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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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1. GENERAL 1.1 Scope a. This Standard Specification describes the functionality and requirements (including dynamic performance) of the Basic Process Control System (BPCS) for non-safety related control systems. This Standard Specification does not cover specific hardware and software details. This is left to the detailed engineering Contractor and/or Owner. Specific operational and maintenance requirements of this equipment are the responsibility of the Owner and/or Contractor. b. Exceptions or variations shown in the UOP Project Specifications take precedence over requirements shown herein. 1.2 References Unless noted below, use the edition and addenda of each referenced document current on the date of this Standard Specification. When a referenced document incorporates another document, use the edition of that document required by the referenced document. a. Normenarbeitsgemeinschaft fr Me- und Regeltechnik {in der chemischen Industrie}, (NAMUR), NE 43 engl., Standardization of the signal level for the breakdown information of digital transmitters. b. National, state, and local laws and codes

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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2. CONTROL SYSTEM PERFORMANCE 2.1 General a. The control response period shall be used as the measure of BPCS performance. The control system can perform proportional, integral, derivative (PID) control using any combination of hardware and software described in sections 2.2 through 2.5. Functions (e.g. signal selectors, summers, calculation blocks, etc.) associated with controllers shall not increase the control response period. b. The maximum allowable control response period is shown in Table 1: Table 1 Maximum Control Response Period * X, (Milliseconds) 300 ms 1000 ms 1000 ms 150 ms 1000 ms

Process Category Flow Pressure Differential Pressure Temperature Level Designated Fast Process Control Loops All Others (Analysis, Density, pH, Etc)

* Shorter control response periods may be required for certain control services (e.g. compressor antisurge, reactor temperature, etc.). Multivariable advanced process control may be implemented with longer control response periods. c. In general, the shorter the control response period, the better the control performance. Control response periods longer than those listed above may degrade performance and affect unit operability. d. Sections 2.2 through 2.5 show examples of typical techniques used for flow control loops. Other process categories, not shown, shall follow the same techniques. See Table 1 for the value of the maximum control response period (X) in each figure.

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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2.2

Control Performance for a Distributed Control System (DCS) using 4-20 mA Field Wiring a. Applies to process control systems whose field wiring is as shown in Figure 1.

DCS

4-20mA

4-20mA

Figure 1 b. The control response period shall be the total time to perform the following steps (See Figure 2): (1) Analog to Digital conversion of 4 - 20 mA signal and writing value to input/output (I/O) processor (2) Pass the input value to the PID controller to perform the PID algorithm (3) Execute the PID algorithm (4) Pass the calculated PID output value to the I/O processor (5) Digital to analog conversion to generate the 4 - 20 mA output signal

0ms

Xms

1
4-20 mA A/D Input conversion of Signal 4-20 mA signal and write value to I/O processor

2
Bus transmission time to pass the input value

3
PID Algorithm execution in Controller

4
Bus transmission time to pass the output value

5
D/A conversion to generate 4-20 mA output signal

Time (milliseconds) 4-20 mA Output Signal

Distributed Control System

Maximum Control Response Period
Figure 2

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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2.3

Control Performance for Single Loop Controller using 4-20 mA Field Wiring a. Applies to process control systems whose field wiring is as shown in Figure 3.
Output
0% 100%

PV SP PV SP

Single Loop Controller

4-20mA

4-20mA

Figure 3 b. The control response period shall be the total time to perform the following steps (See Figure 4): (1) Read the 4 - 20 mA signal by the single loop controller (2) Execute the PID algorithm in the single loop controller (3) Generate and output the 4 - 20 mA signal by the single loop controller

0ms

Xms

1
4-20 mA Input Signal Read 4-20 mA Signal

2
PID Algorithm execution in Controller

3
Generate 4-20 mA output signal

Time (milliseconds) 4-20 mA Output Signal

Single Loop Controller

Maximum Control Response Period
Figure 4

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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2.4

Control Performance for a Fieldbus System Performing PID Control within the DCS a. Applies to process control systems using fieldbus as shown in Figure 5.

DCS

Fieldbus

Figure 5 b. The control response period shall be the total time to perform the following steps (See Figure 6): (1) Execute the Analog Input Function Block in the transmitter and publish the process variable value on the fieldbus (2) Receive the process variable at the DCS and retransmit it internally to the controller (3) Execute the PID algorithm (4) The total bus transmission time to publish the calculated PID output value on the fieldbus (5) Execute the Analog Output Function Block

0ms

Xms
Time (milliseconds)

1
Fieldbus Communications
Analog Input Function Block in Field Device

2
DCS Bus Transmission Time to Controller

3
PID Algorithm Execution in Controller

4
Fieldbus Communications
DCS Bus Transmission Time to I/O Modules

5
Analog Output Function Block in Field Device

Distributed Control System

Fieldbus Field Device Fieldbus Field Device

Maximum Control Response Period

Figure 6

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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2.5

Control Performance for a Fieldbus System Performing PID Control within the Field Devices a. Applies to process control systems using fieldbus as shown in Figure 7. Note the PID controller may be located within the final control element hardware or field transmitter.

