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Rules, Standards & Procedures

Harmonised Equipment Standards

INQUIRY SPECIFICATION
FOR
PROCESS CONTROL
SYSTEMS

OpCos name xxx


Brewerys name xxx
Address xxx
Country xxx
Geographical destination xxx

01.35.71.001 / 01

01.35.50.001 / 03

Heineken
Version

: xxx

Status

: xxx

Author

: xxx

Date

: xxx

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PROCESS CONTROL SYSTEM

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CONTENTS

1. Introduction

1.1. REVISION HISTORY


1.2. HOW TO USE THIS SPECIFICATION
1.3. LIST OF LOCAL EXCEPTIONS FOR THE PROJECT TO THE FIXED PART
1.4. BREWERY & CONTACT DATA
2. VARIABLE SPECIFICATIONS

4
4
4
5
6

2.1.1. Reference documents


2.2. P&IDS
2.2.1. Operational Set-up
2.3. SCOPE
2.4. ORGANISATION
2.4.1. Communication
2.4.2. Planning
2.5. FUNCTIONAL REQUIREMENTS
2.5.1. Functionality
2.5.2. Language
2.6. SYSTEMS & ARCHITECTURAL REQUIREMENTS
2.6.1. Hardware & System Software
2.6.2. Architecture
2.7. DOCUMENTATION

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3. FIXED SPECIFICATIONS

3.1. STARTING POINTS

3.1.1. Reference documents


3.2. SCOPE
3.2.1. Engineering
3.2.1.1 Design & prototyping
3.2.1.2 Application software engineering
3.2.2. FAT
3.2.3. Shipment
3.2.4. On-site activities
3.2.4.1 Set-up System
3.2.4.2 I/O Tests & Network validation
3.2.4.3 Training
3.2.4.4 Witness & Support commissioning
3.3. ORGANISATION
3.3.1. Communication
3.3.2. Planning
3.4. FUNCTIONAL REQUIREMENTS
3.4.1. Functionality
3.4.2. Ergonomics
3.5. SYSTEMS & ARCHITECTURAL REQUIREMENTS
3.5.1. Architecture
3.5.2. Availability
3.5.3. Performance
3.5.3.1 MES Layer
3.5.3.2 Control Layer

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3.6. DOCUMENTATION

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3.6.1. System documentation


3.6.2. Project documentation
3.7. GUARANTEE
3.7.1. Hardware and system software

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18

3.7.2. Application software and services

3.8. MAINTENANCE

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3.8.1. Corrective maintenance


3.8.2. Adaptive maintenance
3.8.3. Functional (Perfective) Maintenance
3.8.4. Tools and spare parts

4. QUOTATION

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4.1. GENERAL
4.2. PRICE SPECIFICATION

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4.2.1. Project cost


4.2.2. Maintenance cost
4.2.3. Rates
4.2.4. Optional
4.3. ALTERNATIVES

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1. INTRODUCTION
1.1. REVISION HISTORY
In the following table an overview of all mayor modifications are listed.
Standard issues
ISSUE
DATE
01
07-10-2004
02
19-11-2004
03
03-05-2006
Project versions
VERSION
STATUS
01
Final
02
Final

DESCRIPTION OF MODIFICATIONS
Initial version
Update N 01
Update for harmonized specifications template.

DATE
xxx
xxx

DESCRIPTION OF MODIFICATIONS
For inquiry
For order
1. paragraph x: change xxx
2. paragraph y: change xxx

BY
G.J.J. Thijssen
G.J.J. Thijssen

BY
xxx
xxx

1.2. HOW TO USE THIS SPECIFICATION


The purpose of this inquiry specification is to assist the supplier to prepare his quotation for the delivery,
engineering and commissioning of the process automation system for the beer production area.
This specification consists of the following parts:
Chapter . describes the project-specific scope of the project.
Chapter . covers requirements that are similar for all Heineken projects.
Although requirements have been listed as fixed there may be reasons to deviate from them. These
changes are considered as local exceptions to the Fixed Part and described in Paragraph 1.3, List of
Local Exceptions for the project to the fixed part
Chapter the deliverables for the quotation are described.
Improvements in the design and this specification will be done on the job in on-going projects and
discussed in yearly review meetings with the suppliers and Heineken.
Suppliers are also requested to challenge this specification for improvement.

