NCNCNS, Ac

EMERSON ARGENTINA S.A.
DOCUMENT N:
15006-0000-DF-001-1
1 UPDATE 01/07/05 LF/CM CM JB

0 FOR CONSTRUCTION 14/02/05 CM/RT CM JB
C FOR APPROVAL 06/01/05 LF LF JB
B FOR APPROVAL 29/11/04 LF/RT CM JB
A FOR APPROVAL 19/10/04 LF CM JB
REV. DESCRIPCION DATE BY CHK. APPD.
CLIENT: SOUTHERN PERU COPPER

JOB: PCS - ILO PROJECT
CLIENT PROJECT NUMBER: 53233300
ILO SMELTER MODERNIZATION PROJECT
TITLE:
FUNCTIONAL DESCRIPTION
PROJECT ENGINEER
All information contained in the
SCALE DOCUMENT N: REVISION
present document is confidential
and property of Emerson.
Reproduction or copy, total or N/A 15006-0000-DF-001-1 1
partial is forbidden without
previous authorization. Replace Doc. N 15006-0000-DF-001-0 Pages: 135
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CLIENT: SOUTHERN PERU COPPER Page Of
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Description Of Changes In This Revision
Date Rev Description Of Change (With Point No. If Applicable) Issuer

01-Jul-05 1 Changes in document note added (section 1.1) Emerson
01-Jul-05 1 FHX files for areas and process cells comment added (section 2.4.3) Emerson
01-Jul-05 1 Workstations information updated (section 2.4.5) Emerson
01-Jul-05 1 Server list table updated (section 2.4.6) Emerson
01-Jul-05 1 Security settings comment added (section 4.1.1) Emerson
01-Jul-05 1 User accounts comment added (section 4.1.2) Emerson
01-Jul-05 1 FHX file comment added (section 4.3) Emerson
01-Jul-05 1 Plant Areas creation comment added (section 5.3.1) Emerson
01-Jul-05 1 Table 5-2. List of DeltaV Controllers - updated Emerson
01-Jul-05 1 Reference to section updated (section 5.3.9) Emerson
01-Jul-05 1 DeviceNet Names section added (section 5.3.11) Emerson
01-Jul-05 1 Profibus Names section added (section 5.3.12) Emerson
01-Jul-05 1 Structured text comment added (section 5.4.3) Emerson
01-Jul-05 1 Example of LG module for PIDs added (section 6.4.1) Emerson
01-Jul-05 1 First Out composite block with 8 conditions added (section 6.4.9) Emerson
01-Jul-05 1 Figure 6-21. PID Control Loop with 4-20mA Devices - updated Emerson
01-Jul-05 1 Control Options parameter comment added (section 6.5.2) Emerson
01-Jul-05 1 Figure 6-26. Slave PID Control Loop - updated Emerson
01-Jul-05 1 Fail safe comment added (section 6.6.1) Emerson
01-Jul-05 1 Fail safe comment added (section 6.6.5) Emerson
01-Jul-05 1 Tag name reference updated (section 6.7) Emerson
01-Jul-05 1 Tables with DSA I/O assignments added (section 6.7.1) Emerson
01-Jul-05 1 DSA Remote operation comment added (section 6.7.1) Emerson
01-Jul-05 1 DSA_V composite block added (section 6.7.1) Emerson
01-Jul-05 1 Table 6-22 updated Emerson
01-Jul-05 1 Table 6-23 updated Emerson
01-Jul-05 1 Figure 6-36. Motor control module for Variable Frequency Driver with Emerson
Jog. - updated
01-Jul-05 1 Figure 7-7. Alarms Banner - updated Emerson
Southern Peru Copper

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01-Jul-05 1 Table 7-7. Color Codes for Process Lines - updated Emerson
01-Jul-05 1 Figure 7-17. Control loop scheme. - updated Emerson
01-Jul-05 1 Figure 7-19. Control valve dynamo. - updated Emerson

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Table of Contents
1. About this Document.............................................................................................................12

1.1. Purpose ............................................................................................................12
1.2. Scope ............................................................................................................12
2. Introduction ..........................................................................................................................13
2.1. Project Organizations ............................................................................................................13
2.2. Plant Areas ............................................................................................................13
2.3. System Architecture ............................................................................................................15
2.4. Main Components ............................................................................................................16
2.4.1. Controllers ..........................................................................................................................16
2.4.2. I/O Cards............................................................................................................................16
2.4.3. Database ............................................................................................................................17
2.4.4. Engineering Workstations.....................................................................................................18
2.4.5. Operator Workstations .........................................................................................................18
2.4.6. Servers...............................................................................................................................18
2.4.7. Control Network ..................................................................................................................19
2.4.8. Foundation Fieldbus ............................................................................................................19
2.4.9. DeviceNet ...........................................................................................................................20
2.4.10. Profibus DP .....................................................................................................................20
3. Technical Documentation......................................................................................................21
3.1. Scope ............................................................................................................21
3.2. Documents Identification.........................................................................................................22
4. System Administration ..........................................................................................................24
4.1. Security in DeltaV ............................................................................................................24
4.1.1. Introduction........................................................................................................................24
4.1.2. DeltaV Locks .......................................................................................................................25
4.1.3. User Accounts and Groups ...................................................................................................26
4.1.4. Operator Workstation Security..............................................................................................26
4.2. Configuration Logbooks...........................................................................................................27
4.3. Configuration File Backup/Security ...........................................................................................27
5. Controller Configuration .......................................................................................................28
5.1. Controllers and Plant Safety.....................................................................................................28
5.1.1. General ..............................................................................................................................28
5.1.2. Controller Cold Restart.........................................................................................................28
5.1.3. Failure Modes .....................................................................................................................28
5.2. Free Time Parameter in DeltaV Controllers................................................................................29
5.3. Tag Names Definitions ............................................................................................................29
5.3.1. DeltaV Areas Names ............................................................................................................29

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5.3.2. Controllers Names ...............................................................................................................31

5.3.3. Modules Tag Names ............................................................................................................32
5.3.4. Motor Control Module Name .................................................................................................32
5.3.5. On/Off Valves .....................................................................................................................33
5.3.6. Sequences Names (SFC) ......................................................................................................33
5.3.7. Device Tag Names (DST) .....................................................................................................33
5.3.8. Fieldbus Block Names ..........................................................................................................33
5.3.9. Classic I/O Tag Names.........................................................................................................34
5.3.10. Reference Parameters Names ...........................................................................................34
5.3.11. DeviceNet Names.............................................................................................................34
5.3.12. Profibus Names................................................................................................................35
5.4. Programming ............................................................................................................35
5.4.1. Function Block Diagrams (FBD) ............................................................................................35
5.4.2. Sequential Function Charts (SFC)..........................................................................................36
5.4.3. Structured Text (ST)............................................................................................................36
5.5. Control Modules ............................................................................................................36
5.5.1. Function Block Scan Rate .....................................................................................................36
5.5.2. Function Block Execution Order ............................................................................................37
5.6. Interlocks Descriptions ............................................................................................................37
5.7. Interlocking and Sequential Definition ......................................................................................37
6. Configuration Standard.........................................................................................................38
6.1. Engineering Units ............................................................................................................38
6.2. Using Fieldbus Technology in the Control Strategy.....................................................................39
6.2.1. Use Only the Available Number of Links ................................................................................39
6.2.2. Understanding Module Execution Time and the Fieldbus Macrocycle ........................................39
6.2.3. Understanding the Stale Link Count Limit ..............................................................................40
6.2.4. Using a Conservative Module Execution Time.........................................................................40
6.2.5. Write Requests Limits to Fieldbus Function Block Parameters ..................................................40
6.2.6. Periodic Writes Limits to Static or Non-Volatile Parameters......................................................40
6.2.7. Using Valid Input and Output Links .......................................................................................41
6.2.8. Using Valid Channel Assignments..........................................................................................41
6.2.9. Using Valid XD_SCALE .........................................................................................................41
6.2.10. Assigning Fieldbus Function Blocks to Devices ....................................................................41
6.3. Control Modules Standard .......................................................................................................41
6.4. Logic Control Modules And Composites Blocks...........................................................................42
6.4.1. LG Modules.........................................................................................................................42
6.4.2. DI (Discrete) Conditional Block .............................................................................................44
6.4.3. LT (Less Than) Conditional Block ..........................................................................................45
6.4.4. GT (Greater Than) Conditional Block .....................................................................................46
6.4.5. LTEQ (Less Than or Equal To) Conditional Block ....................................................................47
6.4.6. GTEQ (Greater Than or Equal To) Conditional Block ...............................................................48
6.4.7. EQ (Equal To) Conditional Block ...........................................................................................49
6.4.8. NEQ (Not Equal To) Conditional Block ...................................................................................51
6.4.9. FIRST_OUT Detection Block .................................................................................................52

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6.5. PID Control Loop Modules .......................................................................................................55

6.5.1. PID Control Loop with 4-20mA Devices .................................................................................55
6.5.2. PID Control Loop With Foundation FieldBus Devices ...............................................................56
6.5.3. VALV Composite Block .........................................................................................................58
6.5.4. PID Control Loop Considerations...........................................................................................58
6.5.5. Master-Slave Control Loop....................................................................................................58
6.5.6. Master-Slave PID Control Loop Considerations .......................................................................60
6.5.7. Alarms in PID Loops ............................................................................................................60
6.5.8. PID Control Modules Scan Rates ...........................................................................................61
6.6. Analog And Discrete Inputs Monitoring .....................................................................................62
6.6.1. Analog Input Monitoring Module ...........................................................................................62
6.6.2. Analog Input Monitoring Module Alarms ................................................................................62
6.6.3. Analog Input Monitoring Module Scan Rates ..........................................................................62
6.6.4. Filters.................................................................................................................................63
6.6.5. Discrete Input Monitoring Module .........................................................................................63
6.7. Motor Control Modules ............................................................................................................64
6.7.1. DSA Composite Block...........................................................................................................65
6.7.2. Motor Control Module for Direct Starter .................................................................................69
6.7.3. Motor control module for Forward-Reverse Starter with Jog ....................................................70
6.7.4. Motor control module Direct Starter with Jog .........................................................................71
6.7.5. Motor control module for Variable Frequency Driver with Jog ..................................................73
6.8. ON/OFF Valve Control Module..................................................................................................74
6.9. Sequential Function Chart (SFC) Configuration Conventions .......................................................76
7. Operator Interface ................................................................................................................79
7.1. General ............................................................................................................79
7.2. Alarms ............................................................................................................82
7.2.1. Alarm List ...........................................................................................................................85
7.2.2. Assignment of Alarms to Consoles ........................................................................................87
7.3. Navigation ............................................................................................................87
7.4. Process Displays ............................................................................................................90
7.4.1. Nomenclature .....................................................................................................................90
7.4.2. Colors.................................................................................................................................90
7.4.3. Graphics .............................................................................................................................90
7.5. Dynamo Sets ............................................................................................................90
7.5.1. Process Variable Indicator ....................................................................................................91
7.5.2. Control Loops Indicators ......................................................................................................92
7.5.3. Motors................................................................................................................................93
7.5.4. Control Valves.....................................................................................................................94
7.5.5. On/Off Valves .....................................................................................................................95
7.5.6. Pumps................................................................................................................................96
7.5.7. Alarm Switches ...................................................................................................................97
7.5.8. Other Dynamos ...................................................................................................................97
7.6. Process Lines ............................................................................................................97

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7.7. History Chart Display ............................................................................................................99

7.7.1. Event Chronicle ................................................................................................................. 100
7.8. Faceplates .......................................................................................................... 101
7.8.1. Faceplate for DI Module..................................................................................................... 101
7.8.2. Faceplate for AI Module ..................................................................................................... 102
7.8.3. Detail Picture for AI Module................................................................................................ 103
7.8.4. Faceplate for PID Module ................................................................................................... 105
7.8.5. Detail Display for PID Module ............................................................................................. 108
7.8.6. Faceplate for Direct Motor Starter ....................................................................................... 110
7.8.7. Detail Display for Direct Motor Starter ................................................................................. 111
7.8.8. Faceplate for Direct Motor Starter with Jog.......................................................................... 112
7.8.9. Detail Display for Direct Motor Starter with Jog .................................................................... 114
7.8.10. Faceplate for Variable Frequency Drive with Jog ............................................................... 114
7.8.11. Detail Display for a Variable Frequency Drive with Jog....................................................... 117
7.8.12. Faceplate for Forward-Reverse with Jog........................................................................... 117
7.8.13. Detail Display for Forward-Reverse Starter with Jog .......................................................... 120
7.8.14. Faceplate for On-Off Valves ............................................................................................ 122
7.8.15. Detail Display for On-Off Valves ...................................................................................... 123
7.9. Help Displays .......................................................................................................... 124
7.10. Reports .......................................................................................................... 124
Appendix A .......................................................................................................... 125
Appendix B .......................................................................................................... 127

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Figures Index
Figure 2-1. DeltaV Explorer Window .........................................................................................................15

Figure 5-1. DeviceNet signals. ..................................................................................................................34
Figure 6-1. Typical LG Module ..................................................................................................................43
Figure 6-2. LG Module Example for PID Modules........................................................................................43
Figure 6-3. Discrete Conditional Composite Block.......................................................................................44
Figure 6-4. Internal View of Discrete Conditional Block...............................................................................44
Figure 6-5. LT Conditional Composite Block ...............................................................................................45
Figure 6-6. Internal View of LT Conditional Block .......................................................................................45
Figure 6-7. GT Conditional Composite Block ..............................................................................................46
Figure 6-8. Internal View of GT Conditional Block ......................................................................................46
Figure 6-9. LTEQ Conditional Composite Block...........................................................................................47
Figure 6-10. Internal View of LTEQ Conditional Block .................................................................................48
Figure 6-11. GTEQ Conditional Composite Block ........................................................................................49
Figure 6-12. Internal View of GTEQ Conditional Block ................................................................................49
Figure 6-13. EQ Conditional Composite Block.............................................................................................50
Figure 6-14. Internal View of EQ Conditional Block.....................................................................................50
Figure 6-15. NEQ Conditional Composite Block ..........................................................................................51
Figure 6-16. Internal View of NEQ Conditional Block ..................................................................................51
Figure 6-17. First-Out 16 inputs Composite Block.......................................................................................52
Figure 6-18. First-Out 8 inputs Composite Block.........................................................................................52
Figure 6-19. Internal View of FIRST_OUT Conditional Block ........................................................................53
Figure 6-20. Internal View of FIRST_OUT8 Conditional Block ......................................................................54
Figure 6-21. PID Control Loop with 4-20mA Devices ..................................................................................55
Figure 6-22. PID Control Loop with Fieldbus Devices..................................................................................56
Figure 6-23. Control Options parameter configuration. ...............................................................................57
Figure 6-24. Internal View of VALV Composite Block ..................................................................................58
Figure 6-25. Master PID Control Loop .......................................................................................................59
Figure 6-26. Slave PID Control Loop .........................................................................................................59
Figure 6-27. Analog Input Monitoring Module ............................................................................................62
Figure 6-28. Discrete Input Monitoring Module ..........................................................................................63
Figure 6-29. External view of DSA composite block ....................................................................................66
Figure 6-30. Internal view of DSA composite block.....................................................................................66
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Figure 6-31. External view of DSA_V composite block ................................................................................68

Figure 6-32. Internal view of DSA_V composite block.................................................................................68
Figure 6-33. Motor Control Module for Direct Starter. .................................................................................69
Figure 6-34. Motor control module for Forward-Reverse starter...................................................................70
Figure 6-35. Direct Starter with Jog Motor Control Module..........................................................................71
Figure 6-36. Motor control module for Variable Frequency Driver with Jog. ..................................................73
Figure 6-37. ON/OFF Valve NO or NC Control Module.................................................................................75
Figure 6-38. SFC Example........................................................................................................................77
Figure 7-1. Operation Screen with Visible Navigation bar ............................................................................79
Figure 7-2. DeltaV Operate Toolbar 1 .......................................................................................................80
Figure 7-7. Alarms Banner .......................................................................................................................82
Figure 7-8. Bottom side of a module faceplate showing acknowledge alarm button. .....................................84
Figure 7-9. Bottom side of the screen showing acknowledge alarm button. ..................................................84
Figure 7-10. DeltaV Alarm List..................................................................................................................86
Figure 7-11. Detailed View of Navigation Side Bar......................................................................................88
Figure 7-12. Detailed View of Navigation Side Bar with Areas Menu.............................................................89
Figure 7-13. Navigation Arrows ................................................................................................................89
Figure 7-14. Process Line Arrows..............................................................................................................89
Figure 7-15. Analog variable indicator. ......................................................................................................91
Figure 7-16. Level indicator......................................................................................................................92
Figure 7-17. Control loop scheme. ............................................................................................................92
Figure 7-18. Motor dynamo......................................................................................................................93
Figure 7-19. Control valve dynamo. ..........................................................................................................94
Figure 7-20. On-Off valve dynamo............................................................................................................95
Figure 7-21. Pump dynamo......................................................................................................................96
Figure 7-22. Filled and Empty Process Line................................................................................................99
Figure 7-23. Process History View........................................................................................................... 100
Figure 7-24. DI Module Faceplate ........................................................................................................... 101
Figure 7-25. Faceplate for AI Module ...................................................................................................... 102

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Figure 7-26. Detail Picture for AI Module................................................................................................. 104