DCS

Fieldbus
AI PID AO PID AI AO

Figure 7 b. PID Controller within the Final Control Element The control response period shall be the total time to perform the following steps (See Figure 8): (1) Execute the Analog Input Function Block in the transmitter and publish the process variable value on the fieldbus (2) Receive the process variable at the controller and execute the PID algorithm (3) Execute the Analog Output Function Block

0ms

Xms
Time (milliseconds)

1
Analog Input Function Block in Field Device Fieldbus Communications

2
PID Algorithm Execution in Controller

3
Analog Output Function Block in Field Device

Fieldbus Field Device

Maximum Control Response Period

Figure 8

Fieldbus Field Device

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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c. PID Controller within the Field Transmitter The control response period shall be the total time to perform the following steps (See Figure 9): (1) Execute the Analog Input Function Block in the transmitter (2) Execute the PID controller Function Block in the transmitter and publish the PID controller output value on the fieldbus (3) Receive the PID controller output value and execute the Analog Output Function Block

0ms

Xms
Time (milliseconds)

1
Analog Input Function Block in Field Device

2
PID Algorithm Execution in Controller Fieldbus Communications

3
Analog Output Function Block in Field Device

Fieldbus Field Device

Maximum Control Response Period

Figure 9 2.6 PID Equation Form

Fieldbus Field Device

The PID controller equation should be of the form in which the derivative action is only based on the change in process variable. Those forms of the PID equation in which the derivative action is based on the change in error (and derivative is used) cause the controller output to spike when the operator changes the setpoint. 2.7 Controller Setpoint Tracking Controller setpoints should track their respective process variables while in manual mode. For cascade loops, the output of each primary controller should track the setpoint of its respective secondary controller when the secondary controller is not in cascade mode. All primary controllers should also revert to manual mode when their associated secondary controllers are not in cascade mode. This allows the controller output tracking to take effect, thereby facilitating bumpless transfer when cascade is re-established. Proper configuration of tracking allows operators to change the mode of any controller from manual to automatic or from local automatic to cascade without causing a process disturbance. 2.8 Controller Central Processing Unit Capacity The control system Central Processing Unit(s) (CPU) shall include sufficient capacity to permit 50% of the slowest controllers at 1000 ms to be changed to 300 ms. Changes to the execution/acquisition rate may be required during process unit operation. Total system spare capacity, including the above, shall be the responsibility of the Owner.
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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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3. OPERATOR WORKSTATION 3.1 General The operators workstation shall include as a minimum, a display monitor and keyboard. Systems may be equipped with multiple display monitors and one keyboard per operating position. The Owner's operating and staffing philosophy shall determine if two or more process units can be combined into one operators workstation. In general, no more than 100 control loops shall be operated from a single operator workstation. Systems with more than 100 control loops per operator shall be analyzed carefully to ensure that the operator workload is manageable. 3.2 Details a. The workstation software shall include scan tasks for interfacing between the real-time tag database and the detailed controller functions. The software shall also provide graphic displays, trend and report capabilities, event, and alarm management tools. b. The real-time tag database shall be capable of updating all tags in a period no greater than 1 second. c. Each workstation shall be powered from the Uninterruptible Power Supply via a separate circuit breaker. Each workstation shall be capable of being taken off-line or powered down independently, without affecting the operation of the control system, including the other workstations. d. Display requirements shall include overview, group, point (individual loop), trend (single and multi-loop), alarm, process graphics, and equipment status and diagnostics. e. Each workstation shall have the capability of printing the information displayed on the screen. Each workstation shall have access to a minimum of two printers, of which at least one should be a color printer. f. The operator interface software shall be capable of acting as a Dynamic Data Exchange (DDE) or OLE (Object Linking and Embedding) for Process Control (OPC) client or server to share real-time data with DDE or OPC compliant applications.

3.3

Graphic Displays a. All control parameters shall be accessible through the graphic display. Navigation through the displays should be easy and intuitive. One overview graphic display per process unit shall be provided in order to quickly access the detailed graphics. Viewing of information in real-time shall include all remote setpoints whether calculated or not. b. All loop controllers shall have faceplates. These faceplates shall allow easy access to tuning variables, trending, setpoint values (both local and remote), alarm settings, auto/manual, remote/local, and percent output. c. Pop-up functions (faceplates, trends, reports etc.) should allow large amounts of detailed information to be quickly accessed without extensive clutter on a process graphic.

