BHP

SGO WP2 Concentrator Project

Sierra Gorda, Chile
Contract: 8500135645

Scope of Interoperability Acceptance Testing

1. Purpose

The purpose of this document is to provide a scope of testing of the hardware and Software,
logic configuration and DCS Process graphics interoperability between the Programmable Logic
Controllers Mill Gearless Drive (SAG and Ball Mills) and Honeywell DCS.

2. Safety

According to Installation Owner

3. Attendees and Responsibilities

 DCS Engineering FS JV
 Communication Engineering FS JV
 DCS Representatives (Honeywell)
 Communication System Representative (Adexus)
 Mill Gearless Drives Representative (Siemens AG)
 FLS Representative (FLS)
 Company Representative

4. Siemens AG Scope

 Facilities (TBD) and personnel Staff

 Electrical Power Supply
 Siemens Simulator according to SGO Project model and version of Bus Configuration and
Communication System.
 Redundant S7-400H PLC according to model and software/firmware version to be
supplied to SGO Project
 Last Application loaded and debugged during the System Test at E-house Germany
 Testing Bus Configuration and Communication System Architecture
 Detailed Procedure and Protocols for testing
 Register of configuration parameters and specific setting
 Technical specialist involved at System Test performed at Germany
 Detailed Schedule Planning by each Testing Function
BHP
SGO WP2 Concentrator Project
Sierra Gorda, Chile
Contract: 8500135645

5. Battery Limit
 The physical battery limit of Siemens AG for these tests will be up to the O/T
Network Switches (by FS)

6. F-S Scope

 Honeywell DCS System Controller/HMI/Communication Module/Server and System

software (by Honeywell)
 Communication equipment’s (Switches according to SGO Topology)
 Configured Database (by Honeywell)
 DCS HMI Application (by Honeywell)
 Data transfer table configured (C300/Experion Server as applicable) (by Honeywell)
 Honeywell Technical specialist – System Engineer
 Honeywell Technical specialist – Application Engineer
 Communication specialist Engineer (Adexus)
 Communication Procedure and Protocols for testing (by Adexus)
 DCS Procedure and Protocols for testing (by Honeywell)

7. Testing Scope

The following testing will be conducted to verify the proper communication and interoperability
between the Mill Gearless Drive and the Honeywell DCS.

A. Data Transfer Configuration (During Engineering Stage)

The data transfer table must complete by Siemens AG (Early July 2018) to be coordinated
with DCS team of Fluor-Salfa and then configured by DCS Provider (Honeywell)

B. Connectivity test Function

 Communication Connectivity Testing (IP Address, Default Gateway, Ping, etc.)

o Siemens S7-400H is properly configured at VLAN Modbus/TCP (VLAN Configuration

by FSJV)
o IP address verification
o Procedure and Protocol by FS
o Testing supported by Siemens AG
BHP
SGO WP2 Concentrator Project
Sierra Gorda, Chile
Contract: 8500135645

C. PLC – DCS Interoperability Test Function

1. Simulated Systems to be Tested (SAG & Ball Mills)

 GMD Control and Operation Modes

 Cooling System
 Brake System
 Lube System
 Grease System
 Cycle-converter Cooling System
 GMD Operation
 Communication

2. Interoperability Testing Function (SAG & Ball Mills)

 Redundancy Behavior Testing

 Interface DCS – PLC (Data Transfer Tables)
o All Memory mapping point-to-point testing PLC – DCS C300 Controller
o All Memory mapping point-to-point testing PLC – Experion Database Cluster
Server (Modbus Interface Driver)
 Analog and Discrete IO Simulation thought Modbus/TCP network
 Range and Engineering Units
 Alarm/Trip Simulation thought Modbus/TCP network
 Interlocks (Permissive, Safety, Equipment, Process)
 DCS Hardwired Interlocking
 Motor Start/Stop Simulation from DCS HMI
 Motor Alarm/trip to DCS HMI
 Control Modes
 DCS Operation (Start/Stop, Speed)
 Normal Stop
 Communication Fail Behavior
 Control Power-Off Behavior
 Shutdown Emergency