5.15 Concept of Energy Measurement -...

INTERNAL TECHNICAL STANDARD

5.15 Concept of Energy MeasurementAmended: 2017-08-09

Ref. no. 3276 Sheet 1/26

Prepared by Guaranteed by Approved by Sheets AnnexesJaček PPU/3Hošek, ŠE-ES

PSZ/1 PS 33 1

This Internal Technical Standard (hereinafter as ITS) Concept of Energy Measurement is valid for all ŠKODA AUTO plants.

Contents1. Introduction ............................................................................................................................................................................................................ 4

1.1. Regulations and Rules ..................................................................................................................................................................................................... 41.2. List of Abbreviations and Nomenclature ................................................................................................................................................................. 5

2. General Requirements ........................................................................................................................................................................................ 62.1. Responsibility of Supplier ............................................................................................................................................................................................... 62.2. Start of Installation............................................................................................................................................................................................................ 62.3. Supplier Obligations .......................................................................................................................................................................................................... 62.4. Operational Resources and Operation Thereof ................................................................................................................................................... 62.5. Technical Meeting.............................................................................................................................................................................................................. 62.6. Extension/Change of the Device ................................................................................................................................................................................ 62.7. Documentation of the Real Execution ..................................................................................................................................................................... 72.8. Certification, Approval, Quality Management ........................................................................................................................................................ 7

3. Measuring Consumption of Energies, MaRSE Systems, and Layers ...................................................................................................... 83.1. Basic MaRSE TZB at ŠKODA AUTO a. s Layout Diagram ................................................................................................................................... 83.2. List of Layers and Matching Technology/Peripherals ........................................................................................................................................ 8

1.1.1. Device Layer ................................................................................................................................................................................................................... 91.1.2. Controller Layer............................................................................................................................................................................................................. 91.1.3. Communication Layer ................................................................................................................................................................................................ 91.1.4. Server Layer .................................................................................................................................................................................................................... 91.1.5. Client Layer ..................................................................................................................................................................................................................... 9

1.2. Measuring and Regulating Systems – Basic Classification .............................................................................................................................. 91.2.1. Monitoring and Controlling Energetic Devices ............................................................................................................................................... 91.2.2. Power Consumption Measurement – System Superstructure .............................................................................................................. 10

2. Measurement of Basic Physical Quantities – Device Layer .................................................................................................................... 112.1. Technical Design of Measuring Points ................................................................................................................................................................... 112.1.1. Pipe Sets for Measuring Instruments and Filters, PHS Standard. No: 1009 ........................................................................................... 112.1.2. Register of the Energetic Data of Objects, Organizational Units, Devices and Machines (Standard PHS. No:1009) ........... 112.2. Measuring Consumption of Individual Energies and Media – Exact Design .......................................................................................... 12

2.2.1. Heat Energy .................................................................................................................................................................................................................. 122.2.2. Gasses and Air (Natural Gas, Technical Gasses, Pressurized Air) .......................................................................................................... 122.2.3. Water (drinking, industrial, DEMI) ........................................................................................................................................................................ 132.2.4. Cooling water............................................................................................................................................................................................................... 132.2.5. Oiled Waters ................................................................................................................................................................................................................. 142.2.6. Measuring Electrical Energy .................................................................................................................................................................................. 14

2.3. Pressure Measurement ................................................................................................................................................................................................. 162.3.1. Manufacturers – Recommendation ................................................................................................................................................................... 162.3.2. Measuring Differential Pressures ....................................................................................................................................................................... 162.3.3. Temperature Measurement .................................................................................................................................................................................. 16

3. Specifications of Individual Subsystems – Substations, Communication, Visualization............................................................... 183.1. Measuring Energies – Mladá Boleslav Production Plant ................................................................................................................................ 18

3.1.1. Information measurement system Control Web ......................................................................................................................................... 183.1.2. Information Measurement System EMI (Air-Conditioning Units) .......................................................................................................... 20Distribution System Protection System (microSCADA MB) ........................................................................................................................................ 21

3.2. Measuring Energies – Kvasiny Production Plant ................................................................................................................................................ 21




