cement schneider

8/10/2019 Cement Schneider

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Build a Process Control Application with

SoCollaborative Engineering - UAG

How can I...

System Technical Guide

Tested, Validated and Documented


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Table of Contents

Introduction.................................................................. 6

Selection......................................................................15

Design..........................................................................35

Configuration..............................................................67

Implementation...........................................................93

Operation...................................................................106


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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.


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The following illustration shows a synoptic view of this approach:


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Chapter 5, Implementation. This chapter explains the final adjustments required

for an application in terms of:

1. generated UAG project: Emphasis is on the incremental generation

and the care to be taken into account in the event of an additional

code implementation.

2. additional code to finalize the generated UAG project: This part

presents the code required for adding to the Unity Pro or Vijeo Citect

applications.

3. fine tuning the PLC, SCADA

4. manual enhancements in the documentation created by UAG

5. computer setup (SCADA system configuration)

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

Note: All sectional architectures are interconnected.

Project Requirements

The project must comply with the following specific requirements:

state-of-the-art cement processing

reduced engineering time

customer standards in terms of engineering, operation, and maintenance

facilitate future extensions

These requirements were observed during the solution development.


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Cement Plant Project Description

The purpose of the project is the development of automation within a cement plant.

The plants processing line (which can be extended to several process lines) can

produced 2000 tons a day. It comprises four main functions. Each function can

include sub-functions, called units.

This illustration describes the complete cement plant:

Here is a short description of each function:

1) quarry and crushing: The function for obtaining raw materials includes three sub-

functions:

1-1) A crusher reduces raw material with jaws

and a gyratory system.

1-2) A 500-meter conveyor moves the raw

material to the plant.1-3) A pre-homogenization

silo is a buffer for the next downstream unit, the

raw mill.

2) raw mill: This function obtains the right composition of raw material to optimize the

combustion in the kiln. It includes three sub-functions:

2-1) Four silos manage the additives (100 m3/h.) according

to the cement recipe.

2-2) A raw mill grinds the raw material, including additives.

2-3) Two blending silos are buffers for the next downstream

function, the Clinker.


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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.


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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 methods, programming, rules, interfaces

(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.)

How to Use This Guide

Please note that the STG does not deliver detailed information about UAG. To find

more information about UAG software, please refer to UAGs own documentation and

training materials.

With a full and correct understanding of both the Collaborative Control Architecture

and UAG software, readers can easily develop customized architectures.

The product descriptions in this document do not replace other Schneider Electric

related user manuals or technical publications.


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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.

Please note that electrical equipment should be installed, operated, serviced, or

maintained only by qualified personnel. No responsibility is assumed by Schneider

Electric for any consequences arising out of the use of this material.


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Tested & Validated

In the architecture building project, How Can I, several STGs (System Technical

Guides) have been tested and validated on a Collaborative Control Architecture.

This concise and readable document has been created to help the reader acquire a

comprehensive understanding of a process application using UAG based on this

Collaborative Control Architecture.


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This chapter contains the following sections:

Selection ________________________________________________________ 16

Functional Analysis ____________________________________________________ 17

Description of the Process ______________________________________________________ 17

Customer Standards __________________________________________________________ 29

Operator Requirements ________________________________________________________ 31

Library Requirements__________________________________________________________ 33


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Selection

This chapter describes how to perform the functional analysis of the process. It gives

the user a methodology for:

analyzing the process of the plant

proposing physical, topological, and procedural models

analyzing the customer standards in order to propose operational rules

selecting the most appropriate library

This illustration summarizes the different steps in our project:


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To follow correctly this methodology, the user has to gather information from different

sources:

functional specifications

operator requirements

process system diagrams (P&ID)

field devices and I/O lists

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 batchprocesses, 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.


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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 siteis 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

function. For a complex function, the ISA-

S88 standard allows you to divide it into

several more simple sub-functions

. An Equipment module combines physical

processing and control modules to perform

activities.

A Control Module is a collection of sensors,

actuators and associated processing

equipment, which can operate as a single

entity. A control module can be composed of

others control modules.

In this project, the plant has one process line.

process

organization


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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:

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 functionalparameters.

Clinker

Raw Material

Cement Mill

Quarry

Line 1


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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.


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This illustration shows the division in the Raw Material SHOP and its four main

functions (SEQUENCE) using the P&ID representation:

Note:The arrows indicate the flow of material.

