Section 5.

6 – PLC-DCS
Programming Techniques

Next Slide 5.6.1

Section 5 Index
 PLC-DCS - Documentation
It is important to have our PLC/DCS documentation up-to-date, containing:

System Configuration:
The system outline, components used and non-default device settings within the entire system should be described.
An example system outline is shown below – it should show all components involved and their unique names, IP-addresses etc.
Components description applies for all hardware and software used, specifying manufacturer, model-numbers, firmware’s,
software versions/service-packs etc.
Every non-default/factory setting should be described as well, such as station/panel-names, screen size/resolution,
communication protocols/speed, TCP/IP settings etc.

Slide 5.6.2
Previous Next Section 5.6 Index
 PLC-DCS - Documentation
Functional Descriptions:
Interlocking/’bubble’ diagrams/CEDs (Cause & Effect Diagrams), flow-charts etc should be
made/documented for describing the process/program functionality.

Firstly we need to understand the processes prior we should/could start setting up flow-charts etc:
• Setup a block-diagram that describes the different process steps (see diagram below – Soybean
Crushing)
• Describe the function, interlocking and special requirements that is applicable for each process-step
• Describe the functions of non-process related such as alarm handling, input/output marshalling,
control typical’s for motors/valves etc.

Slide 5.6.3 Section 5.6 Index

Previous Next
 PLC-DCS - Documentation

Software Structure/Architecture:

The software structure should follow same architecture as the process block-diagram as described in
previous sheet as much as possible – this approach would ease upon trouble-shooting etc.

Program (Modules):

Program subroutines/modules (typicals) that are used for programming/animating motors, On/Off valves,
PID-controllers etc should be described – object oriented programming should be used as much as
possible to ease upon programming and maintenance.

Data Structures:

Program-block/drawer naming, mnemonic tag-names for identifying PLC/DCS addresses should be

described and standardized/consistently all-through the programs - applicable data types, such as
BOOL, WORD and REAL should be described as well.

Slide 5.6.4 Section 5.6 Index

Previous Next
 Main Overview Screen:
Use of Colors - Asia
In slide 3 we discussed setting up a block-diagram that describes the different process steps – it would ease upon
operation/understanding when our screen navigation etc is following similar setup (see screen-dump below (Fatty Alcohol)).

Slide 5.6.5 Section 5.6 Index

Previous Next
 Process pipe-lines:
Use of Colors - Asia
The process pipe-line coloring on our process screens should follow whatever the site/group standard tells which is based on
local requirement/regulations – e.g. in China, green is used for water lines, red for hydrants, yellow for N2 etc, following
local (‘GB’) regulations/norms.

We should prevent using too many line crossings etc – it is important that our process screens looks straight-forwarded
& simple.
We do not have to follow corresponding P&ID’s for 100%, indicating the main product flows is what’s important.
It is strongly recommended to setup our process screens using corresponding P&ID AutoCAD drawings:
• Copy corresponding P&ID AutoCAD drawings
• ‘Strip’ these drawings such that only corresponding instruments/equipment and main process flow lines remains
• Reallocate/change the drawings such that they start to look straight-forwarded & simple
• Have our production department to look at them and advise where necessary
• Revise the drawings until everybody is satisfied
• Start to setup the process screens following these drawings

Slide 5.6.6 Section 5.6 Index

Previous Next
 Use of Colors - Asia
Tag-Name & Color-Animation (also applicable for instruments):

Blue-Background: ‘Healthy’ (No Alarms)

Blinking Red-Background: ‘Unhealthy’ (Alarm – Not Acknowledged)
Steady Red-Background: ‘Unhealthy’ (Alarm – Acknowledged)
Equipment animations – PID-loops:
‘M’ = Manual, ‘A’ = Auto and ‘C’ = Cascade
Set-Point (SP) & Process-Value (PV)
Grey: CV <= 3%
Green: CV > 3%
Blinking Red: ‘Unhealthy’ (Alarm – Not Acknowledged)
Steady Red: ‘Unhealthy’ (Alarm – Acknowledged)

Tag-Name & Control-Value (CV)

‘M’ = Manual, ‘A’ = Auto and ‘C’ = Cascade

Equipment animations – Motors: Color-Animations:

Grey: Stopped & Interlocked

Yellow: Stopped & not Interlocked (ready to start)
Green: Running
Blinking Red: ‘Unhealthy’ (Alarm – Not Acknowledged)
Tag-Name & Control-Value (CV)
Steady Red: ‘Unhealthy’ (Alarm – Acknowledged)
(CV is applicable for VFD motors only)

Slide 5.6.7 Section 5.6 Index

Previous Next
 Use of Colors - Asia
‘M’ = Manual, ‘A’ = Auto and ‘C’ = Cascade

Color-Animations:
Equipment animations – On/Off Valves:
Grey: Closed
Yellow: Traveling
Green: Opened
Tag-Name Blinking Red: ‘Unhealthy’ (Alarm – Not Acknowledged)
Steady Red: ‘Unhealthy’ (Alarm – Acknowledged)

Color-Animation (also applicable for other kind of switches):

Equipment animations – Tank Levels/Switches: Green: ‘Healthy’ (No Alarms)

Blinking Red-Background: ‘Unhealthy’ (Alarm – Not Acknowledged)
Steady Red-Background: ‘Unhealthy’ (Alarm – Acknowledged)

Level Indication 0-100%

Product Type Indication, e.g. MeOH
Level Indication within a bar
Ton’s Indication (see next slide)

Previous Next Slide 5.6.8 Section 5.6 Index

 Use of Colors - Asia
Equipment animations – Tank Overview Screen:
This screen shows all the tanks, applicable product-names, densities etc.
The mass in ton’s is calculated as follows: (Density (Kg/m3) x Tank-Height (m) x Tank-Area (m2)) / 1000 (Kg)
Density is corrected on actual product temperature: Density-corrected = Density (at 20C) x (Temperature – 20C) x 0.0007

Slide 5.6.9 Section 5.6 Index

Previous Next
 Use of Colors - Asia
Equipment animations – Pump/Motor Overview Screen: Running hours when maintenance should take
This screen will show the running hours for each motor, including an
place (advised by corresponding supplier)
alarming/animation function for indicating which motor should be
Color Animation:
maintained during next upcoming maintenance shutdown.
Blue: actual running hours < ‘SET HR’
Red: actual running hours >= ‘SET HR’

Slide 5.6.10 Section 5.6 Index

Previous Next
 PID Parameters – GE Fanuc

Slide 5.6.11 Section 5.6 Index

Previous Next
 Use of Colors – D/3 DCS
Use of color is very important in our graphics displays. The human brain will automatically sort
information based on a variety of parameters – size, movement/blinking and color among others. So it is
very important to use colors consistently so that we can draw attention to dynamic information and away
from static information. We also must keep in mind that many of our workers are color blind, so color can
not be the only method to convey information. We must combine colors with other changes to indicate
status. Below is a standard we developed for our D/3 systems. It is not the only way colors can be used
effectively, but represents a good practice.

Background Color 16 – Gray

PCM Offline 9 – Orange
Normal Dynamic, Open, Running 2 – Green
Non Critical Alarm, Transit 3 – Yellow
Critical Alarm, Closed, Off 1 - Red
Auto 39 – Dark Green
Manual 35 – Dark Red
Manual Override 65 – Blinking Red
Non-Dynamic, NoPower 0 – White
??? Failed, ??? Interlock 5 – Magenta
6 - Cyan

Previous Next Slide 5.6.12

Section 5.6 Index