1.3. LIST OF LOCAL EXCEPTIONS FOR THE PROJECT TO THE FIXED PART
In the List of Exceptions, as mentioned below, you will find the exceptions to the fixed part of the
specifications. In the last column the supplier must confirm the understanding and agree to supply
according to this exception, by writing YES.
List of Exceptions:
ITEMS AS DESCRIBED IN THE FIXED
PAGE
PART OF THE SPECIFICATION

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ITEM AS CUSTOMER PREFERS IT FOR


THIS PROJECT ONLY

INQUIRY SPECIFICATION
PROCESS CONTROL SYSTEM

SUPPLIER AGREES
[YES]

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1.4. BREWERY & CONTACT DATA


Brewery data:
<Opco Name>
<Brewery name>
<Brewery address>
Correspondence in respect of this quotation inquiry shall be addressed to:
Heineken Supply Chain
Burgemeester Smeetsweg 1
2382 PH Zoeterwoude
Corporate Purchasing Department, attn. <buyer name>
Questions regarding this quotation can be addressed to:
<consultant name>
Automation Consultant
dept. Process Control & Utilities
tel:
<telephone number>
email: <e-mail address>

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2. VARIABLE SPECIFICATIONS
2.1.1. REFERENCE DOCUMENTS
The following documents serve as reference for this inquiry and form an inseparable part thereof. These
documents are project specific references. There is also a set of general references. These are listed in
chapter 3.1.1.

no_____________________________________________________________________________________________
document_______________________________________________________________________________________
version_________________________________________________________
date_______________________________________________
status________________________________

V1
V2
V3

Equipment specification
E&I specification
Architectural overview existing system

2.2. P&IDS

no_____________________________________________________________________________________________
description______________________________________________________________________________________
drawing number__________________________________________
issue_________________________________

1
2
3
4

2.2.1. OPERATIONAL SET-UP


Describe here the operational set-up for this project. I.e.:
how many FTEs,
Fully automatic or semi-automatic production etc.
Central control room or not.
Operators full time in operator room or not
Describe maintenance set-up and organisation

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2.3. SCOPE
This part describes the magnitude of the project whereas in chapter 3.2 of the fixed part the deliverables
within this scope are described.
The scope of the works comprises the delivery, engineering and start up & commissioning of the process
automation system of the process cells described below:
Raw materials storage
o Unit 1
o Unit 2
o
Brewhouse
o Unit 1
o Unit 2
o
Tankroom
Filtration & brightbeer
Yeast handling
Production Services
Main description of the scope and tie-in points of the project. When the inquiry for the equipment and the
inquiry for the automation part is sent to the same supplier, a reference to the equipment specification is
sufficient here.

2.4. ORGANISATION
Project specific contractual set-up. Indicate here how the automation is organized in relation to the main
contractor and Heineken.

2.4.1. COMMUNICATION
Communication in relation to the project specific organisation.

2.4.2. PLANNING
Project specific milestones:
milestone

responsibility

Functional specifications ready


Technical design ready
Approved FAT
Start commissioning
First brew
80% production reached
Approved SAT

Heineken
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier

date

A reference to the milestones in the general equipment specification or commercial specification might be
sufficient here.

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2.5. FUNCTIONAL REQUIREMENTS
2.5.1. FUNCTIONALITY
Describe here the main functionalities of the existing system, if there is any.

2.5.2. LANGUAGE
Language requirements for this project:
subject

language

All operator interfaces and reporting


Training
Operator manuals and educational documents
System documentation
Programming (comments etc)
Operating systems and keyboard lay-out
Meetings, communication including email

<language>
<language>
<language>
<language>
<language>
<language>
English

2.6. SYSTEMS & ARCHITECTURAL

REQUIREMENTS

2.6.1. HARDWARE & SYSTEM SOFTWARE


Project specific hardware & system software requirements:
configuration item

brand

type

Remote I/O bus


Instrument bus
Control processor
SCADA software
PC Hardware
Operating Software
Network hardware (switches)
Database engine
MES System

<brand>
<brand>
<brand>
<brand>
<brand>
<brand>
<brand>
<brand>
<brand>

<type>
<type>
<type>
<type>
<type>
<type>
<type>
<type>
<type>

2.6.2. ARCHITECTURE
System and application architecture can be outlined here, if there is any

2.7. DOCUMENTATION
To be updated existing documentation is listed here.
document

deliverable of

General Process Description

Heineken

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3. FIXED SPECIFICATIONS
3.1. STARTING POINTS
3.1.1. REFERENCE DOCUMENTS
The following documents serve as reference for this inquiry and form an inseparable part thereof. These
documents are general references. There is also a set of project specific references. These are listed in
chapter 2.1.1.
no

F1
F2
F3

document

issue

date

Production Automation System Set-up


Brewery set-up according to S88.01
General process requirements

06
04
03

April 2006
May 2005
Jan. 2006

3.2. SCOPE
The scope of works for all process units as described in chapter (variable part) is described in this chapter.