In the following list, each SEQUENCE of the Raw Material SHOP is described. A

SEQUENCE is composed of several PARTS (Equipment in the ISA-S88 model):

1) The Homogenizer SEQUENCE is simplified in our model, as there is only one silo.

This PART has one level transmitter that is realized as a CONTROL MODULE

(Control Module in the ISA-S88 mode).

2) The Additive SEQUENCE is the more complex of the Raw Material SHOP. Two

zones (or sub-sequences) compose this sequence: the Silo Additive and theConveyor. It is possible to define a specific level in the model for each zone, but

in order to simplify; the representation of this level was not added to the sequence.

The silo Additive zone is made up of the four Silos PARTs (S11, S12, S13, S14).

Each silo PART has two levels switches indicators (High and Low), a set point

(additive percent to be added), and a digital motor CONTROL MODULE.

A Belt Conveyor PART with the CONTROL MODULEs Variable Speed Motor

and Speed Indicator that compose the Conveyor zone.


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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.


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Finally, these are our structure levels:


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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:

The Procedure describes a strategy for

handling major processing actions. It is

defined in terms of an ordered set of unit

procedures.

The unit procedure defines a sequence of

operations that takes place inside a

production unit.

Each procedure is a combination of several

operations that define the process tasks.

Theses tasks are divided into elementary

functions named phases.


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The following illustration shows the link between the Physical and Procedural Models

of ISA-S88:


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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.


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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

standalone unit to be controlled

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.

The following illustration shows the complete hardware installation:

SCADA

server

Plant

information

management

Collaborative

control

Motor

control

Instrumen-

tation

PowerManagement

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.


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These illustrations describe each functional unit with their corresponding hardware:

Quarry and Crushing

An M340 PLC is used to control the functional unit.

Through CANopen communications, this PLC controls a contactor (a

TeSys T starter controller) for the Crusher and ATV31 drives for the belt

conveyor management.

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.


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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 _ AAA _ AA 11 _ AA 11 _ VarName

SHOP SEQUENCE PART CONTROL

MODULE

VARIABLE

2 letters 3 letters 2 letters +

2 digits

2 letters +

2 digits +

1 name


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The following table presents the naming rules in our application:

SEQUENCE PART CONTROL MODULES

Actuators Controllers Analog I/OFU: Function

CR: Crusher

HO:

Homogenizer

AD: Additive

MI: Mill

BLS: Blending

Silo

PH: Pre-Heater

KI: Kiln

CO: Cooler

CMS: Cement

Silo

CKS: Clinker

Silo

BC: Belt

Conveyor

SI: Silo

MI: Mill

CR: Crusher

FA: Fan

DP: Damper

GT: Gate

CY: Cyclone

RO: Roller

BU: Burner

MT: Motor (digital or

proportional)

VA: Proportionnel

valve

VX: Digital valve

PID: PID

Controller

ON:

Sequencer

LE: Level Data

SP: Speed

FL: Flow

TC:

Temperature

PR: Pressure

RT: Rate

(percent)

ME:

Measurement


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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.

UNAUTHORIZED SECURITY ACCESS

Protect the password from unauthorized access:

Change or disable default passwords on all devices because default settings are

often easy to find in user manuals.

Change passwords regularly.

Do not choose simple user names and passwords.

Failure to follow this instruction can result in death, serious injury, or

equipment damage.

Note:In our project, dedicated operator profiles have not been created.


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The following figure gives the main criteria to be taken into account and actions to be

implemented:

Note:This illustration represents a general methodology to analyze the criticality of

the information managed in a process application.

The project is divided into three operation areas:

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.


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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:

a logic part (Unity Pro function block)

an HMI part (Vijeo Citect Genie and Super Genie)

The use of an object library facilitates:

standardized design

increased quality and security

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

1 Identifythe control modules used following the P&ID diagram exactly.

2 Groupthe equipment into classes. The following topics define a class :

control logic

displayed information

performed actions

3 Definesub-classes, depending on the occurrences of the equipment and

their functions.

Note: The selection of the library requires a balance between:

the degree of reusability from one application to another

the know-how specific for the process

standardization

A balance leads to a compromise of the objects used to meet these criteria.


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The following table gives the three different libraries you can use:

Library Comments

UAG Process Lib or the

Advanced Process Lib

These libraries are based on standards and can easily be reused,

but they need some add-ons to integrate the expertise specific to

the Cement application.