Figure 7-27. PID Module Faceplate ......................................................................................................... 105
Figure 7-28. PID Module Detail............................................................................................................... 108
Figure 7-29. Direct Motor Starter Module Faceplate.................................................................................. 110
Figure 7-30. Motor Starter Detail Display................................................................................................. 111
Figure 7-31. Motor Starter Module Faceplate ........................................................................................... 113
Figure 7-32. VFD Faceplate Display ........................................................................................................ 115
Figure 7-33. VFD Faceplate Display ........................................................................................................ 118
Figure 7-34. VFD Detail Display .............................................................................................................. 120
Figure 7-35. On-Off Valve Faceplate ....................................................................................................... 122
Figure 7-36. On-Off Valve Detail Display ................................................................................................. 123

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Tables Index
Table 2-1. Ilo Smelter Modernization Project Areas ....................................................................................14

Table 2-2. I/O Controller Card List ............................................................................................................16
Table 2-3. I/O Cards List .........................................................................................................................17
Table 2-4. Sever List ...............................................................................................................................18
Table 4-1. Parameter and Field Locks .......................................................................................................26
Table 4-2. Groups and Attributes in DeltaV................................................................................................26
Table 5-1. DeltaV Areas Names And Descriptions.......................................................................................31
Table 5-2. List of DeltaV Controllers..........................................................................................................32
Table 6-1. Engineering Units ....................................................................................................................39
Table 6-2. Discrete Conditional Block Description Table. .............................................................................44
Table 6-3. LT Conditional Block Description Table ......................................................................................46
Table 6-4. GT Conditional Block Description Table......................................................................................47
Table 6-5. LTEQ Conditional Block Description Table ..................................................................................48
Table 6-6. GTEQ Conditional Block Description Table .................................................................................49
Table 6-7. EQ Conditional Block Description Table .....................................................................................50
Table 6-8. NEQ Conditional Block Description Table ...................................................................................52
Table 6-9. First-Out Detection Block Description Table. ..............................................................................54
Table 6-10. Function Blocks and Parameters Description for 4-20mA PID Control .........................................56
Table 6-11. Function Blocks and Parameters Description for Fieldbus PID Control.........................................57
Table 6-12. Master-Slave PID control loop description table........................................................................60
Table 6-13. PID Control Modules Alarms Definitions ...................................................................................61
Table 6-14. PID Control Modules Scan Rates .............................................................................................61
Table 6-15. Default alarms for analog input monitoring modules. ................................................................62
Table 6-16. Scan Rates for Different Analog Input Variables .......................................................................63
Table 6-17. SPCC/Fluor and DeltaV Terms.................................................................................................64
Table 6-18. Direct Motors I/O Assingments for DSA ...................................................................................67
Table 6-19. Fwd/Rev Motors I/O Assignments for DSA ...............................................................................67
Table 6-20. Motor Control Module for Direct Starter Description Table. ........................................................70
Table 6-21. Motor Control Module for Fwd-Rev Starter Description Table. ....................................................71
Table 6-22. Motor Control Module for Direct Starter with Jog Description Table............................................72
Table 6-23. Variable Frequency Driver with Jog Control Module Description Table. .......................................74

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Table 6-24. ON/OFF Valve Control Module Description Table. .....................................................................75

Table 6-25. Named Set SFC Table .........................................................................................................76
Table 6-26. Step action and transition condition SFC Table ......................................................................78
Table 7-1. Alarm Colors ...........................................................................................................................83
Table 7-2. Objects properties. ..................................................................................................................91
Table 7-3. Motor dynamo objects description. ...........................................................................................93
Table 7-4. Objects description. .................................................................................................................94
Table 7-7. Color Codes for Process Lines...................................................................................................98

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1. About this Document
1.1. Purpose
This document is intended to provide SPCC with pertinent information regarding the planned execution of the
project.
This specification defines the criteria for basic design and the standards to be used by Emerson Engineering
Team in the development of the project in order to meet the technical and functional requirements of the new
DeltaV Control System for the ILO Smelter Modernization Project.
Referenced documents:
2333-617-70-TS-001 Technical specification for process control system.
2333-000-70-DC-001 Design criteria for control system.
2333-617-70-TS-005 Control philosophy for control system.
The objective of this document is to serve as a design reference guide to be followed by every participant of
the project, (considering 3rd party vendors, Fluor and SPCC engineering groups), as well as a scope definition
regarding engineering and configuration activities.
These guidelines will apply not only to the engineering work but also to the selection and use of materials.
Note: By the time this document is issued, there will be a number of aspects in the design not yet defined in the
project by SPCC/Fluor. In this regard, this document must be considered as an initial version which would be
completed and updated during the project implementation whenever new agreements are reached.
Any change to this document once configuration was commenced mat impact upon the Project timeline. 1
1.2. Scope
This Specification for Functional Description covers all the technical aspects related to the engineering and
design regarding Emersons scope of supply for the ILO Smelter Modernization Project.
Each and every aspect will be described herein in order that both Emersons engineering team and customers
representative will know the standards and criteria during the development phase of the project.
Some of these aspects are:
Generation of Technical Documentation
Standards and criteria to be used in the Delta V configuration (Design Criteria for Configuration)

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2. Introduction
The purpose of the Project is to implement a new Control System as part of the Smelter Modernization Process
in Southern Peru Copper Plant in ILO-Peru. Emersons Process Control System, with PC-based Operator
Workstations, will control, supervise, integrate and monitor physical variables by integrating new, modified and
existing facilities.
Drawings and documents such as P&IDs, I/O lists, logic diagrams, loop diagrams, mimics, etc will reflect the
control philosophies, the interlocks/alarms strategies and process and control methods for a logical integrity.
This information and any other information required for the configuration of the system will be supplied by
SPCC as the basis for Emersons engineering and configuration activities.
2.1. Project Organizations
The project will be implemented by an engineering team of high-level specialists with vast experience in similar
applications. The team for this project will comprise resources from our office and representatives in Peru,
Chile and Argentina.
2.2. Plant Areas
The ILO Smelter Modernization Project includes the automation control and the instrumentation for the areas
listed in Table 2-1 according to the list mentioned in the Fluors document called Design Criteria for Control
System.
Area Name
130 Material Handling, Storage & Reclaim
140 Flux, Reverts & Coal Preparation
220 Furnace Raw Material Feed Preparation
230 ISASMELT Furnace
270 Process Air System
290 Peirce Smith Converter
293 Converter Slag Cleaning
294 Anode Furnace
295 Anode Casting

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301 ISASMELT Furnace Waste Heat Boiler

310 ISASMELT Furnace Electrostatic Precipitator
311 ISASMELT Furnace Dust Handling
320 PS Converter Electrostatic Precipitator
321 PS Converter Dust Handling
325 Off Gas Handling Duct Work
340 Secondary Gas Handling
410 Acid Plant No 2, Including Gas Cleaning
420 Acid Storage & Rail Car Loading
425 Acid Railcar Off Loading, Port Acid Storage & Ship Loading
440 Oxygen Plant No 2
460 Effluent Treatment Plant No 2
611 Main Substation
612 Emergency Power
615 Main Power Distribution
617 Control System
620 Seawater Intake Structure & Pumping
630 Plant Air System
635 Instrument Air Distribution
640 Desalination Plant & Potable Water System
645 Steam, Boiler Feed Water & Condensate Distribution
650 Firefighting & Emergency Water System
655 Bearing Cooling Water Distribution
670 Fuel Oil Storage & Distribution
673 Oxygen Distribution
675 Liquid, petroleum, gas (LPG) Storage & Distribution
690 Sewage Collection & Treatment
Table 2-1. Ilo Smelter Modernization Project Areas
To organize the logic control configuration, DeltaV system has a software tool called DeltaV Explorer (Figure
2-1). In the left side of this application there is a tree structure to navigate through the configuration. One item
is called Control Strategies, under which one must be listed the main process areas. The areas names can
content control modules (motor controls, PID control loops, etc.) and Process Cells. The Process Cells are used

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as process sub-areas to content control modules related to a specific part, system or equipment of a main
process area. This organization is useful to keep a clear and easy configuration.
The area names for DeltaV Control Strategies configuration will be defined in this document and the process
cells name will be defined according to the programmers criteria and/or SPPC/Fluor specification.
Figure 2-1. DeltaV Explorer Window
The Figure 2-1, shows the Control Strategies, Area names and Process Cells; the contents of the pointed
element in the left side are listed on the right side. In this example its possible to see a Process Cell pointed in
the left side showing the control modules (of that cell) in the right side. The figure is for reference only since it
is not intended for this project application.
2.3. System Architecture
System architecture will reflect and comply with SPCC/Fluor technical and functional requirements. It will
basically consist of 10 controllers with their corresponding set of I/O modules (handling from one to several
process areas depending on the Plant portion covered), twelve (12) Operator workstations (OWS), two (2)

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Engineering Workstations (EWS), one (1) Fault Tolerant Server (SER-001) for OPC connectivity with PLC
network, and finally two (2) additional servers (SER-002-01 and SER-002-02) in a redundant arrangement to
implement the Bailey System Screen Interface migration. The server named as SER-003 will be used for data
collection and for sharing information with SPCC Administrative LAN.
Ten of the Workstations will be installed in the Central Control Room (CCR), one in No 2 Acid Plant Control
Room, and the last one in No 2 Oxygen Plant Control Room. The Engineering workstations will be installed in
the Maintenance and Metallurgical Offices. And finally, the OPC Server will be installed in the Server Room and
the Bailey Migration Servers in the Acid Plant 1 Rack Room.
Controllers, Workstations and Servers will be linked together by means of a redundant control network to be
used in an exclusive basis by the Delta V System. Backbone will be fiber optics.
2.4. Main Components
2.4.1. Controllers
MD type Controllers provides communication and control between field devices and the other nodes on the
Control network. The controller manages all control activities, control network communication functions, time
stamping and alarming.
Each MD Controller will allocate the real-time database from the areas of concern as configured from the
Professional Plus Station. Each controller in this project will have a redundant architecture in controllers,
ethernet networking and power supplies.
For further information, please refer to DeltaV MD Controller Data Sheet.
Card type Description

VE3005 MD Controller
VE5008 24/12 Vdc Power Supply
VE3051C0 2-Wide Power/Controller Carrier
VE4050S2K1C0 8-Wide I/O Interface Carrier with Carrier Shield Bar
8-Wide I/O Interface Carrier with Carrier Shield Bar and
VE4050S2k1C1
carrier extension cable
Table 2-2. I/O Controller Card List
2.4.2. I/O Cards
The following different types of I/O cards are considered for the project. Nevertheless, other cards available for
DeltaV could be included if needed.

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Card type Description

Analog Input 16 Channels 4-20 mA w/Hart Termination
VE4003S2B6
Block 2-Wire Connection
Analog Output Card: 8 Channels 4-20 mA; HART; Fused
VE4005S2B2
I/O Termination Block
Discrete Input Card: 8 Channels 120 VAC; Isolated; Fused
VE4001S3T1B2
Discrete Input Card: 8 Channels 24 VDC; Isolated; Fused
VE4001S2T1B2
Discrete Output Card: 32 Channels 24 VDC; High Side;
VE4002S1T2B5
Fused I/O Termination Block
VE4014 Profibus DP Interface Card
VE4016 DeviceNet I/O Interface with Termination Block
Simplex H1 Fieldbus I/O Interface (Series 2) with
VE4017P0
Termination Block
Analog Input 8 Channels 4-20 mA w/Hart Termination
VE4003S2B3
Block 4-Wire Connection
VE6101 Carrier Blank Cap
Table 2-3. I/O Cards List
2.4.3. Database
The DeltaV Control Network needs to be designated with a unique database name. This database is the active
database that will store all of the relevant configuration information listed below:
The library of available control modules and function blocks.
Plant Areas and their associated modules that have been created.
Workstation and controller information.
System-wide data, such as named sets, alarm preferences, etc.
Network Domains or Workgroups shall be allocated such that they are unique to the DeltaV environment so as
not to conflict with other Plant Systems at the end users site.
Third parties will provide a single *.fhx file containing all configuration for the project along with an *.fhx file
for each of the process cells. As stated in 5.3.1 each process area and process cell will be prefixed by area
number.
1

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2.4.4. Engineering Workstations
As was mentioned previously, this project considered the implementation of two EWS. So, one of these will be
the Professional PLUS Station for the Ilo Smelter Plant and will contain the global database for the Ilo Smelter
Plant DeltaV system. The location of the Professional PLUS stations will be the Maintenance Office, while the
location of the Professional stations will be the Metallurgical Office. The Engineering Workstations (EWS) will be
DELL PowerEdge 2600 w/single 20 LCD Monitor.
Names are assigned according to Fluors document named Design Criteria for Control System and they will be:
617-EWS-001 (Professional Plus Station) and 617-EWS-002 (Professional Station).
2.4.5. Operator Workstations
For this project two types of OWS are considered:

Dual monitor OWS.
Ten (10) located at Central Control Room (CCR)
Single monitor OWS. Located at:
Oxygen Plant N 2 Analyzer Room (440-OWS-001)
Acid Plant N 2 Satellite Control Room (410-OWS-001) 1
Effluent Treatment Plant N 2 Satellite Control Room (460-OWS-001)
Rotary Holding Furnace. Control Cabin N 1 (230-OWS-001) and 2 (230-OWS-002)
2.4.6. Servers
1
The following table details the Servers included as part of the project:
Server Location Description Model

617-SER-001 Server Room OPC Server w/PLC Network (fault tolerant) Stratus ft 3300
617-SER-002 AP1 Rack Room Bailey Interface Migration Server (redundant Dell PowerEdge 2650
arrangement)
617-SER-003 Server Room Continuous Historian Server + OPC Server Dell PowerEdge 2800
w/Plant Information Network
Table 2-4. Sever List
For detail information about the Bailey System Migration Server please refer to document 15006-0000-DF-002.

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2.4.7. Control Network
The control network engineering will be done by SPCC. Control Network must be a redundant Ethernet LAN
dedicated to the DeltaV System. A combination of Cat5-Twisted Pair (TP) and fiber-optic cables will be used as
the standard communication media.
In normal operation conditions Primary network will be hot while the secondary will be on standby.
Controllers, OWSs, EWSs and SERs will have a redundant connection to the control network. Switches will be
installed in each controllers cabinet, Central Control Room, Maintenance Office, Metallurgical Office, No 2 Acid
Plant, No2 Oxygen Plant, Sea Water Intake, Concentrators, effluent treatment No 2 Plant, Acid Storage & Rail
Car Loading, PCs including Cooling Water.
There will be two types of network switches:
In each cabinet: SC socket Hirschmann RS2-3TX/2FX, 3x10/100 Base-TX. TP cable, RJ45 socket and
2x100 Base-FX, multimode fiber.
At the central control room: Hirschmann MACH-3001.
The DeltaV control network should be designed in conjunction with the overall site plan to define layout and
routing. Note that a maximum of four hubs or switches can be linked together in series when designing the
network. Media converters do not inflict a hop delay on the network, hence they are a transparent device that
does not count in the four-hop cascade limit.
DeltaV automatically assigns IP addresses to all workstations and controllers on the control network. This is
managed through the Professional PLUS station where workstation configuration files can be generated. A
uniform naming convention for the workstations is used to assist design, layout and maintenance of the
system.
The DeltaV System automatically assigns IP Addresses to each node. The DeltaV system also automatically
assigns a subnet mask of 255.254.000.000. These automatically assigned IP addresses should not be manually
changed.
2.4.8. Foundation Fieldbus
Fieldbus Foundation engineering will be done by SPCC/Fluor. As a result of this engineering, instruments will be
assigned to the different segments of H1 modules. Each Fieldbus H1 card has been considered with two
segments. SPCC/Fluors standard is 8 devices per segment, with no more than 2 control valves.
In areas where intrinsic safety is required, the necessary conditioning and powering devices will be included.
Emerson recommends the following format to assign names to fieldbus segments and FDUs. In any case
SPCC/Fluor will define and generate those names.
Fieldbus Segment name format:
AREA CORR.SEG.
SEGMENT: 4XX - XXX

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FDU Name format:

AREA CORR.SEG. CORR.FDU POSITION
FDU: 4XX XXX XXX X
2.4.9. DeviceNet
DeviceNet will be used for communication with MCC starters, where a DeviceNet starter auxiliary device will
collect the I/O signals.
2.4.10. Profibus DP
Profibus DP will be used for communication with Operator Electronic Interfaces (EOI) and when a process
communication is required with other processor (i.e. PLC).

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3. Technical Documentation
3.1. Scope
The Technical Documentation to be supplied as part of the Project will be the following:
Documents List
System Architecture Drawing
Power consumption calculation
Heat dissipation calculation
Cabinet general dimensions drawings
Cabinet Lay-out drawings
Cabinet power supply distribution and grounding drawings
Cabinet detailed internal connection drawings
I/O allocation lists
Graphic Displays Interface list (including Graphic Displays Screens)
Functional Design Specification (Configuration standard)
Bill of Materials (BOM) for DeltaV Hardware and Software
Bill of Materials (BOM) for Third party Hardware and Software
FAT procedures
SAT procedures
Training program
Operation Manual
DeltaV Technical Manual
Third Party Technical Documentation
Note1: Third party documentation consists of all documentation supplied by vendors to Emerson, including any
computer equipment, peripheral devices, and third party software providers.
Note2: All third party documentation will be inventoried during FAT and will be made available to SPCC after
installation.
Note3: Documents submitted by Emerson shall be approved and/or a written notice of deficiencies shall be given
within 10 working days. Any delays over the allocated 14 days will affect the project scheduling.

