement
product, the DFB presents a filter as input too. This DFB can also display a
functional or a detected fault state.
43
3-Design
The following illustration shows the DFB representation:
Pin definition:
44
3-Design
PIN definition:
Start
Stop:
Ack
Fdb1Fdb8
Fdbdefaut
PAR
CdStart
Qstart1Qstart8
Stdefaut
HMI
45
3-Design
The following illustration shows the Vijeo Citect representation:
EQUIPMENT DAMAGE
Respect the state of the art of cement production. The most powerful equipment
must stop only on intrinsic detected faults, and must be the last to start and stop.
Consequently, the most powerful actuator of the installation is linked to the first pin
of the sequencer.
Failure to follow this instruction can result in injury or equipment damage.
Note: The stop is set by a stop request or a detected fault.
46
3-Design
The following illustrations show the startup/ stop principles (grafcet representations)
of the sequencer:
47
3-Design
How to build a SCoD
The following figure illustrates the SCoD role:
This illustration shows some preliminary works are mandatory before building a SCoD,
either in your SCADA (here, Vijeo Citect) or in your engineering software (Unity Pro).
48
3-Design
Preliminary work:
This table presents the main issues you must address before creating the SCoD:
Topic
Question
definition and documentation of the function ensured by
Function
the SCoD
I/O
Symbol Representation
(Genie, Super Genie)
Trends/Alarms
Data
Documentation
The following table shows the steps to create a Vijeo Citect object, (Genie or Super
Genie):
Step
Action
Note: The Genie/Super Genie must fit to its Unity Pro DFB.
49
3-Design
Action
Note: The DFB must fit to its Vijeo Citect Genie/Super Genie.
SCoD Editor (for more details, please refer to the UAG documentation):
Owing to the importance of the library creation, an example of SCoD creation in the
context of our project follows. This table tells you how to create a SCoD (the
sequencer) with a SCoD Editor:
Step
Action
50
3-Design
Click on Open button. A pop-up dialog box confirms your choice. Click on
OK button.
4
51
3-Design
Click on OK.
52
3-Design
Note: By default, variables are created for each pin during the DFB import.
Consequently, you must define the right connection for each variable.
Note: The configuration of each variable is mandatory. After right clicking the
variable, the following pop-up appears allowing you to configure the different
properties of each variable by clicking on the relevant tab. (Alarm Level,
Access Level, Archive, etc.).
Note: Through the Inheritance tab, it is possible to define a variable as a
master variable (source variable) with a master property (source property)
and a slave variable (target variable) with a slave property (target property).
Whenever the master property changes, the slave property inherits of these
modifications.
53
3-Design
54
3-Design
Configure the SCoD pins. After clicking on the DFB Pins tab, connect your
required pins.
Note: Consider your project and/or state of the art before connecting pins.
For example there, to avoid equipment damages, the most powerful device is
connected on the first pin of the SCoD sequence. (Refer to the Sequencer
section in the Design chapter.)
7
Define the SCoD properties. These are the properties of the variables of the
control module. It allows the creation of fields linked to parameters that can
be filled in UAG.
With the SCoD Editor, after clicking on the Properties tab, right-click,
Properties.
The following pop-up appears:
55
3-Design
The arrows show what is created from the SCoD Editor to the UAG SCoD
screen.
8
56
3-Design
Project Customization
The models, adopted conventions (naming rules, alarms), and the system
architecture of the process are defined during the selection phase.. This information is
specific to this project.
Now, the user must create a translation file of all requirements in UAG. This file is
called the Customization file.
The following table presents the main issues you must address before creating the
Customization file:
Topic
Physical Model
Question
Impact
Naming Rules
Do my naming
conventions appropriately
Customization file.
analog information?
57
3-Design
Action
File -> New, Selection of HMI (Vijeo Citect)
Click on OK button.
2
Note: If you create a new customization file, you must include the library.
58
3-Design
The illustration shows the renaming of different levels and the selecting of the model
levels in compliance to our project requirements (for more information, please refer to
Selection chapter):
Note: UAG does not define a procedural model. That is why a specific SEQUENCE
named FU-Function has been added. (Refer to the naming convention in the
Selection chapter). The SEQUENCE procedure and the SEQUENCER object are
embedded in the FU-Function. Consequently, Unique names for this level has been
set to No since each SHOP has a SEQUENCE named FU.