Cement dedicated Lib 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.

Own created Lib, from

scratch

This library fits the need, but it involves more time to design and is

not generic for other processes.

Note:Using the generic objects coming from these three libraries define a compromise.

The following figure illustrates this compromise:


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Design __________________________________________________________ 36

Design Methodology____________________________________________________ 36

Design Principles ______________________________________________________ 36

Library Design_________________________________________________________ 36

Smart Control Devices Introduction _______________________________________________ 37

Requirements identification _____________________________________________________ 37

Process Library Building ________________________________________________ 40

Selected objects from UAG process library _________________________________________ 40

Adapted Objects from UAG process library _________________________________________ 41

Additional Objects ____________________________________________________________ 41

Project Customization __________________________________________________ 57

Creation of the Customization File________________________________________________ 58

Physical Model Levels _________________________________________________________ 58

Naming Rules________________________________________________________________ 59

Archive _____________________________________________________________________ 62

PLC Selection________________________________________________________________ 62

Functional analysis_____________________________________________________ 64

Definition of communication channels _____________________________________________ 64

Definition of the navigation rules linked to the plant operation (SCADA)___________________ 65


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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 customization of the UAG project

the object library from process requirement

the analysis of the functional process description

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.


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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, theprocess 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:

different control/command devices of the actuators with their associated

communication protocols

different measurements (analog, digital, or via bus)

functional requirements of the process

The four following tables present a synthesis, which can be considered as a slicing

method, of each element (SHOP):


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Cement Plant / Synthesis Identification

Shop Equipment Control/

Command

Communication Measurements Assigned

Function

Crusher

Contactor

+

Starter Controller:

TeSysT

CANopen

-Current (3)

-Motor Frequency

(provided by TeSys T)

-Analog Level

-Number of starts per

hour

Quarry

Belt Conveyor Drives: ATV31 (3) CANopenSpeed

(provided by ATV31)

Sequencer

Homogenizer

Analog Level

-Recipe Number

Display

-Additives

Management

Additives Silos (4)

Starter Controller:

TeSys U (4)STB Island

(Ethernet)

Digital Level

(2 per silos,

High and Low)

Additives Conveyor Drive: ATV71 Ethernet

Speed

(provided by

ATV71)

Electric

Measurement of

the Unit

(With PM750

device) +

Sequencer

Raw Mill Drive: ATV71 Ethernet

-Speed

(provided by

ATV71)

-Analog Level

Raw Mill Conveyor Contactor

Raw

Mill

Blending Silos

Analog Level

Temperature

Electric

Measurement of

the Unit

(With PM750

device) +

Sequencer


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Cement Plant / Synthesis Identification

Shop Equipment Control/

Command

Communication Measurements Assigned

Function

Pre-Heater

Decarbonation

Cyclones (4),

analog :

-Temperature

-Pressure

Cyclones

status

(ready or not)

Clinker

Kiln

Contactor

+

Starter

Controller:

TeSysT

Profibus DP&PA

-Current (3)

-Motor

Frequency

(provided by

TeSys T)

-Analog

Temperature

(3)

-Number ofstarts/ hour

Management

of the kiln

temperature

through a PID

regulated valve

+

Sequencer

Additives Silos

Starter

Controller:

TeSys U (2)

STB Island

(Ethernet)

Digital Level

(2 per silos,

High and Low)

Rcpt number,

Additives

management

Additives Conveyor Drive: ATV71 EthernetSpeed (provided

by ATV71)Sequencer

Cement Mill Drive: ATV71 Ethernet

-Speed

(provided by

ATV71)

-Analog Level

Cement

Blending Silos Contactor Analog Level

Sequencer

Note:These lists are defined according to the piping and instrumentation diagram

(P&ID). For more information, please refer to Selection chapter.


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Process Library Building

After this analysis of the elements included in the process, you can select the objects

needed in the Process Library provided by UAG.