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3.2. Documents Identification
Engineering documentation will be identified in accordance with the following criteria. Document numbering
will be as follows:
AAAAA - BBBB - CC - DDD - E . FFF
Project Ref. Number
Area of Application
Document Type
Correlative Number
Document Revision
Extension (file format)
AAAAA: Project Reference Number (for internal use).

For this project the assigned number is: 15006
BBBB: Area of application (following SPCC/Fluor definitions)

2201 Smelter Operation Building (Controlled Area 220)
2301 Anode Casting Control System Room (Controlled Area 230)
2302 Anode Casting Control System Room (Controlled Areas 270, 301)
2303 Anode Casting Control System Room (Controlled Areas 310, 311, 340, 630, 645, 650 & 670))
2901 PSC ESP Electrical Room (Controlled Areas 270, 290, 293, 320, 321 & 325)
4101 No 2 Acid Plant Electrical Room (Controlled Areas 410)
4201 Acid Storage Electrical Room (Controlled Area 420)
4401 No 2 Oxygen Plant Analyzer Room (Controlled Area 440)

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4601 Effluent Treatment No 2 Plant Electrical Room (Controlled Area 460)

6201 Seawater Intake Electrical Room (Controlled Area 620)
CCR0 Central Control Room
0000 General
CC: 2 digit code to represent the document type.

DC Wiring Diagrams (Diagramas de Conexionado)
DF Functional Description (Descriptivo Funcional)
ET Technical Specification (Especificacin Tcnica)
LI List (Lista)
MC Calculation Sheet (Memoria de Clculo)
MD Descriptive Memory (Memoria Descriptiva)
PR Procedure (Procedimiento)
PL General Drawing (Plano)
RT Report (Reporte)
ST Standard (Standard)
DDD: Correlative number assigned per each document type.
E: Document review status. Valid codes:

A, B, C, . . . During engineering
0 For construction review
1, 2, 3 . . . Further reviews, if necessary
FFF: File format. Standard extension for Windows programs. For this project the standard format will be PDF.
Other formats will be XLS (Excel) DOC (Word) DWG (AutoCAD).
The software versions used to create the electronic files are:
Microsoft Office 2003
Adobe Acrobat 5
AutoCAD 2000
Example: 15006-0000-DF-001-A.pdf

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4. System Administration
4.1. Security in DeltaV
4.1.1. Introduction
Through the use of locks and keys, the DeltaV system provides security mechanisms at both the parameter and
fields level, as well as at the function level. At the parameter and fields level, DeltaV system allows you to
control which users can write to specific parameters and parameter fields in the run-time information. At the
function level, DeltaV system allows you to control which users can perform certain functions.
Security settings will be set later for the entire project once all parties have completed their configuration.
1
The DeltaV User Manager application provides an interface to the five essential components of security:
Locks: Prevent users from changing the parameters and parameter fields assigned to the locks, as well as
performing certain functions. You use the Explorer to assign locks to parameters, parameter fields and
functions. It is helpful to think of a lock as something that specifies the name of the key that grants access.
Keys: Provide permission to individual users or whole groups of users. Each key is associated with a lock. You
grant keys under the group and user properties dialogs. Users can be granted any number of keys or none at
all.
Groups: Enable you to classify the group of users, and grant keys to everyone in the group.
Users: They are DeltaV and WindowsXP users. You can assign users to one or more groups. The DeltaV User
Manager application also allows you to create new WindowsXP users without accessing the Windows User
Manager application. When you create a new user, you can specify whether the user is a WindowsXP user, a
DeltaV user, or both.
Areas: DeltaV users can be granted different sets of keys in each area. This feature can be used to grant
parameter write access to operators for control modules within the operators' responsibility, although access to
other similar modules outside their responsibility can also be withheld. You can assign parameter and field
locks to specific areas. The locks listed in Assigned to Functions do not support area-specific assignments.
These function locks must be assigned to area 0 (named Area_A by default).
Locks for parameters are assigned to parameter names rather than to specific instances of parameters. In
other words, a lock on HI_LIM applies to all instances of parameters named HI_LIM. To lock a specific instance
of a parameter, you must create a unique name for that parameter, such as HI_LIM1.
Locks and keys assigned at field level override those on the parameter itself. This means that specific
parameter fields can be open to a large number of users while the parameter as a whole remains generally
restricted.
Note: Because security settings on fields have precedence over parameter security settings, you must be very
careful when defining access to fields. For example, if access to GAIN is restricted, but access to the CV field has
been defined as less restricted, users with less restrictive access will be able to change the GAIN parameter.

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When users make write requests to a specific parameter field, the system checks for a lock on the field. If
there is no lock, the system checks for a lock on the parameter itself. When there is no lock on the parameter,
the default lock is used. Users can write to the field of the parameter only when they have a key corresponding
to the lock. Additionally, the workstation properties can restrict parameter writes by area. That is, the
parameter can only be written to if the user has the key for the area and that area is assigned to the current
workstation.
Locks are also assigned to several user functions such as downloading, uploading, changing the configuration
database and so on. Functions are assigned to default locks initially. You can change the lock associated with a
function.
4.1.2. DeltaV Locks
In the DeltaV system, locks prevent users from changing the parameters and parameter fields assigned to the
lock as well as performing certain functions.
(User accounts with appropriate access will be created during commissioning) 1
Locks Assigned to Function Block Parameters: any function block parameter that is writable has a lock assigned
to it. You can change the lock assignments made by the system. Refer to the Table 4-1 for a complete list of
the parameter and field locks, and a description of each lock's function.
Lock Description
Alarms Assigned to parameters that concern alarms and the alarm horn. The Alarms
lock affects access to the HORN parameter and the HENAB, MACK, and NALM
fields.
Control Assigned to parameters that an operator needs to write to in order to control
the process. Examples of parameters with the Control lock are MODE,
SETPOINT, and OUTPUT.
Restricted Control Assigned to parameters that supervisors and engineers write to in order to
configure the process. Operators typically do not write to these parameters.
Examples of parameters with the Restricted Control lock are CONTROL_OPTS
and DISABLE.
Tuning Assigned to parameters that maintenance technicians and supervisors write to
in order to tune performance. Typically (although not always), operators do not
write to these parameters. Examples of parameters with the Tuning lock are
GAIN, RESET, and HIGH_LIM.
Diagnostic Assigned to parameters that affect diagnostic information maintained by the
system, such as parameters that reset instance counts.
System Records Assigned to parameters that affect the records kept by the system, such as
parameters that turn off the recording of event records.
System Maintenance Assigned to parameters that affect control system operation, such as
parameters that start and stop devices and subsystems.
User Locks 1 through Assigned to parameters that you specify. These locks provide flexibility to your

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10 security scheme. Note When Recipe Authorization is enabled, User lock 06

through 10 are reserved for recipe approval signers.
Table 4-1. Parameter and Field Locks
4.1.3. User Accounts and Groups
Both DeltaV and WindowsXP security is based on user accounts and groups. A user account consists of unique
credentials (login name and password) that allow the user to access resources. A group is an account that
contains user accounts called members. Permissions and access rights are granted to groups and apply to all
members of the group. A group is essentially a classification of users, and it offers a convenient way to set
access permissions for a collection of users of the same type. A user can be assigned to more than one group.
The default groups in DeltaV are:
Maintenance
Operator
Supervisor
Tune
The Table 4-2 shows the defined Users Groups and privileges (attributes), it can be modified according to
customer administration policies.
Group Name
Attributes Maitenance Operate Supervise Tune
Alarms
Control
Diagnostic
Restricted Control
System Records
Tuning
Table 4-2. Groups and Attributes in DeltaV
4.1.4. Operator Workstation Security
DeltaV workstation security is controlled by the DeltaV Flexlock application. This application can be used to
allow various users access to either the Windows Desktop, the DeltaV Desktop or both. Workstation security
can also be controlled using the DeltaV screen saver for Auto-Logon that will log the workstation on to an
account that allows a user to view the plant only so alarms applicable to that workstation can be seen.

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However, initially, for commissioning purposes all Operator Workstations shall be defined with full system-wide
access rights using a System Integrator Key.
4.2. Configuration Logbooks
As the project files for the Ilo Smelter plant are centralized on the Professional PLUS Station, a single logbook
will be used to record configuration and backup activities. This logbook shall contain information on:
Date and brief description of what configuration work has been carried out.
Date and details of each backup of configuration.
Initials of person carrying out the work.
Logbook(s) noting work required to be done will also be maintained during the configuration and
commissioning phases. All logbooks are to be kept in a common area accessible to all persons working on the
configuration.
4.3. Configuration File Backup/Security
The DeltaV DCS uses a electronic media ([Hold] to be defined) to provide file backup facilities. In general,
one(1) CD only is required to backup the entire system. Every electronic backup shall be maintained. They shall
be clearly identified and stored in a suitable location and manner. Each electronic media will contain the
following data:
Database Backup (control strategies, libraries, setup and control network configuration).
Contents of PIC directory (operator displays, details displays and faceplates).
All changes to the configuration or programming of field control stations and/or operator stations will be saved
randomly on to one of the DeltaV machines at least daily, at the end of the working day. The database and PIC
directory will be copied to an appropriate location on the SPCC local server each Friday, weekly a CD with
identical information will also be written each Friday.
Each database backup must be done using the DeltaVs Database Administrator following a procedure that will
be attached in the future to this document.
All backup activities are to be noted in the configuration logbooks and the save date recorded on the updated
cartridge CD Backup requirements are determined by consulting the logbook.
An export to a *.fhx file will be performed as part of the backup procedure.
1

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5. Controller Configuration
5.1. Controllers and Plant Safety
5.1.1. General
The paramount consideration in all configurations shall be to maintain personnel safety through compliance
with International Standards and especially with regard to control of plant electrical equipment. A most
important aspect is to ensure that following power supply interruptions and/or failure of DCS components,
electrical equipment will not be re-energized without specific operator intervention. That is, adequate steps
must be taken to ensure that drives do not re-start when power supply is restored or when a DCS component
recovers without a specific, relevant command from a plant operator.
5.1.2. Controller Cold Restart
The DeltaV Cold Restart option for each controller shall be set to a minimum of 7 days, that is, the perform
cold restart within setting for each controller on the network. This setting means that if power is restored
before this time has elapsed the controller will automatically download itself using the data in non-volatile
memory If this time elapses or if the non-volatile memory is not valid the controller will, in the first instance,
request a user restart and in the second instance initiate a download from the Professional Plus workstation.
The user must be aware that with each online change made to the system a regular upload and download to
the Controller Cold Restart Memory must be made to ensure the plant is returned safely after a power failure.
An upload only, means that the non-volatile memory in the controller is not valid but the system will use the
database held in the workstation for the Cold Restart. If the uploaded information is then downloaded to the
controller as the new Controller Memory, then this database will be used on a Cold Restart.
5.1.3. Failure Modes
All I/O cards in the DeltaV subsystem support failure action operations. The failure action depends on the card
type and the control strategy the I/O is involved in. All configured I/O cards will turn on the red Error LED but
only the output cards will take any further failure action. The following failure action configuration options are
available for configured Output channels:
Failure Action Mode Designates if the channel should Hold Last Value or use the Output Failure
Action Value
Failure Action Value Specifies the value used if the channel is configured to use the Output Failure
Action Value
Note: In the case of a digital output, if the channel is configured as Hold Last Value and is a continuous pulse
output, it will continue with the latest period and duty cycle. If the channel is configured as Hold Last Value and
is a momentary pulse output it will continue to process the current pulse but no additional pulses will be
generated. If the channel is configured to use the Failure Action Value and is either a momentary or continuous
pulse, the pulse is aborted for the failure action value.

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Failure actions of devices will typically be determined by the service that they are controlling, for example, in a
boiler all fuel valves should be closed in the event of a controller failure. Output failure modes can be specified
on a service by service basis but, in general the following guidelines shall apply to output failures:
Digital Outputs shall be configured to open when a controller failure occurs.
Analog Outputs shall be configured to go to 4 milliamps when a controller failure occurs.
5.2. Free Time Parameter in DeltaV Controllers
The FRETIM parameter in the DeltaV controller represents the percentage of time available to run control
modules. A scheduler in DeltaV clamps the module execution at a maximum of 65%, that is, the control
strategy is allocated up to 65% of the CPU usage per controller. If the clamp is active control module slippage
can occur, that is, the modules may not be running at their set execution rate.
The FRETIM parameter also indicates CPU usage for other tasks such as communications, self diagnostics and
other overheads. This CPU usage can exceed the 35% normally required if additional data links are requested
through various bus or serial connections.
When allocating and downloading a strategy to a controller a minimum of 10% FRETIM should be adhered to.
To increase the FRETIM figure module execution rates can be slowed.
The DeltaV Load Estimator can be used to calculate loading on the controller based on the modules to be used
in the control strategy.
5.3. Tag Names Definitions
5.3.1. DeltaV Areas Names
All the DeltaV Area names (only for logic configuration purposes) will be defined by Emerson, SPCC and Fluor.
DeltaV supports a area name itself and area process description also (see Table 5-1). A first approach can be
done considering some restrictions: the areas names in DeltaV cannot exceed 16 characters, must contain at
least one alpha character, and may contain only alphanumeric characters, $, -, or _.
All Plant Area will be created by Emerson, hence all the process Cells created by third parties will be imported
into pre-existing Plant Areas.
1
Area Description
AREA_130 Material Handling, Storage & Reclaim
AREA_140 Flux, Reverts & Coal Preparation
AREA_220 Furnace Raw Material Feed Preparation
AREA_230 ISASMELT Furnace

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AREA_270 Process Air System

AREA_290 Peirce Smith Converter
AREA_293 Converter Slag Cleaning
AREA_294 Anode Furnace
AREA_295 Anode Casting
AREA_301 ISASMELT Furnace Waste Heat Boiler
AREA_310 ISASMELT Furnace Electrostatic Precipitator
AREA_311 ISASMELT Furnace Dust Handling
AREA_320 PS Converter Electrostatic Precipitator
AREA_321 PS Converter Dust Handling
AREA_325 Off Gas Handling Duct Work
AREA_340 Secondary Gas Handling
AREA_410 Acid Plant No 2, Including Gas Cleaning
AREA_420 Acid Storage & Rail Car Loading
AREA_425 Acid Railcar Off Loading, Port Acid Storage & Ship Loading
AREA_440 Oxygen Plant No 2
AREA_460 Effluent Treatment Plant No 2
AREA_611 Main Substation
AREA_612 Emergency Power
AREA_615 Main Power Distribution
AREA_617 Control System
AREA_620 Seawater Intake Structure & Pumping
AREA_630 Plant Air System
AREA_635 Instrument Air Distribution
AREA_640 Desalination Plant & Potable Water System
AREA_645 Steam, Boiler Feed Water & Condensate Distribution
AREA_650 Firefighting & Emergency Water System
AREA_655 Bearing Cooling Water Distribution
AREA_670 Fuel Oil Storage & Distribution
AREA_673 Oxygen Distribution
AREA_675 Liquid, petroleum, gas (LPG) Storage & Distribution

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AREA_690 Sewage Collection & Treatment
Table 5-1. DeltaV Areas Names And Descriptions
5.3.2. Controllers Names
In the PCS, there are ten (10) DeltaV controllers available. So, for PCS configuration, the process areas
mentioned at the beginning of this document, must be grouped to assign the control strategies to these
controllers. According to Fluors document named Design Criteria for Control System, Table 5-2 shows the
controllers tagnames, associated areas and who is in charge of each area.
Controller Scope Location Controlled Areas Equipment

220-DCS-001 V Smelter Operation Building 220 Furnace Raw Material
230 Isasmelt Furnace including burner
230-DCS-001 V Anode Casting Control System Room
+ RHF1 & RHF2
270 Isasmelt Blower
301 Waste Heat Boiler + Drag
230-DCS-002 V Anode Casting Control System Room
Conveyor + WHB Dust Handling
310 ID Fan
230 Isasmelt Furnace Auxiliaries
310 Isasmelt ESP Drag Conveyor and
Superheater *
230-DCS-003 E Anode Casting Control System Room 311 Isasmelt Dust Handling
340 Secondary Gas Handling
630 Plant Air *
670 Fuel Oil Distribution *
270 Process Air (Converters Blower
Header)
290 PSC including Water Cooled Hoods
290 Evap. Cooling System (PSC N 4,
290-DCS-001 E PSC ESP Electrical Room 5, 6 & 7)
320 PSC ESP Off Gases
321 PSC Dust Handling
325 Off Gas Handling
410 Acid Plant N 2
410-DCS-001 V Acid Plant No 2 Electrical Room
410 Acid Plant N 2 Fuel Oil System

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420-DCS-001 E Acid Storage Electrical Room 420 Acid Storage & rail Car Loading
440-DCS-001 V Oxygen Plant No 2 Analyzer Room 440 Oxygen Plant N 2
Effluent Treatment Plant No 2
460-DCS-001 V 460 Effluent Treatment Plant N 2
Electrical Room
620 Sea Water Intake
620-DCS-001 E Seawater Intake Electrical Room
640 potable Water Pumps
Table 5-2. List of DeltaV Controllers

Note1: Letter E on Scope column, means that the configuration will be done by Emerson. Letter V stands for
Third Party Vendors.
Note2: * means on Hold. 1
The rule used to generate the controllers names is:
AAA-DCS-BBB
Where,
AAA : Plant area number.
DCS : Equipment designation provided in Project Procedures Manual (Fluors document).
BBB : Correlative number per area.
Note: All DeltaV controllers are MD type in redundant configuration.
5.3.3. Modules Tag Names
The names for control modules shall conform to the standard defined in the Design Criteria For Control System
considering the same restrictions mentioned for areas names: cannot exceed 16 characters, must contain at
least one alpha character, and may contain only alphanumeric characters, $, -, or _.
In general terms, a control module is related to a motor control, PID control loop, input monitoring, sequences,
etc.
5.3.4. Motor Control Module Name
Typically control modules for motor starters will be tagged with the equipment tag name. The equipment
names are listed in the Fluors Mechanical Equipment List (2333-000-55-LI-001).
The name structure will be:
AAA FFF NNN
Correlative Number
Equipment code
Area number Example: 220CON005 (Transfer Conveyor 220-CON-005)

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5.3.5. On/Off Valves
On/Off valves modules in DeltaV will be tagged following the next structure (the output command to the valve
and position limit switches tag naming will be explained in the next section):
AAA FFF NNN
Correlative Number
Equipment code
Area number Example: 420HIV005
5.3.6. Sequences Names (SFC)
The naming standard will be:

AAA SEQ NNN
Correlative Number
Sequences
Area number
5.3.7. Device Tag Names (DST)
The Device Signal Tag (DST) will be denominated according to the instrument tag itself. They were not used
tags generated automatically by the system. In this way, the tasks of configuration, diagnostics and
maintenance will be considerably facilitated. (For detail information on device tagging please refer to DST TAG
Table - Appendix A)
The name structure will be:
FFF AAA NNN SSS
Suffix order to indicate signal, instrument or element associated to the same function.
Correlative Number
Area number
Identification ANSI/ISA-S5.1-1984 Example: LI290541, 220CON005RUN
5.3.8. Fieldbus Block Names
As far as Fieldbus elements are concerned, the device tag will be indicated in the instrument data base, and
the internal blocks are denominated with the tag before mentioned, followed by the name of the block, which
enumerates the different instances from 1. Example: For a Rosemount 3244 temperature transmitter with tag
TT-340108, the names of the internal blocks they will be TT-340108AI1, TT-340108AI2, TT-340108AI3, TT-
340108PID1, TT-340108PID2, TT-340108ISGCR y TT-340108ARTHM.