3.2.1. ENGINEERING
Engineering consists out of two major parts: Technical design & prototyping of the system and the
application and the actual engineering of the application.

3.2.1.1 DESIGN & PROTOTYPING


Prerequisites
General Process Description
BEAM description of the prototype application.
Activities
During this phase the design of process control system (System architecture) including the design
of HMI and reporting will be made. This results in a set-up of the Technical Design document. The
exact contents of this document are listed in chapter 3.6.1.
Concurrent to the creation of the Technical Design, a prototype is made.
This prototype is used to validate the decisions taken in the Technical Design.
During prototyping, for all typicals an example shall be worked out in such a way that these
examples can be used as a reference to warrant the quality during engineering. Subjects to be
covered:
o Program structures,
o On- and off-line documentation,
o Conventions,
o Parameter allocation (recipe vs. installation parameters),
o Layouts,
o Communications,
o Reporting.
Deliverables
Technical Design Document
Working prototype

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3.2.1.2 APPLICATION SOFTWARE ENGINEERING


Prerequisites
Approved prototype
Approved Technical Design
All BEAM Descriptions
Activities
After approval of the Technical Design and the prototype, the actual engineering of the application
software commences.
In parallel to the engineering of the application, the training material and operating manuals should
be prepared. This material is also subject of test during the FAT.
During the project running time, Heineken is entitled to check the progress of the engineering and
testing activities at your factory or workshop. This applies to the engineering, the development of
software, drawing activities, production and testing activities as well as to any subcontractors, subsuppliers etc.
To guarantee the quality of the engineered application, the supplier should carry out a pre-FAT (Inhouse testing).
The pre-FAT should be eye witnessed by the equipment supplier (invited by the supplier).
Heineken uses the pre-FAT results for a Go-Nogo decision for the official FAT.
Deliverables
Pre-FAT report
Operating manual
Training material
Application software

3.2.2. FAT
Prerequisites
Approved Pre-FAT Report
FAT Protocol by Heineken (2 weeks before FAT)
FAT planning by supplier (1 week before FAT)
To facilitate the FAT a stand-alone test system shall be configured. The system shall at least
consist of:
o 2 operator workstations per process cell,
o Production information database with at least 1 client,
o Simulation of I/Os and basic functionalitys,
o Separate engineering stations, as much the supplier requires, supporting the testing during
the FAT,
Test data should be prepared for historical data in the system.
All production recipes (including parameters) need to be prepared.
Activities
After engineering of the application software a Factory Acceptance Test (FAT) is executed.
The FAT shall be carried out in compliance with the guidelines as contained in the ISO quality
manuals of Heineken.
The FAT will be executed at the suppliers office.
In case of phased execution of the FAT, per process cell or unit, an integral FAT must be held
concerning all process cells and units as final test (Integral FAT for complete beer production,
including communication with packaging, utilities, skids etc.).
The Heineken electronic tool (HEAT) supports management of remaining items and reporting.
The FAT will be executed against the following documents:
o Pre-FAT report,
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o
o
o

General Process Descriptions (leading),


BEAM documents.
Technical Design Document.

Besides the check on the application software and all procedures, the tests will also comprehend
the following subjects
o System reliability and robustness,
o Backup and restore procedures,
o System performance,
o Data integrity,
o Licensing of system software, inclusive development tools,
o Completeness of documentation of hardware and software components.

Deliverables
List & planning of outstanding items (Resulting from HEAT)
Go No go report, approved by Heineken, supplier and equipment supplier
Release for shipment

3.2.3. SHIPMENT
Prerequisites
The following documents should be available:
o Complete list of all shipped components, mentioning all serial numbers,
o Complete list of all shipped software packages, mentioning all license numbers,
o All manuals and documentation of subjected components and software packages.
If a part of the project has to be shipped earlier to the brewery, the development and test facilities at
the supplier should still be adequate, to facilitate further engineering or FAT for the remaining part
of the project.
Activities
If applicable, the supplier shall make available an experienced engineer to attend the unloading
and positioning of the system equipment if on site.
Deliverables
Signed-off shipment documents