Naming Rules
The naming rules are split into two parts: the naming conventions and the creation
rules. As we defined lists to name the different elements of our model, we use the
Designer list in UAG to first set the lists. (Refer to the naming conventions in the
Selection chapter.)
The following table shows the methodology used in the Designer list:
Step
1
Action
List -> Designer
59
3-Design
Add the defined lists, clicking on the concerned object (in this case, Shoplist).
Expand the naming convention node and then link the list to the level.
Note: For the PART and the CONTROL MODULE level, two fields are defined, a list and
two digits. The name of the SHOP has been included in the PLC name in order to easily
identify it. The SHOP list is also used for the Picture Group Name.
60
3-Design
Define how the variable is structured in the Name Creation Rules node after setting all the
naming conventions.
The following illustrations show the result in UAG, with the complete following name,
QU_FU_ON01_Start.
61
3-Design
Archive
The archive settings (location and duration) are defined in the Data/Archive names
node. The archive is used to configure the handling of the trend files in Vijeo Citect.
Here is an example:
Note: In this case, all the trends are stored in the following location: D:\Archive\
PLC Selection
All the PLCs available in the Schneider Electric catalog are pre-selected by default.
Choose your PLC hardware by deselecting the unused ones. As a consequence, the
used modules must be defined in the Customization file. This table has instructions
for adding a new module:
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3-Design
Step
1
Action
Select in the PLC/PLC family node the Unity families.
Tick the different racks and modules that are used in the project.
2
Identify modules that are not defined by default. For example, the PM750 and ATV71 (on
Ethernet) required in the project are not yet part of the predefined list.
The PM750 and the ATV71 on Ethernet are added in the User Defined Module list.
Afterwards, the ATV71 and the PM750 can be used to build the topological model.
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3-Design
Functional analysis
To complete the design phase we recommend defining the communication channels
and the navigation rules, which are funded on the functional analysis of the project.
For more information about the functional analysis, please refer to Design chapter.
This step is preliminary to the configuration phase.
Action
Localization to
PLC
PLC
SHOP
SHOP
PLC
HMI
SHOP
Server
PLC
Net Partner
SHOP
Net Partner
Consequently, variable registers (bit, word) are reserved in each PLC for these
communication channels.
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3-Design
Power
Management
SCADA
server
Instrumentation
Motor
control
Collaborative
control
Plant
information
management
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3-Design
The plant is divided in four main units: Quarry and Crusher, Raw Mill, Clinker and
Cement Mill, for example let us take the Quarry. Then, a click on this unit leads to the
display of the included equipment in this one (Crusher, Conveyor, Homogenizer), and
then on each control module (Crusher Motor) related to these previous equipments
(here, Crusher), and so on.
66
4-Configuration
Configuration ____________________________________________________ 68
UAG Project ___________________________________________________________ 68
Project Organization___________________________________________________________ 68
Project Creation ______________________________________________________________ 71
Topological Model______________________________________________________ 73
Network Segment_____________________________________________________________ 74
Data Servers ________________________________________________________________ 74
HMI ________________________________________________________________________ 75
PLCs_______________________________________________________________________ 76
Network Nodes_______________________________________________________________ 84
Communication________________________________________________________ 92
67
4-Configuration
Configuration
The design has prepared all elements to start the creation of the UAG project.
This chapter tells you how to:
memory mapping
UAG Project
The following sections explain the organization and the creation of a UAG project.
Project Organization
A UAG project is composed of several parts:
libraries of objects (ScoDs) with a logic facet (that is EFB/DFB in Unity library), a
SCADA facet (Genie/Super Genie in Vijeo Citect library), and documentations
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4-Configuration
The following illustration shows the default organization of the components in the
computer disk after an installation:
We recommend modifying this tree to facilitate the saving and restoration of project
operations.