3.2.1. Information measurement system RC Ware ................................................................................................................................................. 213.3. Measuring and Controlling – Vrchlabí Production Plant ................................................................................................................................. 22

3.3.1. VRCHLABÍ – Energetics Information and Controlling System – Johnson Controls........................................................................ 223.4. Direct Energy Measuring – ENERGIS ....................................................................................................................................................................... 24

3.4.1. Direct Energy Measuring Using the Energis System .................................................................................................................................. 244. Basic Installation Conditions ........................................................................................................................................................................... 26

4.1. Electric Distributor Hardware ..................................................................................................................................................................................... 264.2. PLC Installation Principles Including Viewpoint of Electric Safety ............................................................................................................. 26

4.2.1. Manufacturers – Recommendation ................................................................................................................................................................... 264.2.2. Power supply leads: .................................................................................................................................................................................................. 264.2.3. Binary Inputs: ............................................................................................................................................................................................................... 274.2.4. Binary Outputs: ........................................................................................................................................................................................................... 274.2.5. Analogue Inputs and Outputs: ............................................................................................................................................................................. 27

4.3. Cabling .................................................................................................................................................................................................................................. 274.4. Rules for Connecting to the ŠKODA AUTO, a.s. Network ............................................................................................................................... 27

4.4.1. Connecting Devices to a ŠKODA AUTO, a.s. Network ................................................................................................................................ 285. Change Management and Change Request................................................................................................................................................ 28

5.1. Technical Meeting............................................................................................................................................................................................................ 285.2. Table of Data Points ....................................................................................................................................................................................................... 285.3. Creation of Project Documentation ......................................................................................................................................................................... 285.4. Going Live and Hand-Over of the Technological Device (including Controlling Technology HW) ................................................ 285.5. Controlling Programs (Systems) – Creation and Going Live .......................................................................................................................... 295.6. Visualization Systems – Creation and Going Live .............................................................................................................................................. 295.7. Generating Documentation ......................................................................................................................................................................................... 295.8. Result of Every Change – Hand-Over of the Control System, Visualization System, and Hand-Over Protocols .................. 295.9. Addendum ........................................................................................................................................................................................................................... 29

6. Metrology .............................................................................................................................................................................................................. 307. Documentation Extent ...................................................................................................................................................................................... 30

7.1. Documentation for Carrying out the Construction – Minimal Requirements: ....................................................................................... 307.2. Documentation of the Real Execution – Minimal Requirements: .............................................................................................................. 30

8. List of Figures ...................................................................................................................................................................................................... 319. List of Tables ........................................................................................................................................................................................................ 31




The latest updated version of this ITS is available at the “http://cts.skoda-auto.com/” web site, the company is not obligedto notify their business partners on the ITS update. Therefore we strongly recommend that everybody checks the ITS regularly.These documents become valid on the date of their last update. For the contracts signed is decisive the validity of the ITS atthe time of the order.

Note: In case of any differences between the Czech, English or German language mutation of this ITS, the Czech versiontakes precedence.

First issue: 2017-08-09

Change -number:

Date: Comment:

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1. IntroductionThis Internal Technical Standard (hereinafter as ITS) concerns the conceptual processing and method of measuring

mediums and energies in production plants of ŠKODA AUTO, a. s. The concept of measuring energy consumption within theEnergis system is submitted by the planning department PP. The following approval by the solution in question is up to thePS department in cooperation with the ŠE. The solution submitted has to include the project documentation (specificationof measuring tools, connection to the data collection system, etc.) The ŠE Energetics department then handles theaccounting of consumption bills distribution (measuring the energies at the building entrances – balance level). This ITSdescribes all systems (monitoring and regulating) used with energetic devices (non-technological), defines the technicalmethod of execution of individual measuring points, and defines technical conditions for supplies, installations, andcommencing of operation of all monitoring and regulating devices.

Deviation from the content of this ITS has to be justified and approved in writing by a specialized department of ŠKO-ENERGO (hereinafter as ŠE-ES).

Using materials containing carcinogenic compounds, materials with painted surface, and containing silicone (materialscreating craters). It is possible to carry out a test of the material if necessary (department of processes, PPF-L/1). TheSupplier is obligated to submit a certificate on quality and grade of the product.

