2008 Automation Summit

And Users Conference

ID#: 3321
Title: Development of PCS7 HMI Style Guide
Track: DCS Modernization
Topic: Modernization & Retrofit

Presenter: Andrew Coombe

Company: E.I. DuPont de Nemours,
Inc.

Expand your world of automation

 Agenda

‰ DuPont Company Overview

‰ Why Do We Need Design Guides

‰ HMI Style Guide Overview

‰ Making It Work

‰ Summary

page 2
 Company Overview
E. I. du Pont
Our Beginnings….1802
Eleuthère Irénée du
Pont founded E.I. du
Pont de Nemours &
Company in 1802.
Structured as a family
partnership, du Pont,
with $36,000 raised
from investors, built
powder mills on 96
acres alongside the
Brandywine in
Wilmington, Delaware.
First-year sales were
$15,116.

page 3
 Company Overview
DuPont Today

• Is headquartered in Wilmington, DE
• Has $29 billion in revenue
• Operates in 70 countries on six continents
• Employs 59,000 people globally
• Has five core growth platforms
• Produces over 2,400 products

page 4
Company Overview
Coatings & Color Performance Materials
Technologies

ArtistriTM Inks

Delrin®, Hytrel®, Surlyn®, and super- Butacite® glass

tough Zytel® in sports and leisure laminating products
equipment

Water-based topcoat systems

Automotive Refinishing
Automotive Clearcoat
Vamac® wire & cable housing Surlyn® Reflections

page 5
Company Overview
Electronic &
Safety & Protection Communication
Technologies

Nomex®
Kevlar® Protective Apparel
Protective Apparel
OLED Displays Microcircuit Materials
Technology

Cyrel® FAST flexo plates

Sontara® Infection Prevention Fuel

SentryGlas® Plus Medical Fabrics

Conditioner
Processor
O2

Power
Fuel
Fuel Cell Load

Conductive plate

Conductive plate
e- e-

diffusion layer
Stack Anode Cathode H2O
H+

catalyst
Fuel, e.g.,

NAFION
®
H2 ,
Electricity
reformed
or MeOH

[CO2]

Proton Exchange Membrane Fuel Cell

Corian® Surfaces (PEMFC) - Cell Components
page 6
Company Overview
Agriculture & Nutrition

Biotech Unprotected
Protected Product Product
BAX® System

Steward® and AvauntTM insecticides Pioneer® soybean SolaeTM soy protein

page 7
 So what?

Most of these 2400 products divided among 5

growth platforms on multiple continents are
manufactured with the aid of some level of
automation in processes involving operator
oversight.

While recognizing the tremendous contributions

made by control systems, DuPont management
recognizes that these systems are assets that
need to be maximized like any other.

page 8
 Asset maximization

By recognizing, documenting, and

communicating best practices, DuPont attempts
to reduce “wheel re-invention syndrome.”

Believe it or not, I made this term up.

page 9
 Asset maximization of Control Systems

Benefits of corporate best practices include:

•Identification of “good design” which is
proven-in-use.
•Reduction of “poor design” which tends to get
copied indefinitely…even without the benefit of
an official “Worst Practice” document.
•Reduced engineering time on new projects.
•Greater consistency among different
manufacturing units.
•Reduced operator training (easier for operators
to move between units).
•Reduced OJT for new engineers.
•Improved communication with contractors.
page 10
 What is a Design Guide?

In DuPont, a Design Guide is a document

written for a particular control system; e.g.,
Siemens PCS7, which outline strategies,
methodologies, practices, and standards to
ensure the best possible use of investment
dollars.

Design Guides capture good engineering

practices and techniques that have been proven
in the field and make it as easy as reasonably
possible for others to copy and use.

page 11
 Why do we need a Design Guide?

• All too often a “wheel” is reinvented, especially with fast

changing technology. Good secrets remain a secret.
• Selections are all too often based on individual preferences or
the last successful project.
• Design mistakes or lack of design experience can lead to poor
system performance.
• System designers may not utilize vendor equipment to their
fullest potential.