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4-Configuration
Legends:
(1): Dedicated project folder
(2): Library source repository
(3): Unity Pro libraries dedicated to the project development (install forms)
(4): Vijeo Citect libraries and templates dedicated to the project development (backup
files)
(5): UAG SCoDs libraries and documentation dedicated to the project development
(6): Project Model repository
(7): Customization file
(8): UAG project and additional configuration files (Advantys, Profibus, etc.)
(9): Unity Pro source application repository
(10): Vijeo Citect source application repository
(11): Documentation source repository
By this way, the project management and its backup are easier.
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4-Configuration
Project Creation
The project creation comprises the following steps:
The following illustration shows the selection of the customization file (.osc), defined
in the Design chapter, Project Customization section:
T
h
e
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4-Configuration
At this step, the user can start the project building.The following illustration shows the
two models that compose a UAG project (the physical and the topological models):
T
h
e
Note: The building of the Physical and Topological models is described in the
following section included in this chapter.
The project must be saved after creation, and then it is saved automatically.
In large projects, the multi-user programming is compulsory to reduce the engineering
time. The multi-user programming is a native feature in UAG. This means that many
users can work on the same UAG project in the same time. All the modifications
done by one user are available to the others.
Note: You must share the project file (.osp), the customization file (.osc), and the
object library on a server.
Note: When a code generation is launched, the project must be open without shared
aspects to avoid modifications during generation. In this case, anybody is able to
open the same project (except the user who launched the generation).
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4-Configuration
The following table presents the method for creating a shared UAG project:
Step
Action
Paste the customization file (.osc) and the UAG project file (.osp).
Paste all the contents from the folder C:\Program Files\Schneider Electric\
Unity Application Generator\Db in the sub-folder SCoDs Library.
Replace the path in the customization file with the ScoDs Library path.
Topological Model
The configuration phase of the topological model lets you establish the network
segment, the data servers, the HMI part (with all pictures), and the PLC (including all
components configuration).
The mapping of variables and different communication channels are defined in the
topological model, this information has been prepared during the design phase.
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4-Configuration
Network Segment
The architecture comprises several Ethernet networks:
the Ethernet control network that connects the PLC and the servers:
PlantNetwork1
Data Servers
The data server used in the architecture is configured (DS1). The definition of the
data server (DS1) is shown in the illustration. With UAG, the definition of redundant
data servers with a redundant ring is possible. (This feature will be added later.)
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4-Configuration
HMI
The Vijeo Citect project is defined in this section. The breakdown of the Cement Plant,
which has been previously defined, is done here. The following screenshot shows the
three areas (three domains; Quarry, Plant, Packing). This splitting in domains allows
the user to define the management of access rights.
Then, the user defines the different pages in Vijeo Citect, in which are generated in
the Genies configured in the physical model, for each SHOP.
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4-Configuration
For example, the clinker SHOP contains five pages: ClinkerSilo, Cooler, Kiln, Clinker,
PreHeater.
PLCs
In the PLC node, four required PLCs have been added. For each PLC, the complete
hardware configuration is defined:
memory areas
fieldbuses
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4-Configuration
The following table presents the possibilities to add and configure PLCs:
Elements
Comments
Rack and
The Basic tab of the Properties PLC pop-up of each PLC allows the definition of the
CPU
Rack and the used CPU. This action must be done for each PLC in the architecture.
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4-Configuration
Memory
Areas
The Addresses tab of the Properties PLC pop-up allows the configuration of the
different memory areas for the Hardware Modules, the HMI, the Fieldbus, the
NetPartner. and the PLC-to-PLC Communication
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4-Configuration
79
4-Configuration
The fieldbus and the connected devices must be configured in the topological model
Fieldbus on
Ethernet
for each PLC. An example of the RawMaterial SHOP follows. The Ethernet bus has
an Advantys STB, a PM750 (via an Ethernet/Modbus Gateway), and a connected
ATV71. All these devices are selected in the topological model using a right-click on
the PLC, then New Rack.
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4-Configuration
1) The Head Slot, which corresponds to the Ethernet Module to which the
island is linked, here the slot 4.
2) The Configuration File (.isl) from the Advantys Configuration Software. The
creation of this file must be done before UAG is launched.
