BOOK05.

PLANT CONTROL SYSTEM DESCRIPTION & IO List

REVISION HISTORY

REVISION DATE REVISION DETAIL DESCRIPTION

REV A 11/2020 REVISION A OF THE OPERATIONS AND MAINTENANCE
MANUAL FOR THE SPRUCE 7

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BOOK 5. PLANT CONTROL SYSTEM DESCRIPTION

SUBJECTS COVERED

 INTRODUCTION
 OPERATOR INTERFACE
 CONTROL LOGIC SYSTEM
 MASTER AND SLAVE PLC I/O BASES
 PLANT CONTROL INSTRUMENTATION

INTRODUCTION
The control system for the SPRUCE7 series plant consists of an operator interface
utilizing a Microsoft Windows Based Computer; a Siemens S7 PLC consisting of S7-
1500 series PLC and several Remote I/O bases; and I/O measurement and control
instrumentation. The control system is powered through an uninterruptible power
supply (UPS) which provides reliable access to the control system during power
outages. The operator will continue to receive information and have the ability to
operate the control valves for a safe shut down.
For details on the components of the control system, how to service them and spare
parts information please refer to Book 6 (COMPUTER CONTROL SYSTEM) and the
vendor data for the various instruments which is contained in the VENDOR
INFORMATION BOOK.

OPERATOR INTERFACE
The operator interface consists of a standard industrial PC (Dell/Siemens brand or
equivalent), and the Human Machine Interface (HMI) software screens. These tools
provide the operator with the information needed to operate the plant in a concise
format, store the data for future evaluation, and provide the reports necessary to
document the plant operation.
The operator interface is programmed using Siemens WinCC Explorer software
custom programmed for the SPRUCE plant by Cosmodyne. There are multiple
screens that graphically illustrate actual process equipment (compressor, distillation
column, heat exchanger) with associated controls and instruments.
Some of the screens include trending. A master trending screen(s) functions to
provide custom on-line trend point plots of any of the plant’s control points or
instrument measurements. They also contain advanced functions like a zoom
window, statistical analysis for close inspection of trend data and data storage for
later analysis.
Alarm handling for the plant is graphically represented within the HMI. Alarm
indication at the computer screen includes a visual indicator at every display to
enable quick operator response. The alarm summary screen is only one keystroke
away from any display.

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 Detailed information about the operator interface and representative screens found
in the HMI is contained in Book 7.
CONTROL LOGIC SYSTEM
The control logic system is programmed within the Siemens PLC. The logic is used
to control the various modes of operation, adsorption bed switching, plant permissive
start, automatic actions, alarms, and shutdown/trip.
Logic is included for the permissive start-up of various processes in the plant such
as the air compressor, recycle compressor, TBX lube oil system. It also includes the
automatic shutdown of the plant and plant subsystems.
The plant control logic is defined in book 11 PLC logic. The IO list below details the
alarm and trip settings as well as the default P&ID settings

PLC & Remote I/O BASES

Remote input/output bases are installed in several areas of the plant to convey data
to and from the PLC. The I/O bases are used to communicate information to the
PLC via the Siemens Ethernet network interface.
The PLC & 1 Remote IO base is located at the WEM (Warm Equipment Module).
2nd I/O base located at Cold Box Module.
The PLC communicates with the computer via an Ethernet protocol. Each of the
bases contains a selection of digital and analog modules. These include 24 VDC
digital inputs, 4-20 mA analog inputs, 24 VDC digital inputs, isolated relay /
transistorized outputs, and 4-20 mA analog outputs.
Detailed information about the location of various parameters on the I/O bases can
be found on the various Plant Electrical Schematics (see Book 13).
PLANT CONTROL INSTRUMENTATION
The plant control instrumentation supplying information to the operator interface
consists of pressure transmitters, RTD’s, speed transmitters, flow switches, level
switches, and pressure switches. These are augmented with local pressure and
temperature instrumentation as shown on the P&ID. The control instrumentation is
shown in the IO list. The pressure transmitters are made by various manufacturers
including Rosemount, PR Electronics and/or Wika. The RTD instruments are
Platinum 100-ohm elements with IEC specified calibration.

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