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5.3.9. Classic I/O Tag Names
Inputs and outputs shall be tagged with the same tag as the wiring to the input as possible. So, these tag
names must be following the same criteria explained in the section 5.3.7.
5.3.10. Reference Parameters Names 1
As DeltaV is a windows-based system, the user can use relevant definitions for both software and internal tags
that are not bound by character length restrictions. However, to assist ease of configuration a character length
limit of 20 is recommended.
5.3.11. DeviceNet Names

1
DeviceNet will be named using the following convention:
AAA DNT X NN
Correlative number (node)
Network number (correlative)
Designation for DeviceNet device
Area number
As can be seen in the following picture, DeviceNet signals will be named with the symbols listed in the table N
2 from the Appendix A.
Figure 5-1. DeviceNet signals.

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5.3.12. Profibus Names
Profibus DP devices will be named using the following convention:

AAA PFB X NN
Correlative number (node)
1
Network number (correlative)
Designation for Profibus DP device
Area number
Profibus DP slots will be named with the DeltaV default: SLOT000, SLOT001, SLOT002, etc.
For naming the Profibus Signals will use the same convention for naming DeviceNet signals.
5.4. Programming
Control Software supplied with the DeltaV supports three IEC61131-3 graphical control languages:
Function Block Diagrams (FBD)
Sequential Function Charts (SFC)
Structured Text (ST)
These languages provide full analog, discrete and sequencing control within a single DeltaV controller. The
priority is to use function blocks for all programming.
The appropriate use of these programming languages is defined in the next items.
5.4.1. Function Block Diagrams (FBD)
Function Block Diagrams are typically used for the following applications:
Analog Control
Monitoring and Alarming
Totalizing
Continuous Calculations
Motor Control
Valve Control

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5.4.2. Sequential Function Charts (SFC)
Sequential Function Charts can be used for the following applications:

Start-up Sequences
Shutdown Sequences
5.4.3. Structured Text (ST)
This kind of language will be used only in special cases.

S.T. is used in expression development for condition blocks, transition and action function within sequences.
1
5.5. Control Modules
DeltaV Control Studio is used to create the control strategy defined by the functional description. Each loop,
motor or equipment is defined by a module which is based in a group of function blocks. A module is the
smallest part of the control logic that may be downloaded to a controller. These modules should be grouped
into their relevant Process Cells and/or Areas, so that logical groups of equipment are controlled within the
associated controllers. This simplifies commissioning, maintenance and management of the database.
The following properties must be defined for each module:
Module Description: is used on the faceplate, detail displays, alarm sumary and event logger to show specific
description or function about that motor, equipment or control loop. Must be written in mixed-case with initial
capitals with a maximum of 24 characters to be used.
Scan Rate: specify the rate at which the controller executes the module.
Primary Control: specify the primary display filename associated with the module.
Faceplate: specify the faceplate display filename for this module.
Detail: specify the detail display filename for this module.
5.5.1. Function Block Scan Rate
Individual Block Scan Rates can be set within modules. The default setting for each block scan rate is 1 second.
The block scan rate is ratioed to the module scan rate, that is, if the block and module are set to 1 second
each, the block will execute each time the module executes, if the block is set to 5 seconds and the module to
1 second the block will execute every 5th module execution.
This is typically used for cascade control where the two loops are combined into one control module and the
scan rate for the outer loop is set as a multiple of the scan rate of the inner loop.

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5.5.2. Function Block Execution Order
Allow you to set the sequence of function blocks. This determines the order in which they execute. An incorrect
execution order of the module function blocks may make the module appear to scan slower than its actual scan
rate. The loop execution order is selected so that all input blocks are executed before control blocks or output
blocks.
The default execution order is based on the order the blocks are created within the module so care must be
taken to set the correct order of execution.
Please note that this item refers to the execution order setting only, not to the layout of blocks on the drawing
which should always be arranged to assist understanding of the logic or signal flow and to clarify block
interconnections.
5.6. Interlocks Descriptions
Interlocks for a module are generally displayed in the faceplate display for the module. The sense of the text
description must describe the alarm state. For example, where interlock conditions are defined in condition
(CND) blocks, the interlock is also displayed in text in the faceplate display for a module. The display is taken
from the description (DESC) parameter of the CND block.
The text string description length cannot be greater than 40 characters.
5.7. Interlocking and Sequential Definition
Throughout the configuration, interlocking and sequential logic functions shall be kept clearly separated. For
the purposes of this specification, the two types of logic are defined as follows:
Interlocking logic are collections of logic rules that must be continuously monitored and executed. Such rules
guard against unsafe or potentially damaging situations and include rules that determine whether sequential
logic may remain in normal operation or should be interrupted to put the plant into a safe state.
Sequential logic involves the execution of a sequence of steps. Within each step, the logical rules determine
actions relevant to that step only, and/or whether to progress the sequence to another step. Because
sequential logic inherently executes only a limited number of rules pertaining to a particular step at any one
time, it must never contain interlocking logic rules. Sequential logic must always be subservient to interlocking
logic. That is, if interlocking logic determines that an unsafe plant condition has occurred, it must be able to
override the rules of sequential logic in putting the plant into a safe state. In summary, sequential logic may
be used to determine the sequential steps of plant operation when all conditions are healthy but
interlocking logic must execute rules to detect and correct unhealthy/unsafe conditions.

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6. Configuration Standard
This section defines the criteria to be used for the configuration and documentation of the Project. By using
the established technical standard in this chapter, the configuration could be implemented in a consistent way,
and people carrying out the tasks will not be concerned.
The standards explained in this chapter will be done and updated by Emerson to be followed by any person
that needs to add or modify the control strategies for this project. Special cases or special requirements must
be sent to Emerson to generate and update the configuration libraries.
6.1. Engineering Units
The engineering units used for logic control configuration, are taken from the SPCC/Fluor specification in the
document Design Criteria For Control System. Additional units or modifications to the actual list must be
approved by SPCC/Fluor.
Basically, the engineering units listed in the Table 6-1 will be used in Analog Input (AI) and PID Control
function blocks, either using 4-20mA classic I/O or Fieldbus Foundation transmitters.
Special considerations must be taken for Fieldbus Foundation transmitters in the scale parameters. Please refer
to each equipment configuration manuals to check the supported engineering units for it.
Variable Description Unit Comments

Analysis Depends on the variable ppm, g/l, %
Concentration grams per liter g/l
Conductivity Microsiemens S
Current Amperes A
Data Transfer Speed Bits per second bps
Density Kilograms per cubic meter kg/m3
Distance Millimeters mm
Energy Joule, or kilowatt hour J, kWh
Flow (mass) Metric tons per day t/d
Frequency Hertz Hz
Level Percentage, or meter 0-100%, m
pH pH units pH
Pressure Kilo Pascal or Pound per square inch kPa
Pressure (Low) Millimeters of water column mm H2O

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Radioactivity becquerel (1/s) Bq

Speed Percentage, or radians per second 0-100 %, rad/s
Temperature Celsius Degrees C
Torque Percentage, or Newton-meter 0-100 %, Nm
Vacuum Milligrams of mercury mm Hg
Voltage Volts V
Volumetric Flow (gas) cubic meter per hour Nm3/h
Volumetric Flow Liters per minute l/m Liq.< 1.0 m3/h
Volumetric Flow cubic meter per hour m3/h Liq. 1.0 m3/h
Mass Flow Kilograms per hour Kg/h Steam flow
Weight Metric tons mt
Table 6-1. Engineering Units
6.2. Using Fieldbus Technology in the Control Strategy
The following sections provide some guidelines for using Fieldbus function blocks in DeltaV control applications.
All control logic must be executed within DeltaV Controllers and would not execute logic control inside of
fieldbus devices.
6.2.1. Use Only the Available Number of Links
Fieldbus devices allow a limited number of input and output links between their function block parameters and
parameters in other field devices. (Input links are called subscriber links and output links are called publisher
links.) For example, the Rosemount 3244 Rev 3 Temperature Transmitter and the Rosemount 3051 Rev 4
Pressure Transmitter both allow four output links and four input links to fieldbus function block parameters.
These devices allow only four links as inputs to their function blocks and only four links as outputs from their
function blocks. This limit is quickly reached if Feed Forward, Cascade, and Track control methods are used
because these types of control require more inputs and outputs. During application configuration, the DeltaV
system notifies you if the subscriber or publisher limit for a device has been reached. Refer to the "Fieldbus
Device Subscriber and Publisher Links" table under System Capacities for the number of subscriber and
publisher links available per fieldbus device.
6.2.2. Understanding Module Execution Time and the Fieldbus Macrocycle
The module execution time as defined in Control Studio and the fieldbus macrocycle are independent. The
module execution time determines how often the module executes while the fieldbus macrocycle determines
how often the fieldbus function blocks on the port execute. Users can change the schedule macrocycle in the

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DeltaV Explorer. The schedule macrocycle is the user-specified execution time for all the fieldbus function
blocks on the segment. (The required macrocycle is the actual execution time plus any publisher CD time.) To
change the schedule macrocycle, click the right mouse button on the fieldbus port, click Properties, and then
click the General tab.
To check the required macrocycle in the DeltaV Explorer, click the right mouse button on the H1 port, click
Properties, and then click the Advanced tab.
6.2.3. Understanding the Stale Link Count Limit
The DeltaV software automatically configures a Stale Link Count Limit parameter for communication among
fieldbus devices and for communication between DeltaV and fieldbus devices. The Stale Link Count Limit
specifies the number of communications that can be lost before the parameter status is set to BAD. If the limit
is set too low (for example, if it is set to one), then inputs can be set momentarily to BAD and control can go to
MANUAL under normal operation conditions. The default Stale Link Count Limit for the DeltaV software is three
for communications among fieldbus devices. DeltaV can set the Stale Link Count Limit to more than three for
communications between the DeltaV Controller and the fieldbus if the module execution rate is faster than the
fieldbus macrocycle.
Note: This parameter is automatically set by the DeltaV system and is not user configurable.
6.2.4. Using a Conservative Module Execution Time
For fieldbus function blocks, the module execution time (set in Control Studio) determines the rate at which the
controller reads the blocks' parameters over the fieldbus segment (as opposed to non-fieldbus function blocks
where the reading does not occur over wiring from a device). It is highly recommended that you keep the
module execution time as slow as possible to minimize the loading on the fieldbus segment.
Note: If there are links between fieldbus function blocks (running on a fieldbus device) and controller function
blocks (running on the controller), make sure that the module execution rate is a multiple (>=2) of the macrocycle.
Fieldbus links can go to BadNoCommLUV if the module execution rate is not slower than the macrocycle.
6.2.5. Write Requests Limits to Fieldbus Function Block Parameters
Because of the effect on the segment's bandwidth, it is recommended that you limit write requests to fieldbus
function blocks to three (no more than 30 outstanding requests per controller for any one time) and use write
requests only when necessary. Like module execution times, write requests can impact the rate at which the
View List is scanned and can use up a good deal of the fieldbus bandwidth. For example, if a Calc block's
output is linked to an external reference that is tied to the SP of a fieldbus PID block, the system will attempt a
write of the value (over the fieldbus) to the fieldbus device with each execution of the module.
Note: Be especially careful when using periodic writes to static fieldbus parameters in an expression since this
type of write can increment the block's static revision parameter (ST_REV), which then causes the controller to
issue two more requests to read static View List data.
6.2.6. Periodic Writes Limits to Static or Non-Volatile Parameters
It is recommended that you limit the number of periodic writes to all static or non-volatile parameters such as
HI_HI_LIM, LOW_CUT, SP, TRACK_IN_D, OUT, IO_OPTS, BIAS, STATUS_OPTS, SP_HI_LIM, and so on. Static
parameter writes increment the static revision counter, ST_REV, and are written to the device's non-volatile

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memory. Fieldbus devices have a non-volatile memory write limit. If a static or non-volatile parameter is
configured to be written periodically, the device can stop its normal operation after it reaches its limit or fail to
accept new values. Consult the device documentation or the Foundation Fieldbus Specification to determine if a
parameter is static or non-volatile.
6.2.7. Using Valid Input and Output Links
When linking to fieldbus resident function block parameters, DeltaV restricts users to only input and output
parameters. Other non-linkable parameters are not visible for the links. Similarly, Show and Hide parameters
are not supported for fieldbus function blocks.
6.2.8. Using Valid Channel Assignments
Fieldbus Input (AI) and Output (AO) function blocks must have a valid channel number for device signals.
When you configure a fieldbus AI and AO block, you must set the channel parameter to a valid number or the
blocks will remain in OOS mode. Refer to the device documentation for information on channel numbers. To
find values for a partial devices list, refer to the following topic.
6.2.9. Using Valid XD_SCALE
Fieldbus Input (AI) and Output (AO) function blocks must have a valid XD-SCALE. When you configure fieldbus
AI and AO function blocks, you must set valid XD-SCALE units or the block will remain in OOS. Only the AI
function block XD-SCALE units can change the units in the transducer. XD_SCALE EU100 and EU0 do not have
to match because only XD_SCALE units are transferred to the transducer block. Check proper scale and unit
information using the transducer block properties for the specific transmitter. To find units for a partial device
list, refer to the following topic.
6.2.10. Assigning Fieldbus Function Blocks to Devices
If a module contains any <unassigned> fieldbus function blocks, the LAS is unable to generate the schedule
for the entire module even if the module contains properly linked and assigned function blocks.
You are notified of any <unassigned> modules during a download of the fieldbus device. In Control Studio,
click the right mouse button on the function block and then click Assign to Fieldbus Device.
6.3. Control Modules Standard
For this project, there are considered two types of control modules:
Logic Control Modules (see 6.4 section)
Main Control Modules
The Logic Control Modules are designed to execute only logic control as permissives and interlocks conditions,
special calculations, automatic actions and general programming. This module (Figure 6-1) is known as LG
module (LG = Logic) and should be one per each Main Control Module except for Analog and Discrete Input

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Monitoring Modules. If is necessary to program SFCs, LG modules must be linked to the SFC Modules through
External References.
The Main Control Modules are those modules used to control an especific equipment such as:
Motors (see 6.7 section)
PID loops (see 6.5 section)
On-off valves (see 6.8 section)
Analog input monitoring and discrete input monitoring (see 6.6 section)
6.4. Logic Control Modules And Composites Blocks
6.4.1. LG Modules
The control strategy as described previously is based on control modules. The main control module is linked
with the LG module through External Reference Parameters. The logic module scan rates will be set by default
as 1 second of execution time, it could be set according to the process nature.
They will be identified by the same tag name of the correspondent module, but adding the letters LG at the
end. For example, in the case of 220-CON-123 motor:
Motor Control Module Tag Name: 220CON123
Logic Module Tag Name : 220CON123LG
The main target of the LG module is to execute the interlocks and permissive conditions. The conditions must
be done using conditional blocks specially designed for this project and will be described in the next pages.
For properly display functions the interlock condition blocks must be renamed as CNDX, where X is a
correlative number. In the same way, the permissive condition blocks must be renamed as CNDPX, where X is
a correlative number. When interlocks and permissive conditions are used together, a important rule is to
configure the interlock condition blocks as the first ones and the permissive conditions blocks following the
previous order number.
For easy maintenance, conditional blocks can be bypassed individually using Control Studio software having the
enough user privileges.
As programming criteria to be used on the LG modules, all safe interlock parameters based on analog process
values must be linked to alarm parameters of those AI modules or PID modules contenting the process value.