Afterwards, you can directly import the Advantys STB configuration into the UAG
project.
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4-Configuration
Then, open the rack and add the PM750 device, in the Complex I/O Category. The
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4-Configuration
Modbus address 1 is given in the Modules Properties:
In the same way, add The ATV71 Device by defining an Ethernet I/O Rack and
adding in this one the ATV71 Complex I/O Module, in the Properties Rack pop-up:
Then, configure the IP Addresses and the Network Segment in the Properties popup:
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4-Configuration
Builder that is provided with the PTQ module. This software allows the user to
parameterize the properties of the Profibus network, then declare the different
Profibus
Network Nodes
In this part, all additional components in the plant network are defined. In our project,
a Magelis XBTG 4230 has been added as a NetPartner in order to reserve the IP
address.
Physical Model
The UAG physical model represents the translation of the ISA-S88 standard. Based
on the library and the customization previously defined, levels and control modules
specified in the P&ID are now instantiated.
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4-Configuration
Building
These steps show you how to create a physical model in UAG, with the building of the
RM (Raw Mill) SHOP physical model taken as an example:
Step
Action
In the project tree, right-click on Site. This pop-up appears to create the line:
Right-click on LINE, then the following pop-up appears to create the different SHOPs, here
the Raw Material (RM) :
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4-Configuration
The sequences that compose the Raw Material are FU (function), HO (Homogenizer), AD
(Additives), and BLS (Blending Silo). The previous screenshot shows the BLS.
4
86
4-Configuration
This screenshot illustrates the conveyor BC11 of the AD (additives) SEQUENCE of the RM
(Raw Material) SHOP.
5
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4-Configuration
The following illustration shows the complete view of the Raw Material SHOP:
Interlocks
UAG allows the Interlocks creation on the command of the different devices by a
right-click on the module then open interlock. In this way, the interlock helps you to
avoid damage to the operator or the environment by the installation.We recommend
using Unity for interlocks that require complex logic.
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4-Configuration
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4-Configuration
The following screenshot shows the channels between the data server and the PLC
dedicated to the RM (Raw Material) SHOP:
Link Creation
Once the communication channel is defined, you can link the models.
The variables that come from the physical model can be linked to a real hardware
module or exchanged between PLCs. Both are defined inside the UAG Project
through the I/O Points interface or the PLC-PLC Channel. For instance, the link
between a variable and a real hardware module requires that the connection type of
the variable must be an IO_PLC Type.
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4-Configuration
The following table shows how to do this definition. A written value to PLC_RM to
PLC_QU is taken as an example:
Step
Action
In the physical model, drag and drop the variable to the desired position in the
communication table.
Step 1
Step 2
Step 3
Note: The communication between two PLCs is defined in the PLC that produces
variables.
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4-Configuration
Communication
MODNET is the communication protocol that has been selected for communications
between PLCs and the SCADA servers. The MODNET driver is included in Vijeo
Citect by default.
OFS can be used as well. First, you have to set the right parameters in the
customization file of the project.
The following table details operations:
Step
Action
The UAG now uses the OFS server for the communication with Vijeo Citect IO Server.
Note: Since the OFS communication allows using unlocated variables, you can set the
parameter Create unlocated PLC_HMI variables as well.
Note: The type of communication used in the project depends on the project
requirements.
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5-Implementation
Implementation ___________________________________________________ 94
UAG Generation _______________________________________________________ 94
Unity Pro____________________________________________________________________ 94
Vijeo Citect __________________________________________________________________ 97
Incremental Generation ________________________________________________________ 99
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5-Implementation
Implementation
This chapter describes all the final adjustments to finalize the application in terms of:
UAG Generation
Once the configuration of the topological and physical models is done, the Unity Pro
and Vijeo Citect applications can be generated.
In UAG, the user can launch the complete logical generation by clicking Generate>PLC. The generation can be realized independently, by a right-click on each desired
PLC in the topological model.
Concerning the HMI application, select Generate->HMI.