1.1. Regulations and RulesThe key principle for the area of conceptual energy measuring is for the Supplier to adhere to the ČSN, EN, ISO standardsand also the following regulations and standards valid on the date of signing the contract:

· ITS ŠKODA AUTO a.s., http://cts.skoda-auto.com/For electric machinery and equipment mainly:- ITS 1.01 General technical conditions;- ITS 1.05 Information systems a technologies;- ITS 1.09 Shut-off valves, shutting off devices;- ITS 5.11 Electric assembly and installation;- ITS 5.13 Control technology.

· Requirements and more detailed specifications for the construction of the device in the for of technicalrequirement issued for the specific part of production or a project.

· Assessment and minimizing of risks in accordance with ČSN EN ISO 12100 and documents created on the topic areincluded in the scope of delivery of a machine.

· It is mandatory to adhere to the regulations in the sense of ČSN EN 60204-1 ed.2 and ČSN 33 2000-X-XX valid forequipment of electronic machines, machinery and tools which are not manually transportable during operation,are powered from electric sources with nominal voltage between (phase) conductors up to 1,000 V~ and 1,500=.

· Under the provision of the ČSN EN 60204-1 ed.2 the Supplier has to ensure mainly the following:- Safety of persons and property;- Trouble-free production;- Life and economy during operation;- Easy maintenance.

· All devices for measuring and regulating systems of electronic (hereinafter as MaRSE) are carried out inaccordance with the valid rules of technology and Occupational Safety regulations. When installing the MaRSEcomponents, it is mandatory to adhere to and follow the instructions and recommendations of manufacturers.

· This ITS has to be in a full accordance with the methodical guideline MP.1.918 Concept of Energy Measuring andthe organization standard ON.1.018 The Metrology Code.

The technical standards and related regulations as amended:

· ČSN EN 61297 - Industrial Processes Management Systems – Classification of Adaptive Control Units forAssessment Purposes

· ČSN EN 61298-2 ed. 2 - Process measurement and control devices – General methods and procedures for evaluatingperformance – Part 2: Tests under reference conditions

· ČSN EN 61298-3 ed. 2 - Process measurement and control devices – General methods and procedures for evaluatingperformance – Part 3: Tests for effects of influence quantities

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· EU Declaration of conformity, including the CE marking under the provision of Act no. 22/1997 Coll., as amended by Actno. 91/2016 Coll.

· Directive EC 2014/30/EU on technical requirements on products from the point of view of their electromagneticcompatibility.

· Directive EC 2014/35/EU setting the technical requirements for low-voltage electric equipment.

Fulfilling of all valid electrotechnical, fire, and safety standards is mandatory!

1.2. List of Abbreviations and NomenclatureEBI - Enterprise Buildings Integrator - System for integration of buildings, objects, and their systemsIED - Intelligent Electronic Device - Intelligent electronic devicePHD - Process History Database - Database created by the EBI serverMaRSE - - Measuring and regulating systems for energeticsŠA - - Škoda Auto a.s.ŠE - - ŠKO-ENERGO, s.r.o.ŠE-ES - - ŠKO-ENERGO, s.r.o. – Energetic services and managementPLC - Programmable Logic Controller - Programmable logic automat




2. General Requirements

2.1. Responsibility of SupplierThe Supplier is responsible for the correct function of a machine/device supplied. The Supplier has to meet all valid EU

directives, laws, government decrees, regulations, and technical standards valid in the country where the installation isperformed for the machine/device in question.

2.2. Start of InstallationThe Supplier has to submit in a good time after receiving the order before commencing the installation activities at the

site of installation of the ordering party relevant documents defined in the requirement or in the agreed-upon extent, suchas installation layout, realization plans, installation plans, schedules, and personnel deployment schedules. In case of anequipment change, it is necessary to resubmit the changed documents for a new approval in writing by the ŠE-ES/2department.

Changes on the part of the Supplier from the offer to the final solution are not subject to increase of unit prices. TheSupplier will attach to the MaRSE offer a list of technical connection values. The technical documents submitted have toinclude the version of the device, function schemes with description, cable lines, necessary technical data, and schedulewith defined installation progress, test operation, and hand-over.