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Figure 6-1. Typical LG Module
Figure 6-2. LG Module Example for PID Modules 1

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6.4.2. DI (Discrete) Conditional Block
This conditional block is a composite block used to compare discrete (1 or 0) or boolean (True or False) values.
This composite is available in the Composites Library as CND_DI (Figure 6-3).
When the IN_D parameter is 1 the OUT_D parameter will be 1 and is considered as normal condition.
When the IN_D parameter is 0 the OUT_D parameter will be 0. If this conditional block is an interlock or
permissive condition, this situation is considered as abnormal and the Detail display associated with the device
control module will indicate that this condition is interlocking the device.
The BYP parameter can be used to bypass the actual state. When the BYP is set to 1 (True) the condition is
bypassed and the OUT_D parameter always will be 1 until BYP be set to 0 (False).
Figure 6-3. Discrete Conditional Composite Block
Figure 6-4. Internal View of Discrete Conditional Block
Name Description
D Indicates conditional type (Discrete)
IN_D Discrete input parameter. Example temperature switch.
BYP Condition Bypass.
DESC Condition description
OUT_D Discrete Output
Table 6-2. Discrete Conditional Block Description Table.

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6.4.3. LT (Less Than) Conditional Block
This conditional block is a composite block used to compare any analog value, either floating point value or
integer value. This composite is available in the Composites Library as CND_LT (Figure 6-5).
The COMP parameter is a floating point value used as reference value.
When the IN parameter value is less than COMP value, the OUT_D parameter will be 1 and is considered as
normal condition.
For any others values for IN parameter, the OUT_D parameter will be 0. If this conditional block is an interlock
or permissive condition, this situation is considered as abnormal and the Detail display associated with the
device control module will indicate that this condition is interlocking the device.
Figure 6-5. LT Conditional Composite Block
Figure 6-6. Internal View of LT Conditional Block
Name Description
LT Indicates conditional type (Less Than)
COMP Reference value used to compare
IN Input parameter. Example temperature transmitter value.
BYP Condition Bypass

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DESC Condition Description

Table 6-3. LT Conditional Block Description Table
6.4.4. GT (Greater Than) Conditional Block
integer value. This composite is available in the Composites Library as CND_GT (Figure 6-7).
When the IN parameter value is greater than COMP value, the OUT_D parameter will be 1 and is considered as
normal condition.
Figure 6-7. GT Conditional Composite Block
Figure 6-8. Internal View of GT Conditional Block

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Name Description
GT Indicates conditional type (Greater than)
COMP Reference value to compare.
IN Input parameter. Example temperature transmitter.
Table 6-4. GT Conditional Block Description Table
6.4.5. LTEQ (Less Than or Equal To) Conditional Block
integer value. This composite is available in the Composites Library as CND_LTEQ (Figure 6-9).
When the IN parameter value is less than COMP value or equal to it, the OUT_D parameter will be 1 and is
considered as normal condition.
Figure 6-9. LTEQ Conditional Composite Block

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Figure 6-10. Internal View of LTEQ Conditional Block
Name Description
LTEQ Indicates conditional type (Less than or equal to)
Table 6-5. LTEQ Conditional Block Description Table
6.4.6. GTEQ (Greater Than or Equal To) Conditional Block
integer value. This composite is available in the Composites Library as CND_GTEQ (Figure 6-11).
When the IN parameter value is greater than COMP value or equal to it, the OUT_D parameter will be 1 and is

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Figure 6-11. GTEQ Conditional Composite Block
Figure 6-12. Internal View of GTEQ Conditional Block
Name Description
GTEQ Indicates conditional type (Greater than or equal to)
Table 6-6. GTEQ Conditional Block Description Table
6.4.7. EQ (Equal To) Conditional Block
integer value. This composite is available in the Composites Library as CND_EQ (Figure 6-13Figure 6-11).

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When the IN parameter value is equal to the COMP value, the OUT_D parameter will be 1 and is considered as
normal condition.
Figure 6-13. EQ Conditional Composite Block
Figure 6-14. Internal View of EQ Conditional Block
Name Description
EQ Indicates conditional type (Equal to)
COMP Reference value to compare
Table 6-7. EQ Conditional Block Description Table

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6.4.8. NEQ (Not Equal To) Conditional Block
integer value. This composite is available in the Composites Library as CND_NEQ (Figure 6-15Figure 6-11).
When the IN parameter value is not equal to the COMP value, the OUT_D parameter will be 1 and is
Figure 6-15. NEQ Conditional Composite Block
Figure 6-16. Internal View of NEQ Conditional Block
Name Description
NEQ Indicates conditional type (Not Equal)

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IN Analog input Input. Example temperature transmitter.

Table 6-8. NEQ Conditional Block Description Table
6.4.9. FIRST_OUT Detection Block
This composite block is used to detect the first conditional block that has changed the OUT_D state from 1 to 0
(normal to abnormal). This function is useful when two or more conditions are interlocking a device and the
information about the first triggered condition is needed. This composite is available in the Composites Library
as FIRST_OUT for 16 input (Figure 6-17) or FIRST_OUT8 for 8 input (Figure 6-18).
The N_CND parameter is an integer value that must be equal to the number of interlocks conditions. The
actual state of the motor must be connected to the PV_D parameter.
When the IN_D parameter value is 0 the detection function is disabled.
When the IN_D parameter value is 1 or 2 (means motor running) the detection function is enabled and any
change detected in the OUT_D parameter of conditional blocks will set the FO parameter to the number of
conditional block.
The RESET button located in the Interlock list (see Detail pictures in section 7.8) writes the RESET_IN
parameter. This parameter is an input of BFI function block (see Figure 6-19 and Figure 6-20).
Figure 6-17. First-Out 16 inputs Composite Block.
Figure 6-18. First-Out 8 inputs Composite Block.

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Figure 6-19. Internal View of FIRST_OUT Conditional Block

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Figure 6-20. Internal View of FIRST_OUT8 Conditional Block

1
Name Description
IN_D Process Value (PV) Input of the device
N_CD Indicates the number of conditional blocks
FO Represents the value of the first-out condition
CALC1 Write in the Internal Read Parameter the OUT_D value from the
correspondent conditional blocks
CALC2 Write de FO value
CND# Represents the conditional blocks output value from the LG
module, this is read by means of the CALC1 block
Table 6-9. First-Out Detection Block Description Table.

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6.5. PID Control Loop Modules
6.5.1. PID Control Loop with 4-20mA Devices
The basic PID control is usign a single input signal and single output signal. The output signal can be used to
control a regulatory valve, damper, etc.
Figure 6-21. PID Control Loop with 4-20mA Devices
Name Description
AI1 Analog input device block (tipically a transmitter)
AO1 Analog output device block (tipically a regulatory valve)
IN Process value (PV)
FAIL_VAL Its a predefined value used to track the output during a interlocking state.
Tipically is 0% or 100% depending the process nature.
INTERLOCK Discrete input that initiates output tracking function. When the interlock
parameter value is 0 the PID control is locked for the operator and the OUT
parameter goes to the FAIL_VAL value.

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PID1 Standard DeltaV PID controller. See DeltaV Books Online for detailed information
OUT PID output value
BKCAL_IN It is the analog input value and status from a downstream block's BKCAL_OUT
output that is used by a block for bumpless transfer. This connection is necessary
if the PID is a master to another controller in a cascade. Without the connection
the slave controller will not make the transition to CAS and the master PID will
never be active.
BKCAL_OUT It is the value and status sent to an upstream block to prevent reset windup and
provide bumpless transfer to closed loop control
Table 6-10. Function Blocks and Parameters Description for 4-20mA PID Control
6.5.2. PID Control Loop With Foundation FieldBus Devices
Figure 6-22 shows a standard PID control loop and is based on the previous PID definition. Analog input and
output blocks are real fieldbus devices, those blocks are inside fieldbus devices not in a DeltaV controller. Only
PID controller is inside a controller.
Additionally, this module template has a comparison block named as VALV.
Table 2.21 describes each variable. Please see DeltaV manual for more information.
Figure 6-22. PID Control Loop with Fieldbus Devices

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Name Description
AI1 Analog input fieldbus device block
AO1 Analog output fieldbus device block
IN Process value (PV)
INTERLOCK Discrete input that initiates output tracking function. When the interlock
parameter value is 0 the PID control is locked for the operator and the OUT
parameter goes to the FAIL_VAL value.
PID1 Standard DeltaV PID controller. See DeltaV Books Online for detailed information
OUT Manipulated value
BKCAL_IN It is the analog input value and status from a downstream block's BKCAL_OUT
output that is used by a block for bump-less transfer. This connection is necessary
if the PID is a master to another controller in a cascade. Without the connection
the slave controller will not make the transition to CAS and the master PID will
never be active.
BKCAL_OUT It is the value and status sent to an upstream block to prevent reset windup and
provide bumpless transfer to closed loop control
Table 6-11. Function Blocks and Parameters Description for Fieldbus PID Control
For PID functions blocks used in PID control modules described in section 6.5.1 and section 6.5.2, the Control
Options parameter must be configured as shown on the following picture.
Figure 6-23. Control Options parameter configuration.

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6.5.3. VALV Composite Block
In the case of PID loops with valve control actions, the VALV block composite will be included which will detect
failures by deviation and/or lack of instrumentation air in the instruments.
Note: Initially is designed for fieldbus valves but it can be adapted for 4-20mA valves having the actual valve
position information.
It takes the output value sent to the fieldbus valve and compare it with actual position of the valve (OUT_PV
parameter) (see Figure 6-22). The actual valve position is provided by the fieldbus valve positioner. So, when
the difference between the desired valve position and the current valve position is high, a valve alarm (ALM
parameter in Figure 6-24) is generated to inform that something is happening with the valve positioner.
Figure 6-24. Internal View of VALV Composite Block
6.5.4. PID Control Loop Considerations
If the communication is lost the Fail position from the output block must be the same as the valve fail position.
The AO1 block FSTATE_VAL must be set depending on valve fail type. The FSTATE_TIME must be set to 2
seconds.
The option SP_PV Track in Manual in CONTROL_OPTS must be set. This is very important when the
AUTO/MANUAL mode in a loop is changed to manual. The set point must be closed to the process value.
6.5.5. Master-Slave Control Loop
Master-Slave Control Loops are based in the basic PID loop with some modifications to function properly. The
master control loop is designed with one input signal as process value and the slave control loop is designed
with one input signal as process value and one output signal going to a control device, typically a valve.
This kind of control is using two different modules, one for the master control and another one for the slave
control.
The OUT parameter is taken from the master and enters to the CAS_IN parameter in the slave side as set-
point. To proper execution, the master control needs a feedback from the slave; this is done taking the
BCKAL_OUT parameter from the slave control to the BKCAL_IN parameter at the master control side (see
Table 6-12).

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Figure 6-25. Master PID Control Loop
Figure 6-26. Slave PID Control Loop

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Name Description
AI1 Analog input fieldbus device block
AO1 Analog output fieldbus device block
SLAVE LOOP Slave PID control Loop. See Picture 2.20.
CAS_IN Setpoint from Master loop to Slave loop
BKCAL_IN master Manipulated value feedback from slave loop and auto/manual mode.
IN Master/Slave Process value
PID1 Standard DeltaV PID controller. See DeltaV manual.
OUT Manipulated value
BKCAL_IN slave It is the analog input value and status from a downstream block's BKCAL_OUT
output that is used by a block for bump-less transfer. This connection is
necessary if the PID is a master to another controller in a cascade. Without
the connection the slave controller will not make the transition to CAS and the
master PID will never be active.
BKCAL_OUT slave It is the value and status sent to an upstream block to prevent reset windup
and provide bump-less transfer to closed loop control
Table 6-12. Master-Slave PID control loop description table.
6.5.6. Master-Slave PID Control Loop Considerations
The AUTO/MANUAL mode from slave loop is feedbacked to the master PID, so if the slave loop is in manual
mode and IMAN mode is selected (in master loop) the master loop will follow the slave loop set point.
The option SP_PV Track in Manual in CONTROL_OPTS must be set. This is very important when the
AUTO/MANUAL mode in a loop is changed to MANUAL. The set point must be closed to the process value.
Scan rates and alarm levels are the same as simple PID loops.
6.5.7. Alarms in PID Loops
The PID Control Loops Modules has a predefined alarm and will be enabled and set according the SPCC/Fluors
Engineering specifications. Additionally to the typical level alarms, DeltaV defines the deviation alarms. A
deviation alarm takes the error between set-point and process value (SP-PV) and compares it with a reference
value depending if the error is positive (DV_HI_ALM) or negative (DV_LO_ALM). The Table 6-13 shows the
name of this alarms, default limit values, alarm priorities and enabled property (by default).
Note: The ALM_VALV is the valve alarm and is related to the previously defined VALV comparison block (see
6.5.3)

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Alarm name Limit Value Priority Enabled

HI_HI_ALM 100 Critical False
HI_ALM 95 Warning True
DV_HI_ALM 100 Advisory False
DV_LO_ALM 0 Advisory False
LO_ALM 5 Warning True
LO_LO_ALM 0 Critical False
PVBAD_ALM 0 Critical True
ALM_VALV - Warning True
Table 6-13. PID Control Modules Alarms Definitions
6.5.8. PID Control Modules Scan Rates
The scan rates defined in the Table 6-14 area recommended scan rates depending on the process variable.
These values are only a reference and can be adjusted according the SPCC/Fluor definitions.
Variable type Scan Rate (sec)

Temperature 5
Pressure 1
Flow 1
Level/weight Throughput Ratio >50 5
Level/weight Throughput Ratio <50 2
Others 2
Table 6-14. PID Control Modules Scan Rates
NOTE: If any part of a loop is running on fieldbus equipment, the scan rate must be at least 2 times the
macrocycle scan rate.

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6.6. Analog And Discrete Inputs Monitoring
6.6.1. Analog Input Monitoring Module
The standard will be followed by the configuration of the Analog Input Monitoring Modules based on the DeltaV
standard. There are no deep differences between modules based on 4-20mA and Fieldbus devices.
The FAIL_SAFE composite block is added to generate a fixed output in case of bad status on signal from the
field. That fixed valued can be set in the FS_VALUE parameter.
FAIL_SAFE settings shall be set based on the process design or in the control system designers experience.
Figure 6-27. Analog Input Monitoring Module
6.6.2. Analog Input Monitoring Module Alarms
Five alarms for the Fieldbus analog monitoring module variables are defined by default. Initially, the single
alarms HI_ALM, LO_ALM and PV_BAD will be enabled, being capable of allowing the enable or disable
conditions of the Detail Display associated to the module. The default alarms will be:
Alarm Limit value Priority Enable

HI_HI_ALM 100 % Critical False
HI_ALM 95 % Warning True
LO_ALM 5% Warning True
LO_LO_ALM 0% Critical False
PVBAD_ALM 0 Critical True
Table 6-15. Default alarms for analog input monitoring modules.
6.6.3. Analog Input Monitoring Module Scan Rates
Depending on the variable type, different scan rates must be use. However, the scan rates will be checked or
changed depending of the nature of the process and/or the application itself. Please refer to Table 6-16.