The objects are classified in different categories:

motor management

measurement management

sequential control

other devices management

From this analysis, the final library comprises:

objects from UAG process library

objects from UAG process library adapted to the project context

new objects defined for the project, SCoD

Selected objects from UAG process library

For elements that are subjected to analog measurement, the following objects are

used (for more details, please refer to UAG documentation):

ANAIN_P10: scale the analog input values from various hardware devices

ANAOUT_P10: scale or de-scale a process value to an analog output of various

hardware devices

Motors are driven by these objects:

MOT1D1S_P10: control motors with 1 direction of rotation and 1 speed,

especially contactor-driven motors

MOTATV_P10: control different types of Altivar variable-speed drives (ATV71,

ATV61, and ATV31 supported). The speed drives type is selected by parameter

PAR. Type (1: ATV31, 2: ATV61, 3: ATV71)

TESUIO_P10: control motors with the TeSys U

The temperature in the kiln is managed by a regulated valve. To drive this valve, the

following objects are used:

VALPRO_P10: control proportional valves

PIDCTRL_P10: control PID for temperature regulation


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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.

Adapted Objects from UAG process library

To illustrate results, we will simulate all physical values of our cement plant. Therefore,

some objects must be modified to implement links between the objects included in the

previous process library and the simulation variables. These modifications relate to

the I/O-pin connections only. The change consists in the modification of the

connections IO_PLC in simple PLC connection.

Here, the concerned objects are: ANAIN_P10, ANAOUT_P10, MOTATV_P10, and

MOT1D1S.

Additional Objects

Each project is unique and therefore can require additional objects not included in the

process library.

The following part explains these topics:

the created SCoDs and their possible settings

building SCoDs

Examples of new created objects are detailed hereafter:

new devices objects that are not yet part of the library such as PM750

new process objects like sequencer

New Selected Object (SCoD)

This part provides a short functioning description for each newly created SCoD and

its objects representations (for Unity and Vijeo Citect).

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.


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The following illustration shows the DFB representation:

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 frequencymeasurements.



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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.


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Pin definition:

D: input information from the digital sensor

PAR: filter parameters

PD: filtered output information

HMI_Level: information for the SCADA system

The following illustration shows the Vijeo Citect representation:

Functional State Detected Fault State

Sequencer: This object manages the start-stop sequence of several elements in

cascade. A start command from the SCADA starts the sequencer if the required

conditions are true and if there are no detected or stored faults.


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PIN definition:

Start start command of the sequencer

Stop: stop command of the sequencer

Ack detected fault clearance

Fdb1Fdb8 status of each started actuator

Fdbdefaut detected fault on actuator

PAR parameters of start and stop time, for each actuator

CdStart start conditions of the sequencer

Qstart1Qstart8 start command of actuator

Stdefaut fault status word, the Bit0 (decimal value= 1) is associated to the

Equipment 1 and the Bit7 (decimal value= 128) to Equipment 8.

HMI information for the SCADA system


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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.


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The following illustrations show the startup/ stop principles (grafcet representations)

of the sequencer:


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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).


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Preliminary work:

This table presents the main issues you must address before creating the SCoD:

Topic Question

Function definition and documentation of the function ensured by

the SCoD

I/O complete list of I/O

Unity Block(DFB) development with Unity Pro (How many sections?

variables? etc.)

Symbol Representation

(Genie, Super Genie)

Face plate definition

parameters and the commands that are accessed from

the SCADA?

Trends/Alarms Are they required?

Data What are the exchanged Data from the PLC to HMI

and HMI to PLC?

Documentation What is the format of the documentation?

Preliminary work in Vijeo Citect:

The following table shows the steps to create a Vijeo Citect object, (Genie or Super

Genie):

Step Action

1 LaunchVijeo Citect Graphic Builder.

2 Create a new Library Project.

3 From the Filemenu of Citect Graphics Builder, select New.

Click on Genieor Super GenieButton.

Createyour own object.

4 Developyour Cicode function, if needed.

5 Linkyour Super Genie to the Genie.

6 Packyour objects (Genie and Super Genie).

Note:The Genie/Super Genie must fit to its Unity Pro DFB.


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Preliminary work in Unity Pro:

Use these steps to create a block in Unity Pro (DFB):

Step Action

1 Definethe block in Derived FB Type.

2 Definethe I/O, considering the pin order.

3 Definethe sections.

4 Developthe DFB logic.

5 Buildthe DFB.

6 Putthe DFB in a library.

7 The DFB is ready to be exported.

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

1 Launch SCoD Editor.

2 Select the HMI Type, here Vijeo Citect.


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3 Import your created DFB.

File->Import DFB

Click onOpen button. A pop-up dialog box confirms your choice. Click on

OKbutton.

4 Connect the Vijeo Citect object to your SCoD.

Right-click on your SCoD, properties. The following pop-up appears:

In the HMI Symbol section, click the Addbutton.