2.3. Supplier ObligationsThe Supplier is obligated to inform themselves on standards, local regulations, and decrees valid for the production

device in question. When extending or changing the existing systems, the Supplier is obligated to abide by theregulations valid for the given type of the system and is responsible for its overall function. During the warranty periodthe customer service of the Supplier has to be available for maintenance. The service period has to be a part of the offer asa binding commitment for a period of time. In case of a problem in adhering to the technical requirements and abidingby the local custom it is the responsibility of the Supplier to inform the specialized department ŠE-ES/2 without anyundue delay, and propose and consult a solution and get it approved.

The documents supplied by specialized departments to the Supplier cannot be without approval of the Contractingparty copied or made available to a third party or otherwise evaluated. ŠKODA AUTO a.s. will receive free of charge,exclusive, irrevocable, unlimited by space and time, sub-licenced user rights to the results of the work the Supplier willcarry out based on this order for the ŠKODA AUTO a.s. company.

The Supplier is obligated to offer preferentially in the project documentation recommended components listed in thisITS or its Annexes. Other components or non-standard components may be used solely pending approval of the ŠE-ES inwriting.

2.4. Operational Resources and Operation ThereofAll operational resources may be operated only within the limit values defined by the manufacturer and the nominal

element values must not be exceeded continuously. This applies to the limit values for voltage, current, temperature, crashprotectors, vibrations, oil mist, liquid fumes, and other physical quantities.

No materials damaging the environment or health may be used (such as FC-hydrocarbons, asbestos, etc.) No silicone- orTeflon-based materials may be used on production devices. Teflon-based products may be used only with an approval ofŠKODA AUTO a.s.

2.5. Technical MeetingAfter the requirements were sent and the mechanical concept has been submitted, a detailed technical meeting

between the Supplier and the appropriate specialized department of the ŠE-ES/2 has to take place before the constructionis commenced. The Supplier is fully responsible for the overall concept of the measuring proposal, including all relatedareas (emergency stops, protective grids, start-up circuits, etc.). The Supplier is fully responsible for carrying out thecomplete concept, its installation and functionality according to the valid legislation.

2.6. Extension/Change of the DeviceIn case of an extension or change of an existing machinery the Supplier is responsible for the overall functionality of the

devices that will be (are) impacted by the extension or change. When redesigning existing devices/machines, all the now




unneeded components have to be uninstalled and the documentation has to be changed accordingly. The extent of thechanges of the existing machinery and its character will be evaluated by the specialized department ŠE-ES/2. In case theadjustments proposed have the character of reconstruction or a new addition of machinery and incomplete machinery forthe existing machinery, the manufacturer or their authorized representative will before launching the machinery intooperation draw up an ES Declaration of conformity in accordance with the Directive of the European Parliament andCouncil 2006/42/EC (corresponding with the Government Decree no. 176/2008 Coll.) in accordance with the Annex II Part 1Section A, and will ensure that this Declaration is added to the machinery. The acceptance by a competent specializeddepartment of ŠKODA AUTO a.s. or ŠE-ES/3 is fundamentally mandatory (the acceptance has to be carried out inaccordance with the ITS 1.01.).

2.7. Documentation of the Real Execution Latest at the moment of acceptance the MaR Supplier will submit the technical documentation mirroring the real situationin the agreed-upon volume and manner (hard copy or electronic copy). The documentation has to include:

· as-made drawings with precise layout of position of measuring devices, regulation elements, cabling, and sensorswith their markings;

· wiring diagrams with function description;· controlling system description;· complete annotated source codes of individual PLCs (regulators) in accordance with systems and reasons for

implementation – these source codes have to be adjustable at will in the future (untranslated/uncompiled sourcecode for controlling the regulator functionality);

· visualisation description;· filled-out Table of Data Points (hereinafter as TDB) saved to the SQL server;· operation instructions for operators and maintenance;· list of parts used and list of consumable parts, and the recommended intervals of their changes;· (if anticipated)· documents on training the operators;· appropriate inspections;· Certificate of Conformity (see point 2.4)

2.8. Certification, Approval, Quality Management All products and devices subject to mandatory approval and certification in the sense of the Act no. 22/97 Coll. with relateddecrees have to be equipped with the appropriate approval and certification documents in the sense of these acts anddecrees.No installation of such products and appliances on the territory of the plant is possible without these documents. In case the contracting party discovers installed products and devices without appropriate certification documents, allexpenses related to their removal and installation of new products and devices (approved and certified) have to be fullycovered by the contractor of the activities, including damages incurred. Only approval and certification documents acknowledged by the contracting party are those created by accreditedlaboratories (organizations).