3.2.4. ON-SITE ACTIVITIES


Main part of the on-site activities is commissioning. Commissioning takes place between Erection and
Aftercare, covering the activities for Testing, Start-up and Improvement of the installation. Installation
transfer from Supplier through Heineken to the Operating Unit is formalized by two events: after Testing the
'Operation & Maintenance Handing-over' and after Improvement as acceptance the 'Plant Handing-over'.
All on-site activities shall be carried out in accordance with the guidelines as contained in the ISO quality
manual of Heineken. The phases of the quality manual are listed in the left column of the table below. The
responsibilities of the supplier in these phases are listed in the right column.
Heineken project step

supplier responsibility

Chapter

Erect installation

Set-up system
I/O test & Network validation
Training
Witness and support commissioning
Witness and support commissioning
Witness and support commissioning

3.2.4.1
3.2.4.2
3.2.4.3
3.2.4.4

Test Installation + O&M Handing-over


Start-up installation
Improve installation + SAT
Aftercare

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3.2.4.1 SET-UP SYSTEM
Prerequisites
The brewery will take care of the following preconditions:
Space for the equipment must be available and air-conditioned. The control room must be airconditioned. A telephone connection for internal and external calls is available.
Availability of air supply and electrical power.
Activities
Supply and installation of all required hardware for controlling the process installations of the
process cells described in chapter . (PLC rack will be supplied by OEM) such as:
o CPU
o Ethernet cards (PLC rack mounted) for communication with packaging and UCMS system
installations.
o Network cabling etc. from PLC cabinets to workstations, engineering stations, patch panels
and servers.
Building-in and connecting the system in the control boxes, positioning and connecting the
equipment in the operating room and applying the required voltages to all installed equipment;
Supply and installation of all required hardware for communication with control systems of other
process cells,
Supply and installation of all required development tools (software packages),
Installation and testing of all additional and/or modified communication tasks and database
components.
Deliverables
Connected and working system, ready to start I/O testing

3.2.4.2 I/O TESTS & NETWORK VALIDATION


Prerequisites
The supplier should make a control system available for IO testing including the operator interface
to the field components (this could be before the final shipment off all equipment).
Electrical installation must be finished; all control modules must be cabled and tested.
Activities
Guidance and supervision of a full I/O test, pickling a & passivation of installation and water tests
through well skilled engineers who are familiar with the project and has enough knowledge of the
brewing process (IO test could be a cooperation between equipment supplier and system
integrator),
Validation test of network cabling (In accordance specification manufacturer),
The supplier should report on daily basis the progress of the IO testing to the Heineken lead
engineer.
Deliverables
I/O Test report
Network validation report

3.2.4.3 TRAINING
Prerequisites
The training program will be finalized in co-operation with Heineken.
During the training, an experienced application engineer shall be available.
Operating Manual
Training manual

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Activities
All operators, technologists, technicians and trouble-shooters must be trained before the O&M
handing-over.
The actual training will be executed on a separate stand-alone system, parallel with the
commissioning, at the brewery. This stand-alone system should be included in your quotation.
Deliverables
List of persons, having attended the training;
Evaluation report about the feedback on the training, concerning quality of the training and possible
improvement proposals on the functionalities.

3.2.4.4 WITNESS & SUPPORT COMMISSIONING


Prerequisites
During the commissioning, personnel of the supplier have to comply with the brewery rules. This
concerns subjects as safety, backup procedures, etc,
Automation specialists of the supplier should use their own engineering tools.
During commissioning all the workstations and the engineering station are available for the brewery
staff and Heineken Automation,
The connected engineering tools should not influence the performances of the control system.
The brewery will take care of the following preconditions:
A responsible person of the process is available on-site during the commissioning.
Electrical and mechanical engineers will be available during the commissioning.
Activities
The commissioning of the process automation system will be carried out the supplier in close
concert with Heineken and the operators of the brewery and with the suppliers of the Equipment.
The supplier shall play a supportive role during commissioning, taking care of the following tasks:
o Testing and calibrating of the system prior to putting into operation,
o Implementation of procedures (recipes), unit-procedures, route selector, etc,
o Control loops are an integrated part of the system software. Configuration, tuning and
parameterisations are to be done by the supplier,
o Checking & correcting all generated data,
o Solving of outstanding issues found during commissioning or earlier stages of the project.
Deliverables
Weekly commissioning report
Commissioning report
SAT Report

3.3. ORGANISATION
The quotation shall include the suppliers project plan, which shall at least deal with the following subjects:
Suppliers project organisation:
o Project team organisation chart, mentioning persons involved,
o Ensuring the staffing of the project team,
o Communication and consultative structures, both internal and external,
Quality plan,
Specification for the services and information to be provided by the ordering party,
In the project plan it shall be clearly stated which person(s) is/are the vocal point(s) for:
o Detailed planning and control of the project execution,
o Quality assurance,
o Project management.