Click on the Browserbutton: the following pop up appears, which enables

you to indicate the path through which the Genie is located.


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Click on OK.

To validate your operation, tick the checkboxes Genie, Visible.

Choose your SCoD icon through the Browsericon.

Terminate the connection by clicking on OK.


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5 Define your variables by clicking on the Variablestab of your selected

SCoD.

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.


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For more information, please refer to the UAG documentation.


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6 Configure the SCoD pins. After clicking on the DFB Pinstab, 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 Propertiestab, right-click,

Properties.

The following pop-up appears:


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TheGeneraltab allows you to name the property.

The Positiontab represents the mapping of SCoD parameters.

SCoD Editor screen: UAG SCoD screen:

The arrows show what is created from the SCoD Editor to the UAG SCoD

screen.

8 Validate your SCoD. Right-click on your SCoD, then ComitSCoD.


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Project Customization

The models, adopted conventions (naming rules, alarms), and the system

architecture of the process are defined during the selection phase.. This information isspecific 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 Question Impact

Physical Model Does my physical modelhave enough detail?

Do I have enough levels

to model my process?

The levels represent the framework of the process.Therefore, it must be defined at the beginning of the

project. Any modification on the decomposition after

its definition clearly has an impact since the project is

based on this approach.

Naming Rules Do my naming

conventions appropriately

indicate that objects are

uniquely defined?

A unique name for each object avoids confusion and

facilitates the quick localization of detected faults.

Note:Each variable in UAG must have a unique

name.

Archive Do I define the right

archive strategy for

analog information?

The location and duration of archives is defined in the

Customization file.

For Vijeo Citect, this archived information is used for

trending and the storage of the appropriate trend files.


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Creation of the Customization File

The following table presents the methodology to create a new customization file:

Step Action

1 File -> New, Selection of HMI(Vijeo Citect)

Click on OKbutton.

2 The created Customization file appears in the project tree.

Note:If you create a new customization file, you must include the library.

Physical Model Levels

After setting the general data, the physical model levels of the plant must be defined.

By default, the ISA-S88 standard is applied, but it can be adapted to each customer

project requirement


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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 creationrules. 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 Action

1 List -> Designer

To access the Designer.


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2 Addthe defined lists, clicking on the concerned object (in this case, Shoplist).

3 Expandthe naming convention node and then linkthe 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.


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4 Definehow 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.


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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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Step Action

1 Selectin the PLC/PLC family node the Unity families.

Tickthe different racks and modules that are used in the project.

2 Identifymodules 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.

3 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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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 Designchapter.

This step is preliminary to the configuration phase.

Definition of communication channels

The system architecture of the cement project comprises an Ethernet-based network.

An HMI server, 1 Net Partner and 4 PLCs are connected to the control network.

The goal of this section is to define exchanges between different devices. This

definition is funded on the functional analysis, which includes the different links

between the SHOPs. Thus, the user can do its variable mapping linked to the

previously defined communication channels.

The following table shows a methodology that leads to the mapping definition:

Step Action

1 identificationof the variables for the exchanges

2 localizationof the variables in the PLC

Note:For this application, a PLC is assigned to a

SHOP.

3 mapping definitionfor the communication channel,

that is, defining memory spaces in the PLC

The following table illustrates the exchanges in our application:

Exchanges between Localizationto

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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The following illustration highlights the three kinds of exchanges.

SCADAserver

Pla

nt

inform

ation

management

Collaborative

control

Motor

control

Instrumen-

tation

PowerManagement

PLC PLC: Shop Shop

PLC HMI: Shop Server

PLC Net Partner: Shop Net Partner

All the different device networks (Ethernet, Profibus, etc.) are configured during the

implementation phase of the UAGs topological model.

Definition of the navigation rules linked to the plant operation (SCADA)

The conception of a supervision application presents an essential goal: make access

to the targeted object as fast and intuitive as possible. A breakdown of its own

application in a few areas can help the user define and identify the different phases of

the complete process.

As defined in the physical model, the application divides the project into four areas:

quarry, raw mill, clinker and cement. These areas are obviously composed of

elements. (Fore more details, please refer to the Selection chapter.)


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The following illustration describes the navigation rules:

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.