3. Measuring Consumption of Energies, MaRSE Systems, and Layers

3.1. Basic MaRSE TZB at ŠKODA AUTO a. s Layout DiagramEnergy consumption measuring has to be installed at the entrance of every object. Data are forwarded to the Energis

system either directly or through energetics information systems (see further chapters).

Figure 1: MaRSE TZB system at Škoda Auto a.s.

3.2. List of Layers and Matching Technology/PeripheralsMeasuring and regulating systems can be divided into five layers with data communication running reciprocally betweenthem.

MaR MB VZT MB microSCADA MB Vrchlabí Kvasiny

V Clientlayer

ClientControlWeb

ClientEBI

ClientmicroSCADA Pro

ClientMetasys

ClientRCWare

↕IV Server

layerControlWeb EBI microSCADA Pro Metasys RC Ware




↕III Communication

layerPCD2,PCD3

BNA Pro SYS 600C NCM 4510-2 PCD2, PCD3,SAUTER

↕II Layer

of controllersPCD2,PCD3

EAGLE IED DX-9200 PCD2, PCD3,SAUTER

↕I Device

layerThermometers, manometers, flowmeters, calorimeters, electricity meters, …Sensors of position, surface, moisture, Ph, conductivity, …

Table 1: List of Layers and Matching Technology/Peripherals

1.1.1. Device Layer

This layer is common for all the mentioned systems and is described in chapters 7 and 8.

1.1.2. Controller Layer

In this layer is performed data collection from individual connected peripherals to the controller (PLC). The datacollection is performed by analogue or digital manner (according to the chosen input/output and exact purpose of use).Description of this layer is included within the individual systems below.

1.1.3. Communication Layer

The communication elements of this layer differ according to the system that has to be used. In case of MaR at MBthe PLC controller PCD2 is used as a gateway. In case of use of the MB VZT system, the network BNA adaptor is used,and in case of use of energetic system at the Vrchlabí plant premises, the networks control module NCM 4510-2 is used.All communication elements have to have a user name and an IP address assigned. Description of this layer is includedwithin the individual systems below. Rules for connecting to the ŠKODA AUTO, a.s. network are stated in the chapter2.5.

1.1.4. Server Layer

The servers created communicate with the PLC controllers using the ethernet network and provide data to clientsand the superstructural Energis system.

1.1.5. Client Layer

The client layer is used for visualisation and control of energetic devices. We prefer fully-fledged clients forcontrolling visualisation (control). For informative visualization is sufficient a web-based interface.

1.2. Measuring and Regulating Systems – Basic Classification

1.2.1. Monitoring and Controlling Energetic Devices

For monitoring and controlling (visualization) of energetic devices are used the following systems:

PLANT Mladá Boleslav Kvasiny Vrchlabí

Sub-switchboard Honeywell (VZT)SAIA (MaR MB)IED (switchrooms VN)

SAIA, SAUTER J&CSAIA




SW visualization EBI Honeywell (AC)microSCADA (switchroomsVN)ControlWeb (MaR MB)

RC WARE (MaR KV) Metasys J&CEnergomat

Higher system for data visualization Energis Energis Energis

Table 2: Measuring and Regulating Systems

In case of construction of a new energetic device, it has to be incorporated into the existing monitoring andcontrolling systems.