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In the negotiation phase, the ordering party shall retain the right to ask for a presentation by the project
team. By the time the final order is granted, consensus about the formation of the project team is required,
this to guarantee sufficient quality and seniority of the team.
If the supplier attaches financial or planning consequences to any changes, these shall not be affected until
after the ordering party has granted written permission for this in the form of an order for extra or less work.
Therefore, any extra or less work that develops shall be detected immediately.

3.3.1. COMMUNICATION
In case of an order the supplier should integrate at least the following deliverables in the project execution.
The costs should be integrated and must be part of the project.
Engineerings kick-off meeting, initialised by the supplier at least one month after order, to finalise the
plan of action for detail engineering.
Site kick-off meeting (approximately one month after order) to allow the supplier to present the principal
the present the project set-up, plans and execution. This meeting also allows the supplier to familiarise
himself with local (site) conditions. It also allows gives the supplier the opportunity to contact local subsuppliers.
Regular meetings between Heineken, supplier and assigned software integrator should be integrated in
the project execution. In principle these meeting will be held in Zoeterwoude, the Netherlands.
The supplier should issue project planning for in-house and external activities. This planning should
show all mayor activities including the planned Pre-FAT and FAT dates at the suppliers shop and/or
sub-suppliers shop.
The supplier should issue a start-up and commissioning planning.
The supplier will play a pro-active role in communication with the equipment supplier.

3.3.2. PLANNING
The quotation shall include an accurate project planning planning for in-house and external activities.
Milestones such as technical design, prototyping, engineering, pre-FAT, FAT, I/O testing, production startup, SAT, etc. shall be incorporated. The overall planning shall be based on the project specific milestones
as stated in chapter 2.4.2.
To enable overall progress control, the supplier shall issue an updated planning on a bi-weekly basis
without Heineken specifically asking for this. If there are reasons to change this planning, then the supplier
shall inform Heineken without delay and present an updated planning, for approval, within 1 week.

3.4. FUNCTIONAL REQUIREMENTS


3.4.1. FUNCTIONALITY
During production of the Technical Design (TD) and during engineering, an optimum between the following
criteria shall be aimed for:
Maintainability,
Quantity of software,
Processor- & memory load,
Minimum communication between processors,
Certain functions being critical in terms of time,
Minimum operator intervention.
This optimum should be aimed for at all system levels, for as well production automation as for information.
On completion of the project, the plant shall comply with the following objectives:
Full manual control of the installations from the workstations shall also be possible,
Manual control will be overruled by safeguarding interlocks,
Process information shall form an integrated part of control and monitoring. This concerns subjects
such as:
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o Batch management
o Quality management
o Recipe management (including version management)
o Parameter management
o Authorisation
o Ensuring progress parameters
The design of both the system and the application shall be such that the performance of the process
plant is not adversely affected.
The design of the application shall be such that optimum use is made of the available degrees of
freedom of the process plants.
The system must offer fully automatic process management, offering the operator a sufficient level of
freedom within automatic operation to settle field activities and breakdowns.
The system has to comply with international standards.
Engineering, programming and set up of the process control system must be in accordance with the
PASS document (reference F1)

3.4.2. ERGONOMICS
The supplier is responsible for the specific ergonomically aspects for the specified region, for example such
as the average figure of the local people.
The supplier has to design in such a way, that operating, maintenance and control points are well
accessible for operators and maintenance people.
The supplier will bare the costs when it turns out that the delivered installation does not comply with these
ergonomic aspects.

3.5. SYSTEMS & ARCHITECTURAL

REQUIREMENTS

3.5.1. ARCHITECTURE
The following general architectural requirements are applicable:
The system shall allow perfect integration other applications or systems,
Applications in a particular control processor can be loaded in other control processor of same or
higher releases, without changing the application,
Horizontal and vertical interfaces among the various system parts shall be standardized,

Communication with third-party computer equipment and / or third party applications shall be possible
with off the shelf communication software,
During project execution the supplier shall only use official registered and/or licensed software. This
also applies for the needed development tools,
The supplier has to guarantee that the components in the architecture, both hard- and software can be
purchased and serviced for a period of at least 10 years.
Both hard- and system software components need to be purchased as late as possible in the project
running time, so as to assure the latest possible versions of software, hardware, firmware etc.