Design Guides Address:

• Design Strategies
• Standard System Functions
• Application Specific Functions
• Implementation Practices
• Sound Technology Selection Criteria and Process

page 12
 Making it Work, Use of Design Guide
This design guide shall be used in:
- front- end loading (FEL) to estimate or specify the control system
- production design
- operation and maintenance
ƒto help define and integrate control system technologies,
ƒto reduce effort in understanding and implementing the
company's DCS requirements,
ƒto achieve effective DCS control system life cycle
performance.

page 13
 Design Guide Overview
Joint Engineering Website (sitescape)
Alliance Home Page
PCS7 Standard System Documentation
ƒ Sample System Architecture

ƒ System Description

ƒ Engineering Manuals

ƒ Tips & Trick

ƒ Standard Siemens Arrangement drawings

ƒ Links to Siemens websites and useful documents

page 14
 Joint Engineering Website (sitescape)
Alliance Home Page
General Training Events
Status Reports •Overview (webinar 11/29/06) •Achema, Frankfurt, Germany 5_2006
Jan/Feb/Mar 2008 •Training Plan PLC •PCS7 Users Conference 6_2006
•Training Plan DCS
•

Oct/Nov/Dec 2007 •HMI Usability Workshop

•Training Schedule
•

Jul/Aug/Sep 2007
•

•NEW Training Application Procedure oPresentation

•Apr/May/Jun 2007 •Application Form and procedure (outside US) oStyleguide, example
•Jan/Feb/Mar 2007 TTI Sessions/Workshops •SIMATIC IT Workshop July 28, 2006
•Nov/Dec 2006 •Profibus Part 1 oOverview
•Profibus Part 2 oIntelligence Suite
•Sept/Oct 2006
oProduction Suite
•August 2006 Bailey OS Migration Webmeeting
•

oR&D Suite
•July 2006 Profibus DP,PA, ASi, HART, F
•

Hannover Fair 2007

•

News Fieldbus PCS7 Users Conference 2007

•Fieldbus
•

Control Engineering webcast, Cyber

•

latest news
•Alarm Management
o

Security PCS7 Users Conference 2008

Smart MCC
•

Bailey OS Migration Workshop

•

Engineering Process
•

Alliance Team Meeting 6/12/2007

•

Agenda
o

presentation
FEL: RFP Template
•

Introduction OS Bailey
o

Siemens Engineering Process

o

DeviceNet/IP21
ƒ

Introduction PCS7
o

Service & Support

DuPont Working Documents
•

Meeting Report
ƒ

HMI Design Guide rev 1

o

meeting report
o

Service and Support

Process Control Libray rev0
o

support website, instructions

Hardware Design Guide
o
•

Siemens Products and Solutions

Chemical Industry
•

Process News
•

page 15
 Joint Engineering Website (sitescape)
PCS7 SYSTEM DOCUMENTATION SITE MAP
Architecture & Hardware System Configuration Controller Configuration
Architecture Options
•
Installation and Settings of the Function Block and Typical Library
Data Security Guidelines
•
operating system Specification
Installation PCS 7
Hardware components
•

Project structure
DuPont Library
Industrial PC (ES, OS)
o

AS Engineering
Networks, Busses, switches
o

Configuration of the network connections HMI Configuration

ƒScalance Switch Graphics Standards
Controllers
o
Definition of Project Function Blocks Symbol Standards
Safety systems
o

OS Engineering
Standard Faceplates
I/O & Typicals Archiving Alarm Management
Cabinet arrangements
•

Bulk Engineering Linking to documents

Servers. Switches
o
Integrated Asset Management Maintenance information
Controllers & I/O
•
Compile and Download, Maintenance HMI conversion hint
I/O numbering
o

IP.21 Integration
Additional Links
Remote I/O ET200
o

DeviceNet Integration SIEMENS Support

Power & Grounding
• Simatic Manuals
Fieldbus Networks
• E-Pass
Foundation Fieldbus
o

Profibus
o

DP/PA coupler, Y-link

o

DeviceNet
o

AS-I
o

page 16
 DuPont’s hierarchy of standards

US & Intl
Standards

PIP Standards

Corporate DuPont
Standards
Corporate DuPont
Best Practices

Corporate DuPont
Design Guides

DuPont Site
Design Guides

page 17
 DuPont’s hierarchy of standards

US & Intl
Standards

PIP Standards

Corporate DuPont
Standards
Corporate DuPont
Best Practices

Corporate DuPont
Design Guides

DuPont Site
Design Guides

page 18
 Design Guide Overview
and Relation to the Engineering Process

Design Guide
PCS7 Standard
System
Documentation Custom HW
Function Design
Block
HW HMI Library
Design Design
Guide Guide

Engineering Process
SW
Standard Design
HW
RFP Functional Specification
Specification
document

Proposal FEL1- 3 Project Implementation

page 19
 Design Guide Overview
and Relation to the Engineering Process

Design Guide
PCS7 Standard
System
Documentation Custom HW
Function Design
Block
HW HMI Library
Design Design
Guide Guide