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Configuration ____________________________________________________ 68

UAG Project___________________________________________________________ 68

Project Organization___________________________________________________________ 68

Project Creation ______________________________________________________________ 71

Topological Model______________________________________________________ 73

Network Segment_____________________________________________________________ 74

Data Servers ________________________________________________________________ 74HMI________________________________________________________________________ 75

PLCs_______________________________________________________________________ 76

Network Nodes_______________________________________________________________ 84

Physical Model ________________________________________________________ 84

Building_____________________________________________________________________ 85

Interlocks ___________________________________________________________________ 88

Link between Physical and Topological Model ______________________________ 89

Communication channel definition ________________________________________________ 89

Link Creation ________________________________________________________________ 90

Communication________________________________________________________ 92


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Configuration

The design has prepared all elements to start the creation of the UAG project.

This chapter tells you how to:

Organize the project.

Create the topological model:

component configurations and the Net Partner definition

memory mapping

communication between PLCs and with the HMI server

Create the physical model

Link these two models.

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

a model (UAG project) based on customer requirements (UAG customization file)

controller applications (Unity application)

SCADA applications and templates (Vijeo Citect projects)


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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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The following illustration shows the modified structure:

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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Project Creation

The project creation comprises the following steps:

include the customization file

prepare the topological and the physical models

structure the project for multi-user programming if needed

The following illustration shows the selection of the customization file (.osc), defined

in the Designchapter, Project Customizationsection:

T

h

e

f


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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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The following table presents the method for creating a shared UAG project:

Step Action

1 Createa UAG folder on the reference server.

2 Pastethe customization file (.osc) and the UAG project file (.osp).

3 Createa sub-folder named SCoDs Library.

4 Pasteall the contents from the folder C:\Program Files\Schneider Electric\

Unity Application Generator\Dbin the sub-folder SCoDs Library.

5 Replacethe 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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Network Segment

The architecture comprises several Ethernet networks:

the Ethernet control network that connects the PLC and the servers:

PlantNetwork1

the Ethernet device bus located in the RawMaterial: FieldRawMaterial

the Ethernet device bus located in the Cement SHOP: FieldCement

For each network, name and addressing information must be filled.

The following screenshot shows the Properties Network Segment popup:

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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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:

rack and CPU

memory areas

Hot Standby configuration if required

fieldbuses


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The following table presents the possibilities to add and configure PLCs:

Elements Comments

Rack and

CPU

The Basictab of the Properties PLCpop-up of each PLC allows the definition of the

Rack and the used CPU. This action must be done for each PLC in the architecture.


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Memory

Areas

The Addressestab of the Properties PLCpop-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

Note:Quarry-specific configuration.The Quarry SHOP is controlled by an M340 on aCANopen Fieldbus. The related CANopen configuration is completely done inside

Unity. For more information, please refer to the Implementation chapter.

Raw Material-specific configuration.The Raw Material SHOP is controlled by a

Premium Hot Standby with an Ethernet-based Fieldbus. Consequently, the definition

of the monitoring ETY Module for the Hot Standby configuration is required. This link

can be done in the Properties PLCpop-up of this PLC:


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Note:Cement-specific configuration.The cement is also controlled by a Quantum

Hot Standby on Ethernet.. Two devices are linked to this PLC through an Ethernet-

based Fieldbus: an ATV71 and an Advantys STB. The configuration steps are the

same as they are for Raw Material.


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Fieldbus on

Ethernet

The fieldbus and the connected devices must be configured in the topological model

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.

The Advantys STB Islandis defined as an Ethernet device. The following

illustration shows the Properties Rackpop-up with the required parameters to

define:


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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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The PM750 Deviceis seen as a member in a Modbus I/O rack.

In the following Propertiespop-up, you must select the Modbus Gateway (in this

case, TSX ETG100) and define the network segment and IP address:

Then, open the rack and add the PM750device, in the Complex I/O Category. The


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Modbus address 1 is given in the Modules Properties:

In the same way, add The ATV71 Deviceby defining an Ethernet I/O Rack and

adding in this one the ATV71 Complex I/O Module, in the Properties Rackpop-up:

Then, configurethe IP Addresses and the Network Segment in the Propertiespop-

up:


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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

1 In the project tree, right-clickon Site. This pop-up appears to create the line:

2 Right-clickon LINE, then the following pop-up appears to create the different SHOPs, here

the Raw Material (RM) :

3 Right-clickon each SHOP, to create the different SEQUENCE:


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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 Right-clickon the SEQUENCEto access the Properties PART pop-up:


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This screenshot illustrates the conveyor BC11 of the AD (additives) SEQUENCE of the RM

(Raw Material) SHOP.