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Variable type Scan Rate (sec)

Temperature 5
Pressure 1
Flow 1
Level/weight Throughput Ratio >50 5
Level/weight Throughput Ratio <50 2
Others 2
Table 6-16. Scan Rates for Different Analog Input Variables

Note: If any part of a loop is running on a Fieldbus equipment the scan rate must be at least 2 times the
macrocycle scan rate.
6.6.4. Filters
Process variable filters can be enabled, but they are disabled by default. These can be adjusted during startup
if is necessary using the associated display or Control Studio too. These filters are the standard filters for
analog signals in DeltaV known as first order filters.
6.6.5. Discrete Input Monitoring Module
In general terms any discrete or digital signal coming to system will be considered as normal when its a 1 or
True. So, in the opposite way, when the discrete input signal is a 0 or False, it will be considered as abnormal
and will typically generate a new alarm. For example, normally closed contact will indicate a normal signal
when its closed and an alarm will be present when the circuit will open.
The FAIL_SAFE composite block is added to generate a fixed output in case of bad status on signal from the
field. That fixed valued can be set in the FS_VALUE parameter.
FAIL_SAFE settings shall be set based on the process design or in the control system designers experience.
The scan rate for discrete monitoring modules will be 1 second by default, can be adjusted during startup.
1
Figure 6-28. Discrete Input Monitoring Module

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6.7. Motor Control Modules
The motor control modules are based in the DC1 function block (Device Control) and some function to
communicate properly with the motor starter.
To adjust the SPCC/Fluor logic standard to DC1 function block is necessary to rename some terms to be used
in DeltaV. Please refer to Table 6-17.
SPCC/Fluor DeltaV
Permissive Permissive
Interlock Interlock
Manual Mode (MAN) Auto Mode (AUTO)
Auto Mode (AUTO) Cascade Mode (CAS)
Table 6-17. SPCC/Fluor and DeltaV Terms
The Permissive and Interlock conditions will be executed in a separate logic module of the motor control
module, and they will be entered through external references. Bypasses of the Permissive logics and Interlocks
will be available in these logic modules and can be set only using Control Studio having the required privileges.
For the motor control modules, the following nomenclature is assumed:
Area No + Equipment code + Correlative No inside the area (For example 220CON005).
For the logic control modules corresponding to Interlocks and Permissives, the following nomenclature is
assumed:
Area No + Equipment code + Correlative No inside the area + LG (Example 220CON005LG). 1
Plant Operation LOCAL/REMOTE Mode Selection:

For selecting the Local-Remote operation mode, a 2-position software selector switch inside pop-up windows
shall be configured for each motor. At this pop-up window, the following operation modes can be selected.
REMOTE Mode: The motor can be operated only from software pushbuttons located inside pop-up windows,
whether manually or automatically
LOCAL Mode: For this operation, two pushbuttons will exist: Jog pushbutton and Emergency Stop Pushbutton.
In this mode, the motor can be operated only by the Jog pushbutton located in the field. This will be enabled
from the operating station.
The Emergency Stop pushbutton will stop the motor regardless of the position of the software selector switch.
Process Operation AUTOMATIC/MANUAL Mode Selection:

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For selecting the Automatic-Manual operating mode, a 2-position software selector switch inside pop-up
windows shall be configured for each motor, the following operation modes can be selected.
AUTOMATIC Mode: A group of motors can (be) operated according to a specified sequence. In this case, the
plant operator actuates a software pushbutton which initiates the sequence.
MANUAL Mode: In this mode, the motor can be operated either through the software pushbuttons located
inside the pop-up windows or from the JOG pushbuttons, depending on the position of Local-Remote selector.
In the case of local operation, this operation will be only for maintenance purposes.
Plant/Process Operating Modes:

The following operating modes will be available for the plant operation.
REMOTE-MANUAL Mode: In this mode, the plant operator will command the individual pieces of equipment one
by one from pop-up windows configured in the operation stations. In this mode, all the process and safety
interlocks will be enabled.
REMOTE-AUTOMATIC Mode: This mode will be applicable to a group of equipment. In this case, the plant
operator will initiate a pre-defined sequence by pressing a dedicated software pushbutton. The equipment will
start and stop according to the sequence. In this mode, all the process and safety interlocks will be enabled.
Mode LOCAL-MANUAL: This mode will be for maintenance purposes only .The equipment can only be operated
by the physical pushbuttons located in the field. In this mode only the safety interlocks will remain enabled.
Transitions:
Transitions from LOCAL to REMOTE: When a motor is in maintenance mode, with a combination of
Local_manual selector switches, and remote mode is selected, the following events occur:
The equipment will go to a stopped condition, regardless of the previous status
The Automatic/Manual selector switch will remain in Manual
The Remote/Local selector switch will pass to a remote mode, enabling remote operation from the
operation stations.
Transition from REMOTE to LOCAL: When the motor is in Remote Mode, whether Automatic or Manual, and the
Local mode is selected, the following events occur:
The equipment will go to a stopped condition
The Automatic/Manual selector switch will pass to a Manual mode
The Remote/Local selector will pass to a Local mode, enabling operation from the field for
maintenance purposes.
6.7.1. DSA Composite Block
For this project, SPCC/Fluor specifies the Allen-Bradley 100-DNY42R Devicenet Starter Auxiliary (DSA) as
interface with DeltaV to control the motors. So, is developed a specific composite block to communicate with
that device, reading a status word (IN_AUX) from the DSA which contains I0, I1, I2 and I3 inputs and writing

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an output word (OUT_AUX) with OUTA and OUTB signals. The COM parameter is 1 (True) when a
communication error is detected.
Figure 6-29. External view of DSA composite block
Figure 6-30. Internal view of DSA composite block
This composite block will be used for the motors modules explained in the next sections. A special case to
consider is the forward-reverse motor module; it needs two DSA interfaces to control only one motor.

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Direct Motors - I/O Assignments

I0 Running
I1 Emergency Stop
I2 Overload (or Multilin Trip)
I3 Control Power
OUTA Output
OUTB Jog Output
Table 6-18. Direct Motors I/O Assingments for DSA

1
Forward/Reverse Motors - I/O Assignments

DSA 1 I0 Running Fordward
DSA 2 I0 Running Reverse
DSA 1 I1 Emergency Stop
DSA 1 I2 Overload (or Multinin Trip)
DSA 1 I3 Control Power
DSA 1 OUTA Output Forward
DSA 1 OUTB Jog Output Forward
DSA 2 OUTA Output Reverse
DSA 2 OUTB Jog Output Reverse
Table 6-19. Fwd/Rev Motors I/O Assignments for DSA

1
In remote operation the DSA outputs will be as follows:

OUT_A: Acording with the operator command (CLOSED when ON and OPEN when OFF)
OUT_B: OPEN
When in local operation the DSA outputs will be as follows:
1
OUT_A: OPEN
OUT_B: CLOSED (the motor will start with the JOG button only)
If there is a malfunction in the DeviceNet network (link lost, processor lost or DeviceNet Master lost, the DSA
outputs will act as follows:
OUT_A: OPEN

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OUT_B: CLOSED (this action is done internally in the DSA, which needs to be configured to act in the
referred way. This capability to define the relay behavior during communications fault is included by
Allen Bradley since DSA series B which SPCC has specified to the LV MCC vendor)
Another version of this composite block is the DSA_V to be used with Variable Frequency Driver Module
template as explained in the next sections. The main difference between DSA and DSA_V composite blocks is
the logic added to generate alarms from field device signals.
Figure 6-31. External view of DSA_V composite block
Figure 6-32. Internal view of DSA_V composite block

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6.7.2. Motor Control Module for Direct Starter
Figure 6-33. Motor Control Module for Direct Starter.
Name Description
CAS_IN_D Signal from process interlock that starts/stops the motor when this signal is in
one/zero, and the motor is in auto mode and DC1/PERMISSIVE_D is in one,
DC1/SHUTDOWN_D is in zero and DC1/INTERLOCK_D is one.
Interlock Signal to enable or disable the motor start. It must be in one for all motor modes (auto
or manual). When this signal goes to zero the motor goes to stop and manual.
Permissive Discrete input that must be True for OUT_D to pass to an Active state.
Bypass Bypass all permissive for maintenance. Password required.
RUN Contactor signal feedback from device.
COM Communication status with the device. When this signal goes to one the motor
command goes to stop.
DC1 DeltaV device control function block. This function block control the motor device, and
alarm when an abnormal change in the state of the motor has been detected.
FAIL Fail block which put DC1 in manual mode and disable command in fail conditions.
DSA Composite block used to read and write signals from/to the device in the field.

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I Load current from an analog input signal.
Table 6-20. Motor Control Module for Direct Starter Description Table.
6.7.3. Motor control module for Forward-Reverse Starter with Jog
Figure 6-34 shows motor control module and Table 6-21 describes each variable. This control module is
suitable for Forward-Reverse starters.
Figure 6-34. Motor control module for Forward-Reverse starter.
Name Description
CAS_IN_D Signal from process interlock that starts/stops (FORWARD/REVERSE) the motor when
the signal is one/two/zero and the motor is in auto mode and DC1/PERMISSIVE_D is in
one, DC1/ SHUTDOWN_D is in zero and DC1/INTERLOCK_D is in one.
Interlock Signal to enable or disable the motor start. It must be in one for all motor modes (auto
Bypass Bypass all permissive and interlock for maintenance. Password required.
F Forward Contactor signal feedback from device.
R Reverse Contactor signal feedback from device.

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COM Communication status from both devices. When this signal goes to one motor
command goes to zero.
DC1 DeltaV device control function block. This function block control the motor device, and
alarm when an abnormal change in the state of the motor has been detected.
DSA1 Composite block used to read and write signals from/to the device in the field. Used
for forward way.
DSA2 Composite block used to read and write signals from/to the device in the field. Used
for reverse way.
Table 6-21. Motor Control Module for Fwd-Rev Starter Description Table.
6.7.4. Motor control module Direct Starter with Jog
Figure 6-35. Direct Starter with Jog Motor Control Module

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Name Description
Interlock Signal to enable or disable the motor start. Must be in one for all motor modes (auto
Bypass Bypass al permissive for maintenance. Password required.
COM Communication status with device. When this signal goes to zero motor command
goes to zero.
DC1 DeltaV device control function block. This function block control the motor device,
and alarm when an abnormal change in the state of the motor has been detected.
LOCAL_REM Digital signal from HMI which enables JOG function. Operator must select Local in
the faceplate before field operator (located close to the machine) activates the motor
using local JOG button. All permissive and process interlocks are bypassed.
Table 6-22. Motor Control Module for Direct Starter with Jog Description Table.

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6.7.5. Motor control module for Variable Frequency Driver with Jog
Figure 6-36. Motor control module for Variable Frequency Driver with Jog.
Name Description
Interlock Signal to enable or disable the motor start. Must be in one for all motor modes (auto
Bypass Bypass al permissive for maintenance. Password required.
COM Communication status with device. When this signal goes to zero motor command

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goes to zero.
DC1 DeltaV device control function block. This function block control the motor device,
and alarm when an abnormal change in the state of the motor has been detected.
LOCAL_REM Digital signal from HMI which enables JOG function. Operator must select Local in
the faceplate before field operator (located close to the machine) activates the motor
using local JOG button. All permissive and process interlocks are bypassed.
SP Speed set point (can be referenced by a PID control module)
PV_REF Actual process value for the speed. Must be set as external reference to an analog
input monitoring module.
Table 6-23. Variable Frequency Driver with Jog Control Module Description Table.
1
6.8. ON/OFF Valve Control Module
Figure 6-30 shows a standard ON/OFF Normally Open or Normally Close valve control Module. Table 6-24
describes each variable. Only a parameter must be adjusted to change the failure alarm indication.

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Figure 6-37. ON/OFF Valve NO or NC Control Module.
Name Description
CAS_IN Signal from process interlock that energizes the solenoid valve when this signal is
in one AND the valve is in auto mode AND permissive is in one AND no trip is
present.
Interlock Signal to enable or disable the valve open/close condition. Must be in one for all
valve modes (auto or manual). When this signal goes to zero the valve de-energize
and goes to manual.
BYPASS Bypass all permissive for maintenance. Password required.
ZSO Opened feedback
ZSC Closed feeback
CMD Energizes solenoid command
Table 6-24. ON/OFF Valve Control Module Description Table.

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6.9. Sequential Function Chart (SFC) Configuration Conventions
SFCs are typically used for controlling time-event sequences, such as startup or shutdown of a process. SFCs
are made up of steps and transitions, each step contains a set of actions and the transition condition allows the
sequence to proceed to the next step when the condition is true.
As there are no predefined DeltaV module templates for SFCs it is useful to define a flow chart for the
structure to show the various steps required and the associated transitions that need to occur for the next step
to be performed.
A named set should be created to display to the operator the current status of the sequence. This is linked to
an internal parameter within the SFC Module. An example of a named set is shown below:
SMELT_STATUS ISASMELT Lance Auto Lower Lower Sequence Status

Name Value Visible Referenced User
Selectable
Not Ready for Smelting Start 0 Yes Yes Yes
Waiting for Smelting Start 1 Yes Yes Yes
Ready for Smelting Start 2 Yes Yes Yes
ID Fan to Auto and Ramping Up 3 Yes Yes Yes
Feed System Starting Waiting for Warning Sirens 4 Yes Yes Yes
Oxygen and Post Combustion Starting 5 Yes Yes Yes
Smelting Start Complete 6 Yes Yes Yes
Table 6-25. Named Set SFC Table
Additional internal parameters can be added to the SFC module to initiate the sequence start if it requires an
operator action before starting or continuing to a new step during the sequence.
Other internal parameters can be used to create links to external information that may require the sequence to
wait for a change of state before proceeding to the next step.
In the SFC shown below there are several internal parameters that reference Named Sets or parameter values
that are being passed to or from other modules in the strategy.

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Figure 6-38. SFC Example
In generating a new SFC, the standard Sequential Function Chart Algorithm is used, which provides an initial
start step within the control studio display.
If a valid flow chart has been designed and reviewed the Sequence palette item can be used to generate
multiple steps and transitions in one action. Otherwise the standard Step and Termination palette items can be
dragged and dropped as needed while constructing the sequence.
Once the SFC steps and transitions have been added to the module as required a termination palette item can
be used to finish the sequence if it is required to stop. Other sequences can have a true transition state set
after the last step which can be looped back to the sequence start if this is a requirement. This means that
this sequence is always ON.
For each step and transition, expression text will typically be written to allow either an action or a true state to
occur during the sequence. DeltaV provides an expression assistant ad parser to ensure text and syntax are
correct and valid. The parser should be used to test each expression written in the SFC.

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Typical step action and transition condition are detailed in the table below:
Palette Item Type Item Name Action/Condition Text Description

Step WAITING SEQ- Wait until Named Set moves to
STATUS:=SMELT_STATUS:W Waiting for Smelting Start
aiting for Smelting Start;
Transition SEQ_INITIATE INITIATE_REQ.CV=1 Wait until operator selects
SEQ_INITIATE to proceed to
next step
Table 6-26. Step action and transition condition SFC Table
Important syntax rules for writing expressions are as follows:

Step actions use a special assignment operator (:=) and end with a semicolon (;).
Transitions use an equal sign (=) to indicate when the condition is true, the next step is then made
active.
Parameter values are enclosed in single quotes.

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7. Operator Interface
7.1. General
A basic scheme similar to DeltaV Standard will be used. Displays configuration will be made from a main
graphic and other system components, distributed as follows (see Figure 7-1):
3
2
Figure 7-1. Operation Screen with Visible Navigation bar

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Center of Display: The Operation Display in the strictest sense, which has the Process Display with the
different variables of information or commands. This is considered as the effective work area for Emerson and
Third Party Vendors development. This area is marked as 1 in the Figure 7-1.
Upper Area: Different pre-configuration buttons are located in this area, which constitute the direct access
bar to DeltaV. The bar content will change according to the operator permission level. Access is enabled
depending on the condition. This area is marked as 2 in the Figure 7-1.
Figure 7-2 shows the following buttons (the text language its only a reference):
1. Exit DeltaV Operate
2. Print Display
3. Open Faceplate
4. Open Module
1 2 3 4
Figure 7-2. DeltaV Operate Toolbar 1
1. Reset the Default Layout
2. Open Display
3. Back to Previous Display
4. Open Overview Display
5. Alarm List
6. Area Filter Display
7. Alarm Supress Display
1 2 3 4 5 6 7

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1. User Logon
2. Starts FlexLock
3. Starts DeltaV Diagnostics
4. Starts DeltaV Explorer
5. Starts Control Studio
6. Starts Process History View
1 2 3 4 5 6
Figure 7-5 shows the following buttons:

1. Date and Time Settings
2. DeltaV Operate Help
3. DeltaV Books Online
1 2 3

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1. Horn Enable
2. OWS Name
3. System Date and Time
1 2 3
Left Area: Several direct access buttons are located in this area which constitutes the side bar. Each button
may represent a P&ID (Process and Instrumentation Diagram) or an specific part of the process.
By clicking on the button, you access to the corresponding operation screen. This bar will be visible only when
the operator places the pointer near to the border of the screen. This area is marked as 3 in the Figure 7-1.
See 7.3 section for detailed information.
Lower Area: Alarms Banner. It appears as a frame, the 5 alarms of main highest priority present in the
system (10 for the Stations with 2 Monitors). This area is marked as 4 in the Figure 7-1. A detailed view is
shown in the Figure 7-7 (shown tag names are only as reference). At the right side of each alarm button a thin
button is placed to fill the bottom line with detailed information of related alarm.
Figure 7-7. Alarms Banner
7.2. Alarms 1
The colors to represent the different types of alarms are the same than the predefined (Standards) in DeltaV
according to alarms priority levels, beside, it was defined a new priority alarm called PRI_CRITICAL, this alarm
will not have auto-acknowledge. All the signals that have a security interlock function will have this type of
priority alarm.

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The Pri_Critical Alarm, once it appears (on screen or in the alarm list) will remain in this condition until the
alarm disappears and the operator acknowledges it. If the condition which triggers the alarm disappears, but it
was not acknowledged, the alarm list will show a small rectangle () in the left. See the following table:
Priority Color Auto acknowledge

Pri_Critical Red(HIHI,LOLO, Communication) No
Critical Red (HIHI, LOLO, Communication) Yes
Warning Yellow (HI, LO, Abnormal Conditions) Yes
Advisory Violet (SP-PV Deviation in PIDs) Yes
Table 7-1. Alarm Colors
If an alarm occurs, a sound indication will appear, it can be muted, but it will have no effect on the visual
indications neither in the alarm list. In the bar alarm zone the tag of variable appears in a red box. Making a
click over the box the associated faceplate is shown.
Thus, the sound will remain until it is muted, although the condition that made it appear, stops. The alarm will
appear in a temporary alarm list, and in an event log that contains this information permanently, according to
the politics that will be defined during system staging, about Log Files storage.
When an alarm condition occurs:

Screen: the alarm tab blinks with the correspondent priority color.
Alarm List: Appears
When the alarm is acknowledged (visualization), but the condition remains:
Screen: the alarm tab stops blinking, but the color remains according to the priority
Alarm List: Remains, but appears a () symbol next to the alarm (left side).
If the condition alarm disappears, although the acknowledged was not made:
Screen: Returns to its normal condition (the tab disappears)
Alarm List: Disappears
For the definition of types of alarm, acknowledge procedure, DeltaV alarm interface and alarm attributes,
please refer to DeltaV Manuals (DeltaV Books Online), since the predefined standards will be used.
Each process screen will have a general horn sound acknowledge button, that will only affect the workstation
where it was pressed.
No general alarms acknowledge button will be used in process screens. The operator must go to alarm list
screen to see a general alarm acknowledge button.