On behalf of future extensions, the system and application should be able to meet the following
characteristics.
general characteristics

requirement

Number of product recipes (product mix)


Number of units
Number of equipment modules
Number of I/Os
Concurrent batches
Concurrent transfers
Concurrent users MES System
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50 200
200 1000
3000 - 10000
50 200
5 50
5 15
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Number of processors
Number of workstations

10 70
5 - 15

The ordering party does not guarantee the completeness or the adequacy of the system equipment as
offered. If it turns out during execution, after acceptance of the order, that other, more powerful elements
are necessary to achieve the agreed performance, then this will be for the suppliers account. Even when
Heineken engineers may propose a system layout, based on local conditions, the supplier will remain
responsible for the performance and capacity of the system. Therefore the supplier is in the position to
make adjustments on the Heineken system layout proposals.

3.5.2. AVAILABILITY
General availability requirements:
After an unexpected power shutdown the system shall be able to perform a reboot without further
technical support and with fully automatic initialisation of the progress parameters. At the same time,
the integrity of the information database shall be safeguarded. Also the particular transport routes
should be re-aligned. The system should reboot to a safe situation. Processes will be restarted after an
operator start.
A fault in any system part shall not lead to a fault of any other system part.
A failure in a process unit shall not result in failures at other process units. However such failures will
be handled in such a way that the particular process unit and the related process units will execute a
controlled process stop.
Communication loss may not lead in loss of data.
Possibility application and system backup / restore without interfering production.
System reliability should at least fulfil the following requirements:
o No unplanned server restarts allowed. (Always available)
o Only client restart caused by external conditions e.g. electricity
o Restart is defined as a normal restart for the PC (no intervention necessary from automation
engineer.)
o Maximum restart time 15 minutes per client
Possibility for incremental backups during operation and partial restore

3.5.3. PERFORMANCE
General performance requirements:
Horizontal extension of the system at all functional levels shall be possible without affecting the
performance of the existing systems and / or applications,
The performance of any network shall be such, that the total system still meets the performance
requirements during peak loads,
The requirements are defined, taking future extensions into account. If the supplier expects problems in
extending the system in further future, the supplier shall indicate this to Heineken.
The next to chapters list specific performance requirements for the MES layer and the control layer.

3.5.3.1 MES LAYER


For the MES System, the following general performance requirements are applicable:
Period for data storage: 3-5 years
The generation and printing of any report will not effect any production operations.
Performance:
o Response time screen changes within 2 seconds;
o Response time standard basic data displays within 3 seconds;
o Response time standard overviews within 10 seconds;
o Response time reports/graphs once per day within 10 seconds;
o Response time reports/graphs once per week within 30 seconds;
o Response time reports/graphs once per month or less within 100 seconds.

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3.5.3.2 CONTROL LAYER
For the control layer, the following general performance requirements are applicable:
Basic control processor cycle average 750 ms with a maximum of 1 second.
It shall be possible to deal with all I/O, inclusive the related interlocks, within the basic control processor
cycle.
Reporting time after generation of an alarm maximum 2 seconds.
Any processor in the system, measured during a period of 1 second, shall never be subjected to a load
of over 80%. The average load, measured during a longer period of time, shall be smaller than 70%.
In case of a processing peak, the processors belonging to the specific part of the process shall have to
carry out all actions within a period of one second.
The change in status of all digital inputs, the generation of the maximum number of alarms and the
occurrence of an alarm value excess for all analog inputs.
Start-up of one or more process parts and/or process phases shall not, at any time, exceed the load as
defined before: this is applicable to both the processors of the process parts concerned and to the
processors for overall use,
The response time of every display shall be such that the production process involved can be
monitored and controlled in an adequate way. Experiences have shown that the response time shall be
less than 2 sec to assure such.

3.6. DOCUMENTATION
All project specific system shall be submitted in twofold and in an electronic form (CD-ROM) suitable for PC
use. All standard system and software documentation shall be submitted in the form it is purchased (either
hardcopy or electronic or both).
The drawings and diagrams shall be made in accordance with the standard drawing system on
AutoCAD/EPlan using the HNACAD context.
Drawing numbers, panel numbers and administrative codes are supplied exclusively by Heineken. The
symbols used shall comply with the Heineken standard (based on HMESC standardisation).