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d. The DCS output display for all control valves shall be configured such that it is readily apparent to the operator how the output must be changed to manually open or close the valve. Configuration such that an indication of 0% output is closed and 100% is open regardless of valve failure action, or other labeling methods, may be used depending on the Owner's operating philosophy. 3.4 Password Protection Configuration and on-line operation should be password-protected with at least three levels of security (Engineering/configuration, supervisor, and operator) to avoid inadvertent changes. 4. DATA STORAGE AND RETRIEVAL 4.1 Historical Data Storage and Trend Display a. When a data storage and retrieval function is specified for a process variable, the value shall be stored digitally in non-volatile memory or hard drive within the control system equipment, or in auxiliary systems communicating with the control system. The stored information is used for the following purposes: (1) (2) (3) (4) Determination of plant material balances Trend analysis of equipment performance Troubleshooting and analysis of malfunctions Monitoring the day to day operation

b. For the purpose of trouble shooting and analysis of malfunctions, the ability to retrieve and display the actual instantaneous sampled process data, rather than the averaged or maximum/minimum values, is essential. c. The process variable shall be sampled and the instantaneous value shall be stored at intervals of ten seconds or less. Storage capacity shall be sufficient to store process variable data for at least the immediately previous 7 day period. The control system equipment shall be able to access and display the stored data at the operator station console and/or other console on demand at any time. The control system equipment shall be capable of selecting for display the instantaneous values stored in any 1 hour period within the 7 days of data. Stored data shall not be erased by display. Update of data shall be on a point-by-point basis to ensure that the immediately previous 7 days of data are available at any time. d. Storage capacity that is capable of retaining daily averages and weekly averages for a period of one year shall also be provided. The control system equipment shall be able to access and display the stored data at the operator station console and/or other console on demand at any time. e. Data stored for historical review shall be accessible in grouped trend display format. The grouping of the process variables shall be logical with respect to the process. Configuration of trend displays shall have the capability for operators to set up additional trend displays of selected variables for specific troubleshooting activities. Different colors shall be used for each variable trended. Additional trend display capacity shall be available for at least 10 percent of the historical trend display groups.

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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f.

Data for process variables where a data storage and retrieval function is not specified shall also be stored digitally in a non-volatile memory or hard drive system if desired by the Owner of the process unit. For these variables averaged data or various data compression techniques are acceptable. The sampling interval, storage period, and display capabilities shall be selected by the Owner of the process unit.

g. The manufacturers capabilities with respect to the subject of data storage and retrieval shall be thoroughly reviewed by the Owner/operator of the process unit before deciding to accept a particular system. h. The control system must be capable of archiving historical data onto removable media. 4.2 Controller Tuning Display a. Each loop controller shall have a trending display for tuning. This tuning display shall show the loop controller tuning values and include the capability to change the loop controller tuning values while trending. Different colors shall be used for each parameter trended. The minimum controller parameters trended shall be: (1) Setpoint (2) Process variable (3) Controller output signal b. Trending intervals shall be user selectable between 0.25 seconds to 5 seconds. The overall trend display must show as a minimum between 1 minute and 20 minutes of trending per Table 2: Table 2 Sample Interval 0.25 seconds (4 times per second) 0.5 seconds (2 times per second) 1 second (1 time per second) 2 seconds (0.5 times per second) 5 seconds (0.2 times per second) 5. ALARMS 5.1 General a. Alarm functions shall be implemented using the data acquisition and shared processing equipment of the control system. All alarms shall be visually and audibly indicated and shall be connected to event logging facilities. Minimum Duration of Screen Trend 1 minute 2 minutes 4 minutes 8 minutes 20 minutes

