d-subrahmanyam/bulk-engineering

Bulk Engineering for DCS/PLC Automation

The Problem

Typical mid-size plant: 200-500 motors, 100-300 valves, 500-2000 analog loops, 200-1000 discrete I/O. Manual configuration: 15-60 min/instance. Bulk engineering reduces months to days.

General Pipeline

[Instrument Index / Motor List / Valve List]  (Excel/CSV input)
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        v
[Engineering Database]  (SQLite / structured data)
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        v
[Template Library]  +  [Configuration Rules]
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        v
[Code Generator]  (Python + Jinja2 / string replacement)
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        v
[DCS/PLC Project Files]  (PRT, XML, FHX, etc.)
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        v
[Validation]  (cross-reference check, naming, completeness)
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        v
[Import to DCS Engineering Tool]

Input Documents

| Document | Contains | Used For | |----------|---------|---------| | Instrument Index (I/O List) | Every tag, type, range, units, alarms, P&ID ref | Tag creation, scaling, alarms | | Motor List | Motors with power, starter type, protections, interlocks | Motor block generation | | Valve List | Valves with type, fail position, actuator | Valve block generation | | Control Narrative | Control logic descriptions per unit | Logic implementation | | Cause & Effect Matrix | Safety/interlock logic in tabular form | Interlock logic generation |

Output Artifacts

1. Controller programs (function block instances + logic + parameters)
2. I/O assignments (channel-to-tag mapping)
3. HMI/operator displays (graphics, faceplates, navigation)
4. Alarm configuration (priorities, limits, deadbands)
5. Historian tags (trend definitions, storage rates)
6. OPC server configuration

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ABB Freelance Bulk Engineering (Primary Target)

Method 1: PRT File Templating (Recommended)

1. Create a "golden" template PRT for each type (motor, valve, analog, etc.)
2. Export as .prt file
3. Programmatically for each new instance:
   • Read template with UTF-16 encoding
   • Replace all identifiers (node name, MSR name, EAM signals, descriptions)
   • Update parameters
   • Set checksum to 0000000000
   • Write output .prt file
4. Import each .prt into target project in Freelance Engineering Workplace

Template Replacement Map (Motor)

| Element | Template | Replace With | |---------|----------|-------------| | Node name | 11301CLWW1A1 | {area}{equip}{num} | | MSR primary | 11301.CLWW.1A1 | {area}.{prefix}.{num} | | MSR short | 11301.CW.1A1 | {area}.{short}.{num} | | Graph ref | g11301CLWW1A1 | g{area}{equip}{num} | | Description | PHO RCK EXTR CNVR-1 | {description} | | EAM signals | XA1/XA2/XB1/XL/XS1/XS2 + node | Same prefixes + new node |

Method 2: CSV Full Project Manipulation

Parse full project CSV, add new sections, re-import. More powerful but higher risk.

Method 3: DMF Display Templating

1. Create template display in DigiVis
2. Export as .DMF
3. For each new display:
   • Replace TXL text entries (tag names, descriptions, units)
   • Replace ODB variable bindings (DIGI addresses)
   • Update display navigation references

Key Challenges

1. UTF-16 encoding: Must read/write correctly
2. Internal cross-references: EAM, MSR, LAD:PARA_REF must be consistent
3. Checksum: Set to 0, Freelance recalculates
4. Unique naming: No duplicates allowed
5. Area mapping: Tags must map to correct area codes

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Siemens TIA Portal Bulk Engineering

TIA Openness API (.NET)

using Siemens.Engineering;
using Siemens.Engineering.SW;

TiaPortal tia = new TiaPortal(TiaPortalMode.WithUserInterface);
Project project = tia.Projects.Open(new FileInfo(@"Project.ap17"));
PlcSoftware sw = device.GetService<PlcSoftware>();
sw.BlockGroup.Blocks.Import(new FileInfo(@"MotorFB.xml"), ImportOptions.Override);
PlcTagTable table = sw.TagTableGroup.TagTables.Create("Motors");

SiVArc (HMI Auto-Generation)

Rules-based: define rules like "For every MotL FB, create faceplate." Reads PLC structure, auto-generates WinCC displays.

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Emerson DeltaV Bulk Engineering

Class-Based Configuration (Most Powerful)

Define module template (class) -> instantiate many -> template changes propagate to all instances.

FHX File Generation

MODULE TEMPLATE "MT_MOTOR_1SPD" /
  MODULE_CLASS = DEVICE /
{
  FUNCTION_BLOCK "DC-1" / DEFINITION = "DC" /
  { ATTRIBUTE MODE_BLK.TARGET = AUTO ; ... }
}

Text-based, parseable, generatable with Python.

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Recommended Technology Stack

| Component | Technology | Purpose | |-----------|-----------|---------| | Language | Python 3.10+ | Core automation | | Excel I/O | openpyxl, pandas | Read input spreadsheets | | Templates | Jinja2 / string.Template | Generate output files | | Database | SQLite | Engineering database | | File I/O | codecs (UTF-16) | Read/write Freelance files | | XML | lxml | PLCopen XML, SimaticML | | Validation | pydantic | Data validation | | GUI (opt) | Streamlit / PyQt6 | User interface | | VCS | Git | Version control |

Python Template Approach

import codecs
import re
import pandas as pd

# Read motor list
motors = pd.read_excel('motor_list.xlsx')

# Read template
with codecs.open('MOT_template.prt', 'r', 'utf-16') as f:
    template = f.read()

# Generate for each motor
for _, motor in motors.iterrows():
    output = template
    output = output.replace('11301CLWW1A1', motor['node_name'])
    output = output.replace('11301.CLWW.1A1', motor['msr_name'])
    output = output.replace('PHO RCK EXTR CNVR-1', motor['description'])
    # ... more replacements

    # Reset checksum
    output = re.sub(r'\[CHECKSUM\];.*', '[CHECKSUM];0000000000', output)

    with codecs.open(f"{motor['node_name']}.prt", 'w', 'utf-16-le') as f:
        f.write('\ufeff' + output)

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NAMUR NE 148 Requirements

The NAMUR standard for automation engineering tools mandates:

1. Single data source - one instrument defined once, used everywhere
2. Template-based engineering - define once, instantiate many
3. Bulk operations - create/modify/delete in mass
4. Consistency checking - validate cross-references
5. Import/export - Excel and P&ID tool integration
6. Version management - track changes
7. Multi-user - concurrent engineering
8. Target independence - generate for multiple DCS targets

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Third-Party Tools

| Tool | Vendor | Description | |------|--------|-------------| | SmartPlant Instrumentation | AVEVA | Central instrument DB, generates DCS configs for all vendors | | COMOS | Siemens | P&ID to PLC code, TIA Portal integration | | Engineering Base | AUCOTEC | Object-oriented, multi-DCS output | | Unity App Generator | Schneider | Excel-based Modicon PLC generation | | Ignition | Inductive Automation | Database-driven SCADA/HMI with Python scripting |

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Asset-Centric vs Signal-Centric

Signal-Centric (Traditional): Start from I/O signals. AI_Card1_Ch3 -> create tag -> configure. Matches hardware but disconnected from equipment.

Asset-Centric (Modern): Start from physical equipment. Pump P-101A includes motor, flow, pressure, vibration, protection. Easier to template. Aligned with ISA-88/95.

| Approach | ABB Freelance | Siemens PCS 7 | Emerson DeltaV | |----------|--------------|---------------|----------------| | Support | Moderate (MSR hierarchy) | Moderate (plant hierarchy) | Strong (class-based) |