EBI Honeywell – visualization of the air-conditioning units at the Mladá Boleslav plant- All AC units with output higher than 10,000 m3/hr have to be visualized in this environment.- Smaller units have to be equipped at least with the contacts for the performance and defect of the AC unit;

their connection is up to consideration of a ŠKO-ENERGO specialized department.

microScada – switch room controlling and monitoring system (SCMS) at the Mladá Boleslav plant- All IED units (intelligent electronic devices) reserved for preservation, controll, monitoring, and measuring

individual outputs have to be included in the microSCADA system.

Control WEB – system for controlling and monitoring of energetic devices (with the exception of the two above-mentioned types) at the Mladá Boleslav plant- The system is intended for monitoring and regulating of energetic devices such as heating machine room,

compressor stations, cooling stations, pumping stations, neutralization stations, piping, boiler houses, etc.

RC WARE – system for controlling and monitoring of energetic devices at the Kvasiny plant

Metasys J&C – system for controlling and monitoring of energetic devices at the Vrchlabí plant.

1.2.2. Power Consumption Measurement – System Superstructure

The Energis system is a superstructure system functioning mainly in the area of data concentration, reviews,archiving selected data, and creating materials for invoicing.




2. Measurement of Basic Physical Quantities – Device Layer

2.1. Technical Design of Measuring PointsGeneral requirements as per ITS 1.14. For all measuring instruments have to be submitted the setting protocols (of constant,extensions, possible data addresses, etc.).

2.1.1. Pipe Sets for Measuring Instruments and Filters, PHS Standard. No: 1009On all pipe entry into the object create a set of filter and measuring instruments for flow, temperature and pressure.

The measuring instruments have to be provided including a calibration protocol, have to be readable on site and alsohave to have the data transfer to the ŠKODA AUTO, a. s. measurement system. The measuring instruments and filters(pressurized air, water – drinking, industrial, cooling, oiled, DEMI) have to be equipped with bypasses that will providecontinuous delivery of the medium to the object in case of measuring instrument defect, filter clogging, or replacementof the filter cartridge.

2.1.2. Register of the Energetic Data of Objects, Organizational Units, Devices and Machines (Standard PHS.No:1009)

Unambiguous assignment and transparency of energy consumption at the objects of organizational units or ondevices and machinery by installing stable measuring devices or creating access measuring points. This will allowcollection and documentation of data on consumption, identification, and evaluation of potential economy of energies.Requirements: Installation of stable measuring devices or access measuring points based on the type of energy andinput in accordance with the Tables no. 1 and 2. Realization on new devices or during exchange and restructuringmeasures.

Stable measuring points should allow safe placement of permanent measurement with no restriction of runningoperation.

Stable Measuring PointsStable measuring points allow safe placement of permanent measurement with no restriction of operation of therunning device.

Access Measuring PointsAccess measuring points have to allow safe placement of temporary measurement with no restriction of operation,without any necessary changes (rebuilding) to the distribution system during media measurement.

Type of energy Stable measurementInstalled/nominal input Usual connection size

Electricity 100 kW ---Heat 500 kW DN 50Cooled water 400 kW DN 80Cooling water 100 m3/h DN 125Natural gas All consumptions ---Pressurized air 12 bar 500 Nm3/h DN 50Pressurized air 12 bar 300 Nm3/h DN 32

Table 3: Stable measurement

Type of energy Access measuring pointInstalled/nominal input Usual connection size

Electricity 30 kW ---Heat 50 kW DN 15Cooled water 100 kW DN 50




Cooling water 14 m3/h DN 50Pressurized air 12 bar 100 Nm3/h DN 20Pressurized air 12 bar 100 Nm3/h DN 15

Table 4: Access Measuring Point

2.2. Measuring Consumption of Individual Energies and Media – Exact DesignEnergies measured:· Heat energy (kWh),· Natural gas (Nm3), Technical gas (Nm3), Pressurized air 6 and 12 bar (Nm3),· Drinking water (m3), Industrial water (m3), Demiwater (m3), Cooling water (m3),· Electricity (kWh).

2.2.1. Heat Energy

Measuring of heat or coldness consumption is standardly done at the controlling substations. Upon proposal takeinto consideration the extension of operation of the flowmeter to ensure proper measurements in the working pointsdefined. In the machinery part it is necessary to ensure installation of killing sections in accordance with therequirements of the manufacturer of the flowmeter.

