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
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