Unity Pro
The following screenshots illustrate the generation result for the Raw Mill SHOP. The
arrows highlight the corresponding Unity Pro Sections:
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5-Implementation
Physical Model of
Functional view
For instance, opening the corresponding MI11 section in Unity, the user can find the
three objects that have been defined in the UAG physical model. Here, the objects
are: SP01 speed measurement, LE01 analog level, and MT01 Motor.
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5-Implementation
The following screenshot illustrates the BC12 conveyor and its interlock:
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5-Implementation
For each communication channel configured with UAG, a section is created with Unity
Pro.
The following screenshots show examples of the DFBs generated by UAG, which
manage exchanges between the Clinker and the Raw Mill PLCs.
The write data DFB from Raw Mill to Clinker:
Vijeo Citect
UAG generated for the first time a new Vijeo Citect project including all the pages, the
tags for the I/O Servers, the alarms, the trend tags, and their file storage.
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5-Implementation
The following screenshots illustrate the generation result for the complete installation:
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5-Implementation
Note: The previous picture shows what is directly generated: 2 motors, a speed
measurement device and an analog level sensor. The user has to add graphics and
arrange the page.
Incremental Generation
UAG allows for the generation of additional modifications directly to the project, taking
into account the previously generated applications.
The new parts are then generated for Unity Pro and Vijeo Citect projects. This
involves the synchronization of the PLC and the SCADA project databases.
The following table explains how to perform this incremental generation:
Step
Action
In the topological model, right-click on the appropriate PLC, then Generate PLC.
Note: At this phase, the modifications have been generated in the Unity Pro application.
Note: In the event of a SCoD modification, you must do an export/import of the UAG
project. In this case, Unity applications previously generated by UAG are no longer
synchronized with the current generated UAG project. To avoid a loss of data, resynchronize the two databases by executing the TimeStamp.exe tool.
C:\Program Files\Schneider Electric\Unity Application Generator\
TimeStamp.exe
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5-Implementation
Additional Codes
Unity Pro
After the generation of the Unity applications, some modifications have to be added in
the following cases:
Premium HotStandby: The user must add the HotStandby section, which is not
generated by UAG.
Quantum HotStandby: This section is generated, but must be moved to the first
position in the section tree.
Process code: The user adds this code to fit in the process defined in the
functional analysis.
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5-Implementation
The following illustration, which corresponds to the Raw Mill (Premium HotStandby),
shows the process and the additional codes that have been added in the Unity
application.
HotStandby section
in first position
Process section: A
simulation section
Re-organization of
the generated
sections.
Vijeo Citect
This section lists the items where additional codes are required:
SCADA screens: The generated Vijeo Citect project includes the pages declared
in the topological model, with their associated genies. In order to illustrate each
page of the application, you have to import background pictures that represent
the different parts of the cement plant. Then, animations (conveyor animations,
for example) have been added to show the process function. Finally, the
navigation between these different screens allows ergonomic handling of the
Vijeo Citect SCADA and completes our application. The navigation rules
correspond at the navigation principles, previously defined in the Design chapter.
User access right management: To use the access level configuration in UAG,
some users profiles with their corresponding rights must be created.
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5-Implementation
During the generation of the Vijeo Citect application, UAG generates a Cicode
function (Vijeo Citect Function) LoadPreSets. This function loads the parameters of
each variable when the application starts.
To enable this function at the application start, the user must launch the Computer
SetUp Wizard and parameterize it in the launched functions section.
To access the Computer SetUp Wizard, perform these steps:
Step
Action
Note: To deploy the application on other computers, you must copy and paste the
Citect.ini file on the appropriate computers at the path C:\windows\citect.ini. This file
includes the Computer Setup Editor configuration.
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5-Implementation
Address Boundary
It determines whether the compiler checks for correctly-aligned I/O device variables.
Each analog variable in an I/O device usually occupies a word location (16 bits wide).
If the first word is V1, the next is V2, V3, V4, and so on. With some I/O devices, you
can access two words as a long or real value (32 bits wide). The first long will be V1
and the next V3, V5, V7, and so on.
For Vijeo Citect to read these variables correctly, all double-register variables must be
aligned on the same boundary, either an even or odd boundary. When Vijeo Citect
compiles your project and finds a double-register variable, it remembers which
boundary it is on and checks that all other double register variables are on the same
boundary. So, if Vijeo Citect finds a double register variable on address V5, Vijeo
Citect checks that all other double register variables are also on odd boundaries.