Engineering Process
SW
Standard Design
HW
RFP Functional Specification
Specification
document

Proposal FEL1- 3 Project Implementation

page 20
 What does HMI encompass?

page 21
 Design Guide Overview
HMI Design Guide, Content

ƒ Graphics Environment
ƒ Icons and Faceplates
ƒ Custom Icons (DuPont Typicals
Library)
ƒ Static Graphics

page 22
 HMI Style Guide Contents

Content

•Introduction
•Graphics Environment
•Icons and Faceplates
•Custom Icons (The DuPont Library)
•Static Graphics
•References
•Acronyms and Abbreviations
•Glossary

page 23
 HMI Style Guide Contents

page 24
 HMI Style Guide Contents

page 25
 Design Guide Overview
Custom Library (Function Blocks and Templates)
ƒAnalog Indicator • Specification Developed by
ƒBasic PID DuPont/Siemens Team
ƒBasic PID – Cascade • Program Code
• Function Block Description
ƒBasic PID – Override
ƒBasic PID – Ratio Control
ƒBasic PID – Split Range
ƒManual Loader
ƒTotalizer
ƒRatio
ƒInput Selector
ƒDiscrete Controls
ƒType II [Fail-Last Position] Valve
ƒ[Type XX] Motor
ƒDigital Indicator

page 26
 HMI Style Guide Contents

page 27
 HMI Style Guide Contents

page 28
 Making it Work, Benefits
Life Cycle Costs Life Cycle Costs
without Design Guides with Design Guides

Maintenance
Efficiency • reduces time and
Maintenance resources required
Operator Efficiency
Efficiency • maintains the
Operator
quality of design
Efficiency
Software
Software • Assures sound
Design engineering level
Design

Hardware Hardware

Estimated reduction in engineering hours approximately 20-40%

page 29
 The HMI Style Guide Development Process

The process

ƒStrong pull from sites/businesses.

- They didn’t want to have to start from scratch with unfamiliar
system.
ƒFacilitated by central corporate engineering.
- Impartial. Not pushing one particular site’s approach.
ƒStrong participation by end users.
- Must understand the needs of folks who will be using this.
- Some end users already with projects underway and getting to
know PCS7 beyond the sales pitch and classes.
ƒHeavy collaboration with Siemens.
- Initial draft based on Siemens’ Software Design Specification
- Received advice from Siemens on content.
- Siemens engineers proivded both explanations and customized
solutions to issues that came up.

page 30
 The HMI Style Guide Development Process

What worked well…

ƒSupport from Siemens

ƒStealing shamelessly
- Siemens’ “Software Design Specification”
ƒ Incorporating learnings from vanguard end users
- Compare and contrast at nuts-and-bolts level
ƒ Enlisting services of technical writer

page 31
 The HMI Style Guide Development Process

What worked well…less well

ƒConference calls just don’t cut it.

ƒNobody reads multi-page documents before conference calls.
ƒSite engineers working on projects are pretty busy and single-
focused.
ƒGetting consensus from a bunch of independent-minded site
engineers is like herding cats.
ƒFolks from [insert region here] can be pretty stubborn.
ƒThere are standards and then there are recommendations…
ƒCorollary: There’s a big difference between “you shall” and “you
should.”

page 32
 The HMI Style Guide Development Process

What I would do differently if I had to do it again…

ƒMake much better use of caller ID.

ƒJust say No!
ƒGet management to lay out “rules of compliance” at the start.
ƒGet users to develop an HMI functional spec to capture their
expectations and get them thinking HMI through.
ƒClearer realization of how quickly projects get cast in cement.
ƒGet more training early on.
ƒGet involved at nuts-and-bolts level in a real project early on.
ƒArrange a few face-to-face meetings.

page 33
 Acknowledgements
ƒLeadership
- Yiannis Dimitratos, DuPont
- Dennis Inverso, DuPont
- Winfried Stach, Siemens

ƒContributors
- Cindy Benedict, Siemens
- Dale Morris, Siemens
- Vincent Turmel, Siemens
- James A Simmons, DuPont
- Eric J Bauer, DuPont
- Gary D Holmes, DuPont
- Geert J Soulje, DuPont
- Guy A Burnaman, DuPont
- J Randall Peal, DuPont
- James A Price_Jr, DuPont
- Joe R Valenzuela, DuPont
- Kevin Schultz, DuPont
- Marc N Skop, DuPont
- Paul M Dill, DuPont
- Dennis Inverso, DuPont
- Christopher McHugh ,
DuPont Contractor

page 34