Form QUA-03-2

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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b. The UOP Project Specifications include the minimum process based alarm requirements and initial settings. During detail design, and following the Owners Process Hazard Analysis, additional alarms may be required. The Contractor shall be responsible for adding these alarms and determining their proper settings. UOP will participate in pre-commissioning activities and review changes from the UOP Project Specifications. If an alarm setting from the UOP Project Specification appears to be inappropriate, or a nuisance alarm is anticipated, UOP personnel on site will identify these alarms and advise the Owner. 5.2 Critical Alarms a. These alarms are considered to be of high importance and are associated with a process condition or a special circumstance that requires immediate operator action. Examples are shutdown pre-alarms, shutdown alarms, and critical equipment alarms. b. Alarms in this category require a unique display and audible tone to clearly distinguish them from non-critical alarms. Critical alarms shall be distinguished from other alarms by a unique color, grouping, or graphical display on the DCS and/or displayed on a separate, backlightednameplate annunciator panel located above or adjacent to the operator station. c. Hardware-based critical alarm functions are an acceptable alternate and shall be repeated into the operator station alarm display and logging facilities. 5.3 Non-Critical Alarms This category alarm is generally for services not associated with a shutdown function or critical equipment protection. 6. HART (HIGHWAY ADDRESSABLE REMOTE TRANSDUCER) COMMUNICATIONS Analog 4 20 mA input and analog 4 20 mA output cards shall not prevent HART communications for configuring smart field devices using HART handheld communicators or PCs using HART modems. If analog 4 20 mA input and output cards cannot allow for HART communications then HART filters shall be installed in the DCS cabinets to allow for HART communications. 7. TRANSMITTER FAILURE DETECTION Analog 4 - 20 mA input cards shall be capable of differentiating between an out of range measurement signal and a failed transmitter signal. The control system vendor shall coordinate with the Contractor to determine what field device failure alarm levels have been selected (such as NAMUR NE 43 engl. compliant transmitters). Upon detection of either high or low transmitter failure alarm signal, the control system shall generate a critical alarm (visual and audible). 8. HARDWIRED MANUAL CONTROL CENTER SWITCHES When specified, hardwired manual control center switches shall be installed in appropriately located subpanels attached to the BPCS operator console. Duplication of the manual switch functions within the BPCS is optional; any such duplication shall consider the effects of failure modes of the BPCS.
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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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9. INPUT AND OUTPUT (I/O) 9.1 Thermocouple Input The thermocouple input shall be capable of measuring and linearizing the following types of thermocouples: Type: Digital Accuracy: Resolution: E, J, K, T (grounded or ungrounded). 1.5F, (0.83C) Minimum 12 bits

Cold junction compensation shall be provided. 9.2 Resistance Temperature Detector (RTD) Input The RTD input must be capable of measuring and linearizing the following type of 3 and 4 wire RTDs: Type: Digital Accuracy: Resolution: 9.3 Analog 4-20 mA Input Non-isolated or isolated 4 - 20 mA input may be used depending on Owner preference and local codes or practices. Normal measuring range: Resolution: 9.4 Analog 4-20 mA Output Non-isolated or isolated 4 - 20 mA output may be used depending on Owner preference and local codes or practices. Output range: Resolution: 9.5 Fieldbus I/O Fieldbus technology, such as, Foundation Fieldbus H1 segments and Profibus PA Fieldbus may be used for linking, operating, and controlling field devices as long as the control response period meets the requirements of this Standard Specification. 4 - 20 mA Minimum 12 bits 4 - 20 mA Minimum 12 bits PT100 0.5F, (0.28C) Minimum 12 bits

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UOP LLC 25 East Algonquin Road Des Plaines, Illinois 60017-5017 USA

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9.6

Digital Inputs Digital inputs shall be true when contacts are closed (energized) and false when contacts are open (de-energized). Inputs may be either sinking (where current flows from the I/O module through the external device to the return) or sourcing (where current flows to the I/O module from the external device).

9.7

Digital Output a. Contractor to determine maximum current load. Each output channel shall power no more than one final control element. Details shall be coordinated between the Contractor and the control system supplier. b. Outputs to solenoid coils or other inductive loads shall include a high voltage suppressor or diode to provide protection against high induced voltage. The protection devices shall be provided by the Contractor or with the solenoid coil.

10. PROCESS CONTROL SOFTWARE CONFIGURATION The control system shall be capable of being modified and performing back-ups of any portion of the system (e.g. process control software, graphical user interface package, historian, asset management applications, etc.) while the process unit(s) are operating, without interrupting the control software, upsetting the units, or preventing the operator from controlling the unit(s). Graphical methods of configuration are preferred. 11. CONTROL SYSTEM UNINTERRUPTIBLE POWER SUPPLY The Uninterruptible Power Supply (UPS) for the control system shall maintain power to all control center equipment, field transmitters, controller output field devices, and shutdown circuits for a minimum duration of one hour upon loss of source power. 12. LOOP POWER SUPPLY The power supplies for field devices shall have separate AC power supply breakers or fuses so a single power supply can be taken out of service for replacement or repair. The power supplies shall receive their AC power supply from the Control System UPS. 13. SINGLE LOOP INTEGRITY Single loop integrity to prevent a single component failure from affecting more than one control loop, although recommended, depends on Owner requirements for the site. The Owner shall determine the need for redundancy of devices such as I/O processors, CPUs, power supplies, operator workstations, communications, etc.

Form QUA-03-2