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Every faceplate has a button to acknowledge the alarms related to that module. This button is located in the
faceplates bottom side as part of a toolbar (see Figure 7-8).
Module
Acknowledge
Alarm Button
Figure 7-8. Bottom side of a module faceplate showing acknowledge alarm button.
Another button is placed on the bottom side of the screen next to the Alarms Banner to acknowledge all alarms
related to modules placed in the actual process display (center area of screen). Button numbered as 4 in Figure
7-9.
7 8 9
1 2 3 4 5 6
Figure 7-9. Bottom side of the screen showing acknowledge alarm button.
Figure 7-9 shows the following buttons:

1. Alarm Banner Help

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2. Enable to show Faceplates when the operator click on Alarms Banner buttons (see Figure 7-7)
3. Enable to change actual process display when the operator click on Alarms Banner buttons (see Figure
7-7)
4. Acknowledge all alarms on actual shown process display
5. Horn Enable/Disable (Only available with supervisory or administrator password)
6. Horn Sound Acknowledge
7. Last DeltaV node (workstation or controller) in failure
8. DeltaV node alarm indication
9. DeltaV network status
7.2.1. Alarm List
The Alarm List is a list of all the active alarms the current workstation is monitoring for the current user. The
Alarm List Picture displays up to 250 active alarms in areas within the operator's span of control.
The Alarm List picture can be opened from the DeltaV Operate toolbar, from the Alarm Filter picture, or from
the Alarm Suppress picture (see Figure 7-3. DeltaV Operate Toolbar 2). You can acknowledge an alarm by
clicking the Ack column for the alarm. You can open the Direct Access picture by clicking on the Description
column. For other alarm operations, select an alarm from the list and then use the buttons and context menu
on the Alarm List picture to work with the selected alarm. The Alarm List picture uses the Alarm Summary
Object to display the alarms (see Figure 7-10).

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Figure 7-10. DeltaV Alarm List
The Alarm list picture shows the total number of active alarms, the number of unacknowledged and suppressed
alarms for the current area, and lists active alarms by:
Ack - the acknowledged status.
Time In - the time at which the alarm went active. If the alarm is active when a controller switchover
occurs, the alarm is regenerated with a new time stamp.
Unit - the name of the unit that owns the module that is in alarm.
Module/Parameter - the name of the module that contains the alarm and the active alarm.
Description - a description of the module.
Alarm - an abbreviation or acronym such as COS (Change of State) or CFN (Change from Normal) that
appears when the alarm is active. The alarm word is a characteristic of the alarm type.
Message - a message associated with the alarm. The format of the alarm message is determined by
the alarm type.
Priority - a word, such as Critical, Warning, Advisory, Pri-critical or any user-configured priority that
indicates the importance of an event to the operator and the priority of the alarm at the workstation.
The priority affects the order in which the alarm appears in this picture and in the Alarm Banner.

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7.2.2. Assignment of Alarms to Consoles
Alarms and system events will be visible (regardless of the event or alarm priority level) on the consoles
according to the assignment of the corresponding areas. This assignment should be defined by SPCC/Fluor and
Emerson.
7.3. Navigation
To introduce the navigation section, display hierarchy definition is needed. The display hierarchy is based on
four levels:
General Plant Overview: This picture can be accessed directly clicking on Open Overview Display (button
No 4 in Figure 7-3) and will show a plant view defined by SPCC/Fluor.
Area Overview: shows main variables related a SPCCs Plant Area defined for this project.
Process and Diagnostics Displays: shows a different part of process within an area or special equipment
operation interface. Some special system diagnostics display will be defined by SPCC/Fluor.
Pop-up Windows: such as faceplates, detail displays, help displays or special display defined for a specific
application.
Navigation through different system screens may be done basically in three ways depending on operator
requirements:
DeltaV Operate Toolbar buttons: in the toolbar described in 797.1 section (Figure 7-3) there are two
buttons to navigate, one is the Open Overview Display (already described), and the other one is the Open
Display button to show a list with all displays contents in the DeltaV Picture directory.
Navigation Side Bar: for this project, Emerson has developed a new operator interface and a important
innovation is this bar (Figure 7-11 and Figure 7-12). It will be visible when the mouse pointer is near the
screen left edge. Additionally, there will be overview area displays with links to other sub-areas.
Process Displays Arrows: must be possible to navigate from display to the other with links located on the
process line inlets/outlets (Figure 7-13 and Figure 7-14).
This navigation bar will incorporate a red button that will be visible when there is an alarm involving a security
problem in the area. This button will guide you through the alarm summary screen. These alarms will be
selected during configuration stage.

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Area List (see

Figure 7-12)
Last Viewed Areas
Process Display within

a selected Area
Figure 7-11. Detailed View of Navigation Side Bar

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Figure 7-12. Detailed View of Navigation Side Bar with Areas Menu
Figure 7-13. Navigation Arrows
Figure 7-14. Process Line Arrows

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7.4. Process Displays
7.4.1. Nomenclature
The files with extension grf that are used in the development of DeltaV Operate will be named according to
the following description: Pic_AAA-BB-CCC.grf
AAA: SPCC Area Code (230, 220, 270, 301, 310, etc).
BB: Type of display defined on DCS, 2 characters max. (AM: area mimic, G: group, O: overview, T:
tendency, H: help, SU : start up, SD : shutdown, SS : safety system).
CCC: Correlative number.
The actual display file name is displayed in the upper area of the screen. Thus, a typical display for Plant Air
area will be: pic_630-AM-001.grf
7.4.2. Colors
Color 170 from the System Default color palette in DeltaV Operate will be used as background color. The titles
on the process graphics will be in gray color.
The color of the process lines will be set according to the color standard defined by SPCC/Fluor (see the next
pages).
7.4.3. Graphics
The resolution will be 1600 x 1200 pixels and 32 bits. The screens will not be enabled for automatic scaling in order
to achieve a better aspect in the high resolution graphics.
7.5. Dynamo Sets
We will use dynamos specifically developed for this application for every animated element on the screens.
For every animated element on the screens, dynamos which are specifically designed for this application will be
used. They will enable us to create multiple instances starting from the same object, which will improve the
configuration tasks.
Some specifications will be common for all dynamos:
The background of numeric indications such as measurements, valve positions, etc. must be in black color
when the process variable has good status. In bad status condition the background color must change to
orange (RGB = 255,147,68) and will blink until the status back to normal.

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The numeric indication fonts must be Tahoma, 12 size, bold style, light green color. The tagnames must be in
white color, Tahoma font, 10 size, bold style. And the engineering units muste be in Arial font, 10 size, bold
style. The tanks and special equipments names must be in Tahoma font, 11 size, bold style, in white or black
color depending on background.
Note: The final sizes of dynamos and detailed specification (including the new animations features) will remain
on hold until final revision be delivered.
7.5.1. Process Variable Indicator
Analog variables indicators will be shown as follows:
Figure 7-15. Analog variable indicator.
Object Name Properties

Tag Font Verdant 10, Bold, and White Color
Process Value Font Verdant 14, Regular, and Green Color.
Units Font Verdant 12, Regular in White Color
Table 7-2. Objects properties.
The background of the box next to the indicator will start blinking when a new module alarm appears and the
background color will be set according to the alarm priority. When a bad status signal is detected the actual
black background (of the indication) will start blinking to orange color (RGB: 252, 147, 68) and will remain the
last process value.
For tank level indicators, the percentage value on an animated bar is included as shown on Figure 7-16. When
a new alarm appears the bar will change the color to the alarm priority color and will start blinking. In
communication lost case the level bar will change to orange color (RGB: 252, 147, 68).

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Figure 7-16. Level indicator.
7.5.2. Control Loops Indicators
For control loops, the faceplate access will be achieved by clicking the control element, valves, pumps or
motors. To identify the loop, the associated elements will be joined by dotted lines.
Special loops, i.e. control with two final control elements, will include one controller icon, where the loop will be
controlled.
The controller set-point will not be visible on screen.
Figure 7-17. Control loop scheme.

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7.5.3. Motors
The following scheme shows the different indicators for motors.
TAG
MOTOR
MODE LOCK
LOAD
ALARM
LOCAL
BYP
Figure 7-18. Motor dynamo.
Object Description
TAG Device Tag Name.
MOTOR Shows the motor status using the following color table
Red: Stopped
Green: Running (with movement animation [HOLD])
Orange blinking: Abnormal function or communication fault.
BYP It shows up when at least one interlock bypass is activated.
ALARM The alarm bar start blinking when a new alarm is triggered. The color of it will be according to
the alarm priority level.
LOCK It signs that the start of the device is not allowed because an interlock condition is not right or
some other device condition is blocking it.
LOCAL This indicator will be shown only when the motor control module is set in LOCAL mode. No
indication in REMOTE mode.
LOAD It indicates the power or current driven by the motor. This indication applies only to those
motors where that information is available.
MODE When the device is in Remote mode, this indicator show M in green if the motor is in Manual
mode and A in yellow if the motor is in Auto mode.
Table 7-3. Motor dynamo objects description.
By left clicking on the motor, the corresponding faceplate will be shown, and right clicking, the detail display
will be show.

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7.5.4. Control Valves
TAG
MODE VALVE
LOCK
OUT
ALARM
1
Figure 7-19. Control valve dynamo.
Object Description
TAG Device tag name. Includes a automatic generated tag name from upstream PID control
and a manual generated tag name with the field valve name.
OUT Real valve position for Fieldbus Foundation case, for 4-20mA valves, it will show the PID
output.
VALVE The body of the valve is color animated according to the following table:
Red: Closed
Green: Opened (more than 5%)
ALARM The alarm bar starts blinking when a new alarm is triggered. The color of it will be
according to the alarm priority level.
LOCK Shows an output tracking or interlock condition. It means the operator cannot operate
over the controller.
MODE Indicates the PID operation mode
M: Manual
A: Automatic
C: Cascade
RC: Remote Cascade (Supervisory)
I: IMAN (Initializing Manual)
Table 7-4. Objects description.

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By left clicking on the graphic, the corresponding faceplate will appear, and right clicking will show the detail
display.
Note: In Fieldbus Foundation control valves case, the numerical indicator in the dynamo shows the real position
of the valve. For 4-20mA Control Valves the numerical indicator in the dynamo shows the PID output value.
7.5.5. On/Off Valves
The following scheme shows how the on-off valves dynamo will represent the different status.
TAG
VALVE
MODE OUT
LOCK
ALARM
BYP
Figure 7-20. On-Off valve dynamo.
Object Description
VALVE The body of the valve will change according to status from limit switches
Red: Closed
Green: Opened
Orange blinking: communication fault
Yellow: Valve positioner in transition
OUT Shows the output command to the valve.
BYP It appears when at least one bypass is activated.
LOCK It signs that the start of the device is not allowed because an interlock condition is not
ok or some other device condition is blocking it.
MODE This indicator will be displayed M in green if the valve is in Manual mode and A in
yellow if the valve is in Auto mode.

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By clicking on the graphic, the corresponding faceplate will appear.
7.5.6. Pumps
The following scheme shows how the different pumps status will be represented. Like motors, clicking on the
graphic opens the faceplate.
TAG
PUMP
MODE
LOCK
LOAD
ALARM
LOCAL
BYP
Figure 7-21. Pump dynamo.
Object Description
MOTOR Shows the motor status using the following color table
Red: Stopped
Green: Running (with movement animation [HOLD])
BYP It shows up when at least one interlock bypass is activated.
LOCK It signs that the start of the device is not allowed because an interlock condition is
not ok or some other device condition is blocking it.
LOCAL This indicator will be shown only when the motor control module is set in LOCAL
mode. No indication in REMOTE mode.
LOAD It indicates the power or current driven by the motor. This indication applies only to
those motors where that information is available.

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MODE When the device is in Remote mode, this indicator show M in green if the motor is
in Manual mode and A in yellow if the motor is in Auto mode.
By clicking on the graphic, the corresponding faceplate will appear.
7.5.7. Alarm Switches
Alarm switches (e.g. level or flow) or general discrete signals will be shown with a text in color related to the
assigned alarm priority level. This kind of indicators will be visible only when the signals are abnormal. Thus, 1
or True value means normal and 0 or False means abnormal.
7.5.8. Other Dynamos
If necessary, while the application is being developed, new dynamos will be created. The look and functionality
of these new dynamos will be similar to the ones previously shown.
7.6. Process Lines
The color of process lines will be implemented according to SPCC/Fluor specifications. There are two thickness
sizes for process lines (main pipes are in 11 pixels and secondary pipes in 7 pixels) and must have animation
depending on if the pipe is empty or filled (Figure 7-22). All process lines with no flow must be in light gray
and for filled pipes the color are depending on the product nature.
Additional products not defined on this list will be considered as miscellaneous and should be represented
with a distinguished color. If there is a specific need to declare a new product, it will be included in this table in
a future revision.
Please refer to table 7-7 below.

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Table 7-7. Color Codes for Process Lines

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Control connections must be done with dashed lines in white color.
Secondary line with flow
Secondary line without flow
Primary line with flow
Primary line without flow
Figure 7-22. Filled and Empty Process Line
The process lines will change color according to the state of the upstream associated equipment, this means, if
the upstream device is running (e.g. motor) or in an open (e.g. valve) condition the process line will be filled; if
it is stopped or in a close condition the process line will be shown without flow. In case of modulated valves,
the process line will be filled if the valve is opened more than five percent (>5%), if it is opened less than or
equal to five percent (< = 5%) the process line will be shown without flow.
7.7. History Chart Display
The history and trend charts are configured and executed with the Process History View application included
into DeltaV. These charts show information of history files, real time trends and system events.
SPCC/Fluor will supply lists of variables and parameters to be included on these screens, taking into account
that each chart allows up to 6 variables (for this project), and that the quantity of charts per screen cannot
be greater than 6.
Figure 7-23 shows a screenshot of Process History View software displaying a kind of chart having history data
and events. In the upper side of the window there is a toolbar with buttons to open or save charts and
navigation buttons too. The navigation buttons allow to user to review the history chart in small or big time
steps. Zoom function is available to zoom-in or zoom-out depending of user criteria to see a specific part of the
chart. Depending how was configured; the chart can display multiple scales in the right or in the left side. The
lines colors are customizable. Under the curves graphic, a list with the variables are displayed, showing the tag
name, access path, description, value at cursor, engineering units, date and time.
With basic licenses, the Continuous Historian can manage up to 250 parameters per each workstation. The
maximum capacity to storage historical data depends on how the continuous historian is configured, having
only disk space restrictions.

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7.7.1. Event Chronicle
DeltaV workstations are each capable of collecting alarm and event data. The Alarms and Events subsystem
helps you maintain a database of events and alarms called an Event Chronicle. Event Chronicle databases store
alarms records, event records, log messages and events from Sequence of Events Cards.
You determine which workstations maintain an active Event Chronicle database and the areas for which the
workstation collects the events. The Process History Viewer application enables you to view and query the
alarms and event records for any machine on the control network. The Event Chronicle cans storage a
maximum of 500000 records and a minimum of 2500 records per each workstation.
The Events can be classified by type, each one with a different color, so its easier to see. Its also possible to
filtrate the events by any desired sort criteria like Area, event type, category, node, etc.
The Figure 7-23 shows a special chart that content an event list also in the bottom side of the window, in
which one its possible to see some fields and general presentation of events in DeltaV. An important idea is
that the software used to see history data is the same used to see events.
For more detailed information, please refer to DeltaV Books Online or Process History View help files.
Figure 7-23. Process History View.

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7.8. Faceplates
The system will have Faceplates on each device, starting from the DeltaV standards.
7.8.1. Faceplate for DI Module
The following faceplate will be used for a DI Monitoring Module. No detail picture is needed.
Figure 7-24. DI Module Faceplate
Position Button: This button is used to toggle the position of the faceplate to the left or right side of the
screen. Each time the display is opened, it defaults to the most recent position.
Close Faceplate Button: This button is used to close the faceplate.
Limits Alarm State: The state of the discrete input that causes an alarm. Any number from 0 to 255 can be
entered, although only 0 and 1 produce an alarm. State 255 specifies that no alarm indication is to be shown.