3.6.1. SYSTEM DOCUMENTATION


document

deliverable of

contents

General Process Descriptions

Heineken

BEAM Descriptions

Heineken

Technical Design Document

Supplier

Basic process description,


Recipes,
Batch management,
Information management.
Physical model,
Unit procedures,
Operations,
Phases.
List of definitions,
Graphical overview of the system architecture,
Graphical overview of the application architecture.
Program arrangement on the basis of the functional
arrangement of the process plants in the FS, throughout
the complete system. In fact this means that the program
overview is not restricted to production automation, but is
also applicable for information and communication tasks,
HMI Design,
All front-end typicals, as well for database clients as for
operator workstations,
Print screens of all displays,
Main programs (unit and route procedures),
Selections and route selection,
Database communication (transactions, authorisation

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Supplier
Supplier

etc.),
Communication between Control processors, Units,
Device drivers,
Data Dictionary of the production database,
Detailed summary of all applied hardware,
Detailed summary of all applied software including
version-numbers,
Structure of equipment modules and allocation of the
control modules (per processor),
Parameter lists (recipe and installation parameters),
Control loops, settings and interlocks,
Deviations from Beam specifications,
Operating manual should be suitable for all target groups:
operators, maintenance engineers, supervisors,
technologists, etc.
How to operate the Process Control System:
Auto/manual mode,
Acknowledge alarms,
Maintaining parameters,
etc.
How to deal with exceptions,
How to start/restart recipes,
Recipe management,
etc.
Handouts indicating the most important part of the
operating manual.
Quick reference for trouble shooting,
Directory structure & Contents,
Back-up & restore procedures,
etc.
Comments in software
-

Supplier

Operating manual

Supplier

Training material

Supplier

Maintenance manual

Application software
Documentation package
system hardware
Documentation package
standard software

Documents above should be delivered as built on an agreed date in the milestone planning (to be
indicated by the supplier in the quotation)

3.6.2. PROJECT DOCUMENTATION


document

deliverable of

contents

Pre-Fat report

Supplier

FAT Protocol

Heineken

I/O Test report

Supplier

Weekly commissioning
report

Supplier

Deviation from BEAM specification,


Deviation from reviewed technical design,
Outstanding non-conformities,
Solved non conformities,
GO- No Go FAT recommendation, to Heineken (decision
to carry out the FAT).
Guidelines for FAT,
General planning,
Describing the tests to be executed during the FAT.
I/O test results,
Ranges of instruments,
Validation report network.
Progress of commissioning,
Performance Clients & Servers (memory load, CPU load
etc.),
Network performance (validation),

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Commissioning report

Supplier

Virus detection report (all systems should be checked on


a virus weekly),
Quality of reporting information.
Warranty of tuning and calibrating parameters.
List with interlocks

3.7. GUARANTEE
3.7.1. HARDWARE AND SYSTEM SOFTWARE
The party accepting the order shall guarantee the hardware up to and including 12 months after the last
Site Acceptance Test.
This guarantee shall offer the same services as an all-in service contract. The guarantee shall cover all
hardware components that may have to be replaced. Service personnel shall be on site to remedy any
failures within 4 hours after being called, and shall be available 24 hours a day, including Saturdays,
Sundays and holidays.
Prior to expiry of the guarantee period Heineken will inform whether the system as a whole complies with
the pertaining performance requirements. In case of non-compliance, Heineken will notify the party
accepting the order in writing, making available any relevant test reports. Heineken will then enable the
party accepting the order to make such corrections to the system as are required to ensure compliance.
After that, Heineken shall be allowed 2 months time to assess and accept the modifications.
The party accepting the order shall specify the following:
The period during which the materials to be supplied will remain obtainable;
The expected life span of the materials;
Which of the products offered are strategic;
In what way the products offered will be developed further

3.7.2. APPLICATION SOFTWARE AND SERVICES


The party accepting the order shall guarantee all standard software, customized software, configuration
software and application software up to and including 12 months after the last SAT. Hidden faults that
appear after the last SAT must be solved.
This guarantee shall offer the same services as an all-in service contract. The guarantee shall cover all
necessary software replacements or modifications (including new software released and software updates).
This guarantee shall also include repairs of the software mentioned, either as indicated by the party
accepting the order or by Heineken.
Proper functioning of all combinations of possible software types shall be part of this guarantee. This shall
also include overall system integrity.
The party accepting the order has to address their location responsible for the maintenance and after sales
service. The maximum required time to assure service personnel to be on site, taking in consideration all
necessary requirements such as visa (if required), flights, etc. must be mentioned in your quotation.
The party accepting the order shall guarantee that the software will be supplied absolutely virus-free.