5 Right-clickon the PARTto access the Properties Control Module pop-up:

The MT01 motor of the BC11 conveyor is provided as an example.


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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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This screenshot shows an example of the BC12 conveyor of the RM SHOP:

Link between Physical and Topological Model

After creating the physical and topological models, the user has to link them.

The following sections explain how to declare the different communication channels

(between PLCs and Net Partners) and how to properly link the physical and

topological models.

Communication channel definition

Once the two models have been defined, the communication between the PLCs, the

Data server, and the Net Partners must be declared. (Refer to Designchapter,

Definition of Communication Channelssection.)


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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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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

1 In the topological model, openthe channel of the PLC_RM.

2 Choosethe concerned PLC Communication Table (RawQuarry).

3 In the physical model, drag and dropthe variable to the desired position in the

communication table.

The following screenshot illustrates the previous method:

Note:The communication between two PLCs is defined in the PLC that produces

variables.

Step 1

Step 3

Step 2


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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

1 SelectVijeo Citect and open the configuration screen.

2 Set the parameter use OPC Server to true.

3 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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Implementation ___________________________________________________ 94

UAG Generation _______________________________________________________ 94

Unity Pro____________________________________________________________________ 94

Vijeo Citect__________________________________________________________________ 97

Incremental Generation ________________________________________________________ 99

Additional Codes______________________________________________________ 100

Unity Pro___________________________________________________________________ 100

Vijeo Citect_________________________________________________________________ 101

Vijeo Designer ______________________________________________________________ 104

Documentation ______________________________________________________________ 104

System Backup/Restore________________________________________________ 105

Library ____________________________________________________________________ 105

Project ____________________________________________________________________ 105


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Implementation

This chapter describes all the final adjustments to finalize the application in terms of:

additional codes implementation

incremental generation to be taken into account in the event of some additional

code implementation

fine tuning in PLC, HMI, and documentation

manual enhancements in the documentation created by UAG

system backup/ restore

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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Visualization of the sections:

The following screenshots zoom explicitly on the UAG MI11 section.

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.

Physical Model of

the RawMill in UAG

Unity Pro Generated Application

Functional view


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The following screenshot illustrates the DFBs generated by UAG:

The following screenshot illustrates the BC12 conveyor and its interlock:


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Visualization of the communication section:

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:

The read data DFB from Clinker to Raw Mill:

Vijeo Citect

Visualization of the generated Vijeo Citect pages:

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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The following screenshots illustrate the generation result for the complete installation:

Visualization of the components included in the RM view, which corresponds to

the Raw Mill SHOP:

Topological Model in UAG Vijeo Citect Explorer


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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

1 Openthe existing UAG project.

2 Dothe desired modification in the physical model.

3 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.

4 To generate the corresponding modifications in the Vijeo Citect application, click on

Generatethen HMI. The modifications are now included in the project.

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, re-

synchronize the two databases by executing the TimeStamp.exe tool.

C:\Program Files\Schneider Electric\Unity Application Generator\

TimeStamp.exe


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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.

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.

HotStandby section

in first position

Re-organization of

the generated

sections.

Process section: A

simulation section

has been added to

steer our simulator.


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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

1 LaunchVijeo Citect Project Editor.

2 Clickon the Tools menu.

3 ChooseComputer SetUp Wizard.

The following illustration shows this SetUp Wizard:

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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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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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-> Reportand fill in the DialogBox Report.

Note:This report can be customized by a Word template.

The following screenshot shows the Reportdialog box:


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The following illustration shows an example of documentation:

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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Operation_______________________________________________________ 107

User Guide___________________________________________________________ 107

Home _____________________________________________________________________ 107

Navigation _________________________________________________________________ 108

Alarms ____________________________________________________________________ 111

Trends ____________________________________________________________________ 111


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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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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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The following screenshots show the navigation sequence for accessing the control

panel of the CONTROL MODULE Motor Crusher:


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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 tomanage the alarms display by a simple click:

: This icon enables/disables the audible alarm notification.

: This icon displays the alarms that have been disabled.

: This icon displays the hardware alarm page.

: This icon displays the alarms, with historian sort.

: This icon displays all alarms.

If you click on a notified alarm, the SCADA leads you to the appropriate equip

cement schneider

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