The Vijeo Citect compiler displays the "Address on bad boundary" message if the
address of a long or real variable is not aligned correctly.
In our application, this rule is not taken into account. Its parameterization is in the
Computer Setup Editor Tree, especially in the General part (citect.ini file).
The following screenshot illustrates the General Part:
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5-Implementation
Vijeo Designer
A Magelis HMI has been implemented with Vijeo Designer to steer or modify the
different parameters of our application simulator. UAG enables the importing of
variables to the HMI from a generated .CSV file. Currently, this file is compatible only
with the Magelis XBT-L1000 series.
Documentation
UAG creates a project folder that includes information linked to the project. Click on
File-> Report and fill in the DialogBox Report.
Note: This report can be customized by a Word template.
The following screenshot shows the Report dialog box:
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5-Implementation
System Backup/Restore
To maintain project integrity, backup all the applications on a regular basis.
Library
The main goal is to recover a consistent environment after updates or object
modifications. We recommend a backup after any library modifications.
Note: The user does this backup manually.
Project
UAG provides a tool to manage versions for the UAG, Unity, and Vijeo Citect
applications. This operation must regularly occur. For more information about this
UAG feature, please refer to the UAG documentation.
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6-Operation
Operation_______________________________________________________ 107
User Guide___________________________________________________________ 107
Home _____________________________________________________________________ 107
Navigation _________________________________________________________________ 108
Alarms ____________________________________________________________________ 111
Trends ____________________________________________________________________ 111
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6-Operation
Operation
User Guide
This chapter provides a methodology for using the application through the SCADA
application that was developed on Vijeo Citect. It presents the content of the SCADA
in terms of navigation rules, alarms management, and trends performing.
Home
Once the application is launched, the SCADA proposes the user a global view of the
cement plant. On the top of the screen, a navigation tool bar is available. In another
hand, on the bottom, the user finds the display dedicated to the alarms. Finally, the
current date/time are displayed on the bottom right corner.
The following figure shows the home screen:
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6-Operation
Navigation
The navigation takes place through a graphic environment. Once the SCADA runs, a
screen displays the complete installation. The user can click on the four following
main units: Quarry and Crusher, Raw Mill, Clinker and Cement Mill. The mouse
pointer makes them highlighted by a square. After, a simple click on the desired unit
leads to the display of included equipment in this unit, then on each control module
related to these equipments, and so on. The goal is to make the navigation intuitive,
following the ISA-S88 industrial slicing: unit-> element-> equipment-> control
module
General Rules
In each unit, the equipments can be directly accessed through the CementScada
menu, in the Navigation tool bar. A click on this menu displays the list of the units,
with their corresponding equipments.
The following figure shows the global navigation rules:
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6-Operation
109
6-Operation
The following screenshots show the navigation sequence for accessing the control
panel of the CONTROL MODULE Motor Crusher:
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6-Operation
Alarms
The bottom of the home page is dedicated to the alarms display. At the center, a
screen displays the current alarms. On the left corner, five icons allow the user to
manage the alarms display by a simple click:
If you click on a notified alarm, the SCADA leads you to the appropriate equipment.
Some filters are available on the left of the alarm screen. Finally, to go back to the
main screen and click the Home button.
Note: All these previous functionalities are available on the main navigation toolbar
through the Alarms menu.
Trends
On the main navigation toolbar, the menu Trends is available. It permits the user to
represent the trends of values through a graphic tool. You can access this graphic
trend tool clicking directly on the Trends button.
The tool proposes the following display modes: single, both trends simultaneously, or
pop-up. After the graphical tool starts, select the desired value by clicking on the
browser icon.
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6-Operation
The following figure illustrates a trend display:
This tool proposes two tool panels: data and graphic management.
The following table explains the different proposed tools:
Data management
Graphic management
112
6-Operation
113
Due to evolution of standards and equipment, characteristics indicated in texts and images
in this document are binding only after confirmation by our departments.
Print:
www.schneider-electric.com
Version 1 - 10 2008