3.8. MAINTENANCE
This chapter states the requirements to service and maintain the system. With respect to maintenance and
service the following points are minimum requirements towards the supplier:
Continuity in knowledge and manpower are guaranteed for support of the software and the tools;
Availability and maintainability of the software; e.g. delivering of programming software/tools and
training of the maintenance technicians concerning the necessary maintenance software/tools is part of
the scope

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Maintenance activities have to be executed within the stated guidelines and against cost-effective price
and quality.

The guidelines of maintenance are described in the next three paragraphs. There are three main kinds of
maintenance:
Corrective maintenance aims at the correction of failures;
Adaptive maintenance aims at the adaptation of the software to changing peripheral conditions;
Functional (perfective) maintenance aims at the functional improvement.

3.8.1. CORRECTIVE MAINTENANCE


The goal of corrective maintenance is to correct software failures immediately, depending on the kind of
failure. A failure could be categorized in one of the three following groups:
Fatal (the continuity of the production process is damaged);
Warning the failure is inconvenient, but not harmful for the continuity of the business process);
Others (not of the category Fatal or Warning ).
If the failure is of fatal nature, the supplier should correct the failure or conduct another intervention (e.g.
temporary solution) within 8 hours after reporting. After the intervention, the failure should be corrected or
meet the indication warning.
If the failure is of the category warning, then the supplier should start to locate and repairing the
deficiencies within 24 hours after reporting. The supplier should strive to find a solution within 2 working
days.
Other failures will be dealt with after consulting the brewery.
A local automation engineer makes the primary qualification of the failures. Exceptions in the time spans
can be made in case of circumstances not under control of the supplier or omission at the side of the
brewery.

3.8.2. ADAPTIVE MAINTENANCE


The goal of adaptive maintenance is to adapt the software to changes in the technical infrastructure in
which the software operates, like new hardware, new operating systems or changes in interfaces with other
systems. With adaptive maintenance no functional changes are realized, though the functionality in the
current version should be retained in the new version.

3.8.3. FUNCTIONAL (PERFECTIVE) MAINTENANCE


The goal of functional (perfective) maintenance is to adapt the software to new requirements from the users
organisation, like new functionality or performance upgrading. In case of functional (perfective)
maintenance the requisite documents (e.g. Project Plan and Functional Design) are made by Heineken.
These activities are subject to the procedures in the Heineken Quality Manual.
For the activities related to adaptive and functional (perfective) maintenance, the supplier has to take care
for the resources. The resources must have a sufficient knowledge level. The adaptations must be joint less
connected to the current applications and have to fit in the existing concept. The releases of new versions
have to be subject to an adequate version management procedure.

3.8.4. TOOLS AND SPARE PARTS


The quotation should optional list all tools and spare parts, for software and hardware as specified in the
quotation, to assure adequate maintenance and minimize down time in case the previous mentioned
maintenance is required. The tools and spare parts should be sufficient for a period of at least 2 years.

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4. QUOTATION
4.1. GENERAL
The below mentioned items should be described in the quotation:
Terms of reference
Scope of the project
o Deliverables;
o Software & development tools;
o Specification hardware;
Process control system & Process Information System
o Human Machine Interface & operating philosophy;
o Process Control System architecture
o Process Control Hardware architecture
o Specification of workstations, engineering stations and servers.
o Architecture of UPS system
o Interface with other installations
Project execution
o Project organisation
o Quality assurances
o Schedule of deliverables
o Project documentation
o Training schedule per type (duration)
o Training manuals per type
After care & maintenance
o Maintenance contract
o Remote support
o Spare parts
Price specifications see chapter 4.2 Price specification

4.2. PRICE SPECIFICATION


4.2.1. PROJECT COST
item

Price (Euro)

System hardware
System software including all required licences
Licenses of development tools
Project management.
Engineering
Technical design;
Application software control system
Application configuration control system
FAT
Commissioning / on-site assistance
SAT
Training
Transport cost free brewery
Documentation.
Total order amount

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4.2.2. MAINTENANCE COST


item

Price (Euro)

Cost of maintenance contract per year, hardware and


software
Tools and equipment required for maintenance
Spare parts required for maintenance
Rates for on call duty

4.2.3. RATES
item

Price (Euro)

Rates for project management


Rates for training
Trainer per day (on site) incl. expenses
Rates Engineering in-house
Rates Engineering on-site
Overtime rates

4.2.4. OPTIONAL
item

Price (Euro)

Training system incl. all required licences and engineering


Extra workstations incl. all required licences and engineering

4.3. ALTERNATIVES
During the tender phase of the project the supplier has the freedom to propose alternatives, as option, that
have a major influence on the lead-time of the project and / or the cost of the project

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