IEC 62603

Industrial Process Control Systems

Guideline for evaluating process control systems

COMITATO ELETTROTECNICO ITALIANO TC65B, WG6

Micaela Caserza Magro – Paolo Pinceti

1 – Tool for the Technical Evaluation of the proposals from different PCS Makers

2 – Common Procedures for Factory Acceptance Tests (FAT) of PCS

Users espressed two requests:

The origin of the idea… F

UK

I

NL

Group of Users of Instruments and Systems

2

Goals of the Project

3

4

• Project: PNW 65b-647 Ed.1 Industrial process control systems - Guidelines for evaluating the performance of Process Control Systems - PCS

March 2008

Result of Voting Approval Criteria Result

Number of P-members: 24

P-members voting: 20

P-members approving: 18 = 90 % > 50% APPROVED P-members ready to participate in the development and approving addition of the proposal: 6

>=4 (if <=16) >=5 (if >= 17)

APPROVED

COMITATO ELETTROTECNICO

ITALIANO

The Project Team

5

TC65 Industrial-process

measurement, control and automation

65A System aspects

65C Industrial networks

65E Devices and integration in

enterprise systems

Liasons IEC

6

Liason D

Exera (FR) Profibus Network

Organisation

Fieldbus Foundation

7

8

User/Engineer

Function #1

Function #2

…

…

…

Function #n

Function #1

Function #2

…

…

…

Function #n

Tech. Specs

Maker/Supplier

Tech. Proposal

Check List

Evaluation/

Ranking

9

The process of PCS selection

PROCESS REQUIREMENTS

PCS UNDER TEST

PCS TECHNICAL

SPECIFICATIONS

PCS TECHNICAL PROPOSAL

VENDOR SPECIFIC ARCHITECTURE

Air

IEC 62603

Logical flow

10

Function #1

Function #2

…

…

…

Function #n

the function is of little use weight: D

the function would help weight: C

the function should be implemented weight: B

the function must be implemented weight: A

the PCS does not meet the function vote: 0

the PCS does not meet the function,

but it can be applied or created vote: 1

the PCS meets the function vote: 2

the PCS fully meets the function vote: 3

Function #1

Function #2

…

…

…

Function #n 12

IEC 62603: Heuristic rules for

voting

For considering a bid acceptable, all the functions with weight A and B must

have a vote not lower than C. For defining a global bid vote, first a numerical

value must be assigned to weights and votes, then the average vote can be

calculated with the following Equation

n

ii

n

ikii

k

w

vw

valueBid

1

1

)(

)(

where:

n is the number of functions

Technical

Requirement Weight

Bid

#1

Bid

#2

Bid

#3

Item #1 w1 v11 v21 v31

Item #2 w2 v12 v22 v32

...... ... ... ... ...

Item #n wn v1n v23 v33

wi is the i-th function weight

vki is the vote of bid “k” for the i-

th function 13

IEC 62603: Evaluating an offer

WEIGHT FUNCTION WEIGHT BID 1 BID 2 BID 3

A 8 1 3 8 3 80 2 64 3 80

B 4 2 3 8 3 80 3 80 2 64

C 2 3 2 4 2 32 3 40 3 40

D 1 4 0 1 2 8 2 8 1 4

5 1 2 1 8 3 20 1 8

VOTE 6 2 4 3 40 2 32 2 32

3 10 7 2 4 3 40 1 16 3 40

2 8 8 3 8 1 32 2 64 3 80

1 4 9 1 2 3 20 3 20 3 20

0 0 10 2 4 2 32 2 32 2 32

45 8,27 8,36 8,89

USER DEFINED

14

IEC 62603: a numerical example

For the technical evaluation of a

Process Control System it is

necessary that the Technical

Specification of the required PCS

defines a clear list of requirements

to check-out.

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11 15

IEC 62603 – Part 1

16

IEC 62603 – How to use it

17

IEC 62603 – How to use it

This part describes the general characteristics of the PCS, namely the physical structure and the

preliminary sizing of the components. The scope of this part is to identify the general characteristics of the desired PCS, the fundamental technologies, the

topology of the system and its size

18

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

System architecture

This part describes the general characteristics of the environment in which the PCS and its components are installed.

The operating conditions for the PCS components are divided into four main categories, according to the classification made by the standard IEC 60654 family:

• the climatic conditions of the location in which the components are installed (i.e. temperature, humidity, etc.);

• the power supply to which the components are connected: the minimum EMC requirements in terms of immunity and the power supply characteristics;

•mechanical influences to which the components are exposed during their operation (i.e. vibration, shock, etc.);

• corrosive and erosive influences to which the components are exposed during their operation (i.e. sand, gases, corrosive liquids, etc.) 19

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

System architecture

Characteristics that influence the PCS structure and capability. System

scalability

System expandability

Integration of subsytems

System configuration:

on-line, off-line, graphical,

etc.

Documentation

Programming languages for

control

20

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

System characteristics

• Reliability: self diagnostic, fault tolerance, hot swappable components

• Availability: admissible degraded conditions, stand-by configurations, redundancy criteria

• Maintainability: strategies for maintenance, spare capacity of the system

• Safety: emergency shut-down, safety requirements (SIL)

This part deals with the concept of system DEPENDABILITY, that

includes: reliability, maintainability and maintenance

21

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

Reliability and availability

22

NORMAL

non-criticalfailure

criticalfailure

redundantarchitecture ?