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Simulation Enable: Enables simulation and allows you to enter an input value and status when
SIMULATE_IN_D is not connected.
Simulation Value: The simulated discrete input value used when simulation is enabled.
Field Value: The discrete process variable used in block execution.
Alarms: This is the area designed for alarm enabling and alarm suppression.
Discrete Alarm: Alarm indication as result of matching the alarm setting and the process value.
Communication Alarm: Alarm indication as result of communication or I/O error.
7.8.2. Faceplate for AI Module
The following faceplate will be used for AI Monitoring Modules based on 4-20mA transmitters or Fieldbus
Foundation instruments.
Figure 7-25. Faceplate for AI Module

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Process Value: This area displays the PV value of the AI block in yellow. The background color of the 3-D box
changes from black to brown when the PV status becomes uncertain or bad. The PV value is visible in the
decimal format provided by PV_SCALE.F_DECPT when this value is 0,1,2 or 3 digits.
PV Units: This is the engineering units description for the PV as defined in the PV_SCALE parameter.
PV EU 100: This is the value corresponding to 100% of scale for the PV.
PV EU 0: This area shows the value corresponding to 0% of scale for the PV.
Tick Marks: This vertical arrangement of black lines is used to indicate percentages of PV and Output scale.
Bar Graph: This graph indicates the value of the PV parameter for the block, which is the same as the value
displayed in the PV display box.
PV Alarm Limits: These arrowheads are vertically positioned relative to the PV bar graph to indicate the high
high, high, low, and low low alarm limits for the PV. Although these arrows cannot be dragged with the mouse,
the values they indicate can be modified using the block's detail display.
Detail Display Button: This button is used to open the detail display for the AI block.
Trend Button: This button is used to open the trend display for the AI block.
7.8.3. Detail Picture for AI Module
The following detail picture will be used for AI Monitoring Modules based on 4-20mA transmitters or Fieldbus
Foundation instruments.

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Figure 7-26. Detail Picture for AI Module.
Hi Hi Lim: This area displays the maximum value of the PV in engineering units before the high high limit
active bit (HI_HI_ACT) is set. Click this field to enter a new limit.
Hi Lim: This area displays the maximum value of the PV in engineering units before the high limit active bit
(HI_ACT) is set. Click this field to enter a new limit.
Lo Lim: This area displays the minimum value of the PV in engineering units before the low limit active bit
(LO_ACT) is set. Click this field to enter a new limit.
Lo Lo Lim: This area displays the minimum value of the PV in engineering units before the low low limit active
bit (LO_LO_ACT) is set. Click this field to enter a new limit.
Sim Value: This area simulates the field value. When simulate is enabled, you can scale the sim value using
the Out scale to calculate the PV value. Click the value to enter a new value.

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7.8.4. Faceplate for PID Module
The following faceplate will be used for a PID controller with single input and single output. Special cases must
be reviewed on a case by case basis.
Figure 7-27. PID Module Faceplate

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OUT: This area displays the OUT_READBACK value of the PID block in cyan. The background color of the 3-D
box changes from black to orange or red when the Output status becomes uncertain or bad, respectively. In
the absence of a configured IO_READBACK DST, the OUT_READBACK value shown is equal to the implied
output value of the loop. The OUT_SCALE.F_DECPT parameter field determines the displayed decimal format
of OUT_READBACK. The value of this field corresponds to the number of digits displayed past the decimal
point. The values of OUT_SCALE.F_DECPT that are supported by this faceplate are 0,1,2, and 3. No value is
displayed when the value in the OUT_SCALE.F_DECPT field is larger than three. This indicator always will show
the output value from the PID controller for 4-20mA and Fieldbus Foundation Devices.
Process Value: This area displays the PV value of the PID block in yellow. The background color of the 3-D
box changes from black to orange or red when the PV status becomes uncertain or bad, respectively. The PV
value is visible in the decimal format provided by PV_SCALE.F_DECPT when this value is 0,1,2 or 3 digits.
Output Units: This is the engineering units description for the Output as defined in the OUT_SCALE
parameter.
PV Units: This is the engineering units description for the PV as defined in the PV_SCALE parameter.
Output EU 100: This is the value corresponding to 100% of scale for the Output .
PV EU 100: This is the value corresponding to 100% of scale for the PV.
AUTO/MAN: Buttons These buttons are used to set the target mode of the PID block to the corresponding
mode. The visibility of these three buttons is based on permitted modes of the PID block. Buttons for AUTO
and MAN mode are displayed when the respective mode is a permitted mode.
More Button: This button is used to display a list of the target modes available for the block. Click one of the
permitted modes to set the block target mode to that mode. To close the mode selector box, click the X
button.
Setpoint Slew Keys: These gray buttons with a white arrowhead pointing up or down are used to increment
or decrement the setpoint value by 1 PV engineering unit if PV_SCALE.F_DECPT is less than or equal to 1. If
PV_SCALE.F_DECPT is 2 or greater, each click changes the setpoint by 0.1 engineering unit. The setpoint slew
keys are visible if the target mode is AUTO, MAN, or OOS.
Output Bar Graph: This field indicates the value of OUT_READBACK, which is the same as the value
displayed in the OUT_READBACK display box.
Output Slider: This large cyan arrowhead to the left of the Output Bar Graph is displayed only when the
target mode of the block is MAN or OOS. To move this button, hold down the left mouse button while the
cursor is over the arrowhead and then move the mouse up or down to correspond to the new Output value
desired. The new value is then written to the Output parameter of the loop. The arrowhead remains in the new
position.
Output Limits: These cyan arrowheads are vertically positioned relative to the OUT_READBACK bar graph to
indicate the high and low Output limits. Although these arrows cannot be dragged with the mouse, using the
blocks detail display can modify the values they indicate.
Tick Marks: This vertical arrangement of black lines is used to indicate percentages of PV and Output scale.

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Bar Graph: This graph indicates the value of the PV parameter for the block, which is the same as the value
displayed in the PV display box.
Setpoint Limits: These white arrowheads are vertically positioned relative to the PV bar graph to indicate the
high and low SP limits. Although these arrows cannot be dragged with the mouse, using the blocks detail
display can modify the values they indicate.
Deviation Alarm Limits: These purple arrowheads are vertically positioned relative to the Setpoint Slider to
indicate the high and low SP-PV deviation limits. Although these arrows cannot be dragged with the mouse,
using the modules detail display can modify the values they indicate. When the deviation limit values are
changed from the detail display or Control Studio Online, you must reopen the faceplate for the new
positioning to take effect.
PV Alarm Limits: These blue arrowheads are vertically positioned relative to the PV bar graph to indicate the
high high, high, low, and low low alarm limits for the PV. Although these arrows cannot be dragged with the
mouse, the values they indicate can be modified using the block's detail display.
Output EU 0: This area shows the value corresponding to 0% of scale for the Output. 1
PV EU 0: This area shows the value corresponding to 0% of scale for the PV.
Detail Display Button: This button is used to open the detail display for the PID block.
Trend Button: This button is used to open the trend display for the PID block.
Faceplate Button: This button is used to open the module faceplate display.

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7.8.5. Detail Display for PID Module
Figure 7-28. PID Module Detail

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Hi Hi Lim: This area displays the maximum value of the PV in engineering units before the high high limit
active bit (HI_HI_ACT) is set. Click this field to enter a new limit.
Hi Lim: This area displays the maximum value of the PV in engineering units before the high limit active bit
(HI_ACT) is set. Click this field to enter a new limit.
Dev Hi Lim: This area displays the maximum positive deviation of the PV from SP in engineering units before
the high deviation limit active bit (DV_HI_ACT) is set. Click this field to enter a new limit. The valid input range
for this value is 0 to + PV span.
Dev Lo Lim: This area displays the maximum negative deviation of the PV from SP in engineering units before
the low deviation limit active bit (DV_LO_ACT) is set. Click this field to enter a new limit. The valid input range
for this value is 0 to - PV span.
Lo Lim: This area displays the minimum value of the PV in engineering units before the low limit active bit
(LO_ACT) is set. Click this field to enter a new limit.
Lo Lo Lim: This area displays the minimum value of the PV in engineering units before the low low limit active
bit (LO_LO_ACT) is set. Click this field to enter a new limit.
Out Hi Lim: This area displays the maximum value of the output in engineering units. Click this field to enter a
new limit. The valid input range for this value is -10 to 110 % of the output scale in engineering units.
Out Lo Lim: This area displays the minimum value of the output in engineering units. Click this field to enter a
new limit. The valid input range for this value is -10 to 110 % of the output scale in engineering units.
Sim Value: This area simulates the field value. When simulate is enabled, you can scale the sim value using
the Out scale to calculate the PV value. Click the value to enter a new value.
Red Arrow: Show the FIRST_OUT.
1
Reset: Set button acknowledge the FIRST_OUT.

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7.8.6. Faceplate for Direct Motor Starter
The following standard Faceplate will be used basically for 2-state motor starters, i.e. a start-stop basic motor.
More detailed specifications will be added depending on each starter definition.
Figure 7-29. Direct Motor Starter Module Faceplate

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Communication Failure: It shows when the communication between DeltaV and Starter went lost. Their
characteristic is high critical (red color)
Device Status: this area shows information about motor control status and starter conditions.
Current: Load current alarms, can be enabled or disabled as needed.
Auto Man: Mode of assigned module. DeltaV has as a standard, Auto / Cas conditions that were replaced
(only in the visual aspect of the operation screen) by Man / Auto, respectively.
7.8.7. Detail Display for Direct Motor Starter
Figure 7-30. Motor Starter Detail Display

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This display allows modifying module parameters as well as status and diagnostics.
The bottom side of the display shows four interlock conditions (in this example). Similarly, it shows the
following information:
Close Detail Display Button: This button is used to close the detail display
Tag name: Tag names of modules that use this faceplate must be limited to 12 or fewer characters. If the tag
name has more than 12 characters, the faceplate will not be opened
Load Current: it shows the load current
Interlock: interlock conditions located in the LG module. When any interlock condition is active, a red
arrowhead appears, indicating which condition is active.
Alarms: it shows the alarm type with the enable or disables option.
Reset: reset button for the FIRST_OUT detection.
7.8.8. Faceplate for Direct Motor Starter with Jog
The following standard Faceplate will be used basically for 2-state motor starters, i.e. a start-stop basic motor.
Additionally to the previous motor, this one has a REMOTE/LOCAL selector in order to enable or disable the
local jog function.

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Figure 7-31. Motor Starter Module Faceplate

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Local Remote: Local/Remote selector to enable local jog function.
7.8.9. Detail Display for Direct Motor Starter with Jog
This detail display for this kind of module is the same used for Direct Starter (see 7.8.7 section).
1
7.8.10. Faceplate for Variable Frequency Drive with Jog
The following standard Faceplate will be used basically for variable frequency drivers. More detailed
specifications will be added depending on each driver definition.

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Figure 7-32. VFD Faceplate Display

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SP: Speed set point.
PV: Actual process value for speed.

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7.8.11. Detail Display for a Variable Frequency Drive with Jog
This detail display for this kind of module is the same used for Direct Starter (see 7.8.7 section).
7.8.12. Faceplate for Forward-Reverse with Jog
The following standard Faceplate will be used basically for variable frequency drivers. More detailed
specifications will be added depending on each driver definition.

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Figure 7-33. VFD Faceplate Display

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Communication Failure DSA1: It shows when the communication between DeltaV and Starter went lost.
This alarm is related to the DSA device used for forward-way. Their characteristic is high critical (red color)
Communication Failure DSA2: It shows when the communication between DeltaV and Starter went lost.
This alarm is related to the DSA device used for reverse-way. Their characteristic is high critical (red color)
Command Buttons: This faceplate includes new buttons to command the motor: forward, reverse and stop.

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7.8.13. Detail Display for Forward-Reverse Starter with Jog
Figure 7-34. VFD Detail Display
This display allows modifying module parameters as well as status and diagnostics.
The bottom side of the display shows four interlock conditions (in this example). Similarly, it shows the
following information:
Close Detail Display Button: This button is used to close the detail display
Tag name: Tag names of modules that use this faceplate must be limited to 12 or fewer characters. If the tag
name has more than 12 characters, the faceplate will not be opened
Load Current: it shows the load current

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Interlock: interlock conditions located in the LG module. When any interlock condition is active, a red
arrowhead appears, indicating which condition is active.
Alarms: it shows the alarm type with the enable or disables option.
Reset: reset button for the FIRST_OUT detection.

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7.8.14. Faceplate for On-Off Valves
Figure 7-35. On-Off Valve Faceplate
Communication Alarm (FC): It shows when the communication between DeltaV and Starter is lost. Their
Bypass: this text appears only when the Bypass condition is active, which excludes the permissive condition.

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7.8.15. Detail Display for On-Off Valves
Figure 7-36. On-Off Valve Detail Display
Bypass: General Bypass condition. Set button enables bypass, producing a color change to red on the frame
around it. It disables the permissives and indicates the condition on the bypass.
Interlock: interlock conditions located in other module. When some interlock condition is active, a red
arrowhead appears, indicating which condition is active. Besides, it has a bypass frame that disables the
interlock condition.
Communication Alarm. It show the type of alarm and offers options to enable and disable.
Reset: Set button acknowledge the FIRST_OUT.

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7.9. Help Displays
Help displays are pop-up windows with a text that describe in summarized form, the process showed on the
active graphic. Actions to be taken in the event of abnormal function or alarms should be included as well.
As alternative is possible to do a configuration that enable open some specific document in Acrobat or Word
format.
7.10. Reports
SPCC/Fluor will supply a detailed list of the different reports associated to each area, defining the variables that
should include execution schedule and formats. [HOLD]

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Appendix A

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Appendix B
1
SideBar Configuration Procedure

Note: Before to execute these steps, XPTools must be installed in the workstation.
Step 1. Open Navigation Setup Window.

With DeltaV Operate in Run Mode, right-click on the side bar. A small pop-up window will appear (see Figure
1).
Figure 1. Sidebar Setup Window.

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Step 2. Navigation Menu Settings.

Click on Navigation Menu Settings and a new configuration window will appear (see Figure 2).
Figure 2. Navigation Menu Settings.

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Step 3. Adding a Menu Item (Used to add plant areas).

Click on Menu item at the left side of the window. In the right side of it, fill the following stuff (see Figure 3):
Name: This field is the name of the item (only as internal reference).
Text: The name shown on the navigation bar; it should be the plant area number and name.
Item Type: when the item to add its a plant area, Menu must be selected.
So, clicking on Add button the window should be as shown in Figure 4.
Figure 3. Adding a Menu Item.

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Figure 4. Menu Item Added.

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Step 4. Adding a Picture Item (Used to add process displays from a Plant Area).
Click on an existing Plant Area item at the left side of the window. In the right side of it, fill the following stuff
(see Figure 5):
Name: This field is the name of the item (only as internal reference). Its recommended to match it
with the picture file name.
Text: The name shown on the navigation bar; it must describe shortly what is shown in the related
display.
Item Type: when the item to add its a process display, Picture must be selected.
Picture: if Item Type field is Picture, this field is enabled to select the display filename. The file must
be stored on D:\DeltaV\DVData\Graphics-iFIX\Pic directory.
So, clicking on Add button the window should be as shown in Figure 6.
To add more process displays under this plant area back to Step 3.
Figure 5. Adding a Picture Item.

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Figure 6. Picture Item Added.

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Step 5. Saving Actual Configuration.

Once finish adding items, click on Save button (see Figure 7).
Figure 7. Saving Menu Settings.

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Step 6. Closing Navigation Menu Settings Window.

Clicking on Close button, the program will alert to the user to save changes. Clicking on Yes button, the
changes will lose if are not saved (see Figure 8).
Figure 8. Closing Navigation Menu Settings.

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Step 7. Detail and Faceplate pictures.

With these steps, the sidebar should be as shown in the Figure 9.
Figure 9. Navigation sidebar.

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1 UPDATE 01/07/05 LF/CM CM JB

CLIENT: SOUTHERN PERU COPPER

Description Of Changes In This Revision

Date Rev Description Of Change (With Point No. If Applicable) Issuer

Southern Peru Copper

Southern Peru Copper

1. About this Document.............................................................................................................12

Southern Peru Copper

5.3.2. Controllers Names ...............................................................................................................31

Southern Peru Copper

6.5. PID Control Loop Modules .......................................................................................................55

Southern Peru Copper

7.7. History Chart Display ............................................................................................................99

Southern Peru Copper

Figure 2-1. DeltaV Explorer Window .........................................................................................................15

Figure 6-31. External view of DSA_V composite block ................................................................................68

Southern Peru Copper

Figure 7-26. Detail Picture for AI Module................................................................................................. 104

Southern Peru Copper

Table 2-1. Ilo Smelter Modernization Project Areas ....................................................................................14

Southern Peru Copper

Table 6-24. ON/OFF Valve Control Module Description Table. .....................................................................75

Southern Peru Copper

1. About this Document

Southern Peru Copper

2.1. Project Organizations

2.2. Plant Areas

Southern Peru Copper

301 ISASMELT Furnace Waste Heat Boiler

Table 2-1. Ilo Smelter Modernization Project Areas

Southern Peru Copper

Figure 2-1. DeltaV Explorer Window

2.3. System Architecture

Southern Peru Copper

2.4. Main Components

Card type Description

Table 2-2. I/O Controller Card List

2.4.2. I/O Cards

Southern Peru Copper

Card type Description

Table 2-3. I/O Cards List

Southern Peru Copper

2.4.4. Engineering Workstations

2.4.5. Operator Workstations

For this project two types of OWS are considered:

Server Location Description Model

Table 2-4. Sever List

Southern Peru Copper

2.4.7. Control Network

2.4.8. Foundation Fieldbus

Southern Peru Copper

FDU Name format:

Southern Peru Copper

Southern Peru Copper

3.2. Documents Identification

Project Ref. Number

Extension (file format)

AAAAA: Project Reference Number (for internal use).

BBBB: Area of application (following SPCC/Fluor definitions)

Southern Peru Copper

4601 Effluent Treatment No 2 Plant Electrical Room (Controlled Area 460)

CC: 2 digit code to represent the document type.