2ndfailure

repair

NO

YES

DEGRADED

ALARM

FAULT

2nd failure

repair

repair

Failures & Operating Modes Transitions

Redundancy is the key for achieving high system

availability

Specifications of the Input/Output of the PCS: conventional I/O (4-20 mA, 0-10 V), digital I/O, Hart I/O and fieldbus. For each type of I/O the user should specify the resolution, the accuracy and the repeatability.

According to IEC 60050, the following definitions apply:

• resolution (for measurement): smallest change in the measurand, or quantity supplied, which causes a perceptible change in the indication;

• resolution (for analog converters): the maximum capability of a system that is used to convert an analog signal into a proportional digital value. Generally, resolution is expressed in bits, from which the actual resolution may be determined (bits per word);

• accuracy: the ratio of error to the full-scale output or the ratio of the error to the output, as specified, expressed as a percentage;

• repeatability (cfr. ISA-37.1-1975 (R1982)): is the ability of a transducer to reproduce output readings when the same measurand value is applied to it consecutively under the same conditions and in the same direction

23

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

Input/output

This part deals with the requirements for software used in a PCS: the database, the simulator as well as cyber security and access management

• System database requirements

•Cyber security

• Software simulator

•Remote supervisory functions

24

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

Software

The HMI requirements include:

•Control room HMI hardware: architecture, machines, monitors,…

•Control room HMI software

• Local operator interface

•Alarm management

•Event management

•Historical archiving

•Trend and statistics management

25

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements – HMI

The levels of communication networks are:

Fieldbus

between the field devices and the controllers. (e.g.

Fieldbus Foundation)

controller network

it guarantees horizontal

communication.

control room network

it supports the interface between the controllers and the workstations in

control room.

corporate network

communication between the PCS and

the ICT.

Communication plays a key role

in a PCS. Usually communication networks may be divided into three or four

levels according to the

technology used

26

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

Communication

HMI HMI EWS

4 level communication network (PLC based)

SRV

LEV

EL 1

LEV

EL 2

LEV

EL 3

LEV

EL 4

Corporate Network

Control Room Network

Controller Network

Fie

ldb

us

Fie

ldb

us

Fie

ldb

us

3 level communication network (DCS)

HMI HMI EWS SRV

LEV

EL 1

LEV

EL 2

LEV

EL 3

Corporate Network

Control Room Network

Fie

ldb

us

Fie

ldb

us

Fie

ldb

us

Server

27

PCS technical requirements –

Communication

This part specifies the performances the PCS should guarantee for satisfying the

requirements of the controlled process.

29

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

Performances

Time performances: response time,

timestamp, absolute time

synchronization, switch over time,

etc.

Controller performances:

real time requirements, scan time, etc.

HMI performances:

call-up time, refresh time,

real-time, etc.

Assett management:

system benchmark,

definition of KPI, definitionof OEE,

generation of maintenance

requests

This part defines the technical/commercial services that should be offered :

• Training of the personnel

• Requirements for support

•Warranties

•Hardware/software upgrade

• References of the company

• Core competencies

•Application experience

• References for similar applications 30

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements –

Technical and commercial support

General definitions and procedures of the Factory Acceptance Test (FAT), Site

Acceptance Test (SAT), and Site Integration Test (SIT) for a PCS are

described in the IEC Standard 62381.

The type and the extension of the PCS testing must be defined in the

specifications, and may represent an important item to be evaluated

31

PCS

Technical Requirements System

Architecture

Installation Environment

System

Characteristics

Reliability &

Availability

Input/Output

Specifications

Software

Requirements

HMI

Communication

Requirements

Required

Performances

Technical

Support

pos. 4.1

pos. 4.2

pos. 4.3

pos. 4.4

pos. 4.5

pos. 4.6

pos. 4.7

pos. 4.8

pos. 4.9

pos. 4.10

FAT

Specification

pos. 4.11

PCS technical requirements – FAT

Specification

HMI

CONTROLLER

TERMINATION

FIELD

FAT LEVELS OF DEPTH

PROCESS

1 2 3 4 5

32

FAT Levels

Function Level Extension notes

System configuration 1 100 %

Graphic screens 1 100 %

Control loops and sequences 3 30 % only critical functions

Safety related functions 4 100 %

Interface with external systems 4 5 % only selected data

Redundancy check 3 100%

Alarm check 2 5 %

Advanced control functions 5 100 % Specific

HMI

CONTROLLER

TERMINATION

FIELD

FAT LEVELS OF DEPTH

PROCESS

1 2 3 4 5 FAT Specs

33

A Level 5 architecture:

35

SoftPLC

Hardwired

connection

Remote I/O

Fieldbus

converter

Fieldbus

Manager

Process

Simulator

SW interface

(e.g. OPC)

PCS I/O cards &

fieldbus interfaces

fieldbus

connection

36

Part 1: General considerations and methodology

Part 2: Assessment methodology

Part 3: Assessment of system functionality

Part 4: Assessment of system performance

Part 5: Assessment of system dependability

Part 6: Assessment of system operability

Part 7: Assessment of system safety

Part 8: Assessment of non-task-related system properties