If installation of calorimeter is required (use only in case of measurement for invoicing of external customers), thesignals from the temperature sensor and flowmeter are directed into the calorimeter (always consult the ŠKO Energo).Consumption transfer signal is then, together with the momentary flow signal, transferred into the controlling substationusing a communication line (e.g. RS485, M-Bus).

Technical Design of the Measuring PointThe heat energy is measured by the combined measurements of flow and temperature of the intake and

return contours of the hot (cooling) water (for the calculation two paired temperature sensors have to be installed,one each on the intake and on the return). The flowmeter installed has to be dimensioned for the parameters of themedium measured (DN, PN, Q, t), induction or ultrasound type. The flowmeter is installed in the intake branch of thehot water pipe. The flowmeter will be equipped with a display. Shall the flowmeter be installed at an inaccessiblesite, a separate display should be used. The heat energy is calculated by the mathematical element of the set (suchas Inmat). In case of invoicing measuring instruments the minimum killing sections have to be installed before andafter the flowmeter always in accordance with the specification and recommendation of the manufacturer; insuch cases the Technical Sheets of the products have to be submitted (induction flowmeter min 5D and 3D,ultrasound flowmeter 10D and 5D). For acceptable accuracy the minimum speed of the flow have to be maintained,0.25 m/s for an induction flowmeter and 0.5 m/s for an ultrasound flowmeter, and the maximum speed of 4 m/s.Reductions are used to ensure the optimum flow speed of the hot water.- Analog flowmeter output has the value of 4-20 mA (momentary flow), impulse output (total flow), set up for

maximum frequency of 3 Hz;- The flowmeter has to be separated on both ends by shut-off fittings;- The measuring instrument has to be equipped with a bypass for easy dismantling.

Manufacturers – RecommendationKROHNE, ZPA, SIEMENS, KAMSTRUP, COMACAL, E+H

2.2.2. Gasses and Air (Natural Gas, Technical Gasses, Pressurized Air)

Measurement the gas consumption is done by combined measurement installing temperature sensors (with 4-20mA output, equipped with a display), as well as pressure and flow sensors in the pipe of the medium measured. Thesensor parameters are defined by properties of the medium measured. The flow is measured by a quantometer(equipped with a display) with the 4-20mA output signal (momentary flow) and a pulse signal (total flow) with themaximum frequency of 3 Hz. Shall the flowmeter be installed at an inaccessible site, a separate display should be used. Inthe machinery part it is necessary to ensure installation of killing sections in accordance with the requirements of the




manufacturer of the flowmeter. When the MaR components are used for a natural gas pipeline, it is mandatory that theyare in the Ex design for the appropriate zone as per the technology specification! When appropriate, it is possible to usethe communication interface RS485 or M-Bus.

Technical Design of the Measuring PointThe flow is measured by a quantometer with an impulse output with a maximum frequency of 3 Hz. To

capture the impurities a filter of 5m m class of accurateness or better is installed before the gas meter. In case ofinvoicing measurements the minimum killing sections have to be installed before and after, always in accordancewith the specification and recommendation of the manufacturer; in such cases the Technical Sheets of theproducts have to be submitted. In case of two and more inputs into one joint distribution system of the object areverse flap is installed before the gas meter.- The gas meter has to be separated by shut-off fixtures on both sides and equipped with a bypass for easy

dismantling.- It is recommended to dismantle the device from the pipeline once a year when replacing the filter and visually

check the condition of the turbine.

Manufacturers – RecommendationELSTER, TESTO, E+H, Krohne, Siemens

2.2.3. Water (drinking, industrial, DEMI)

Measurement of water consumption is done using the water meters with pulse output (standard measurement 1impulse/1m3 – possible constant 10, 100 or 1,000 l/impulse), or possibly RS485 or M-Bus. On the drinking water intake atemperature sensor will be installed with the 4-20 mA output and a display. The digital and analogue signal is transferredto the controlling substation where the temperature and consumption values are recorded.

Technical Design of the Measuring PointAn impurity filter is installed before the water meter. In case of invoicing measurements the minimum killing

sections have to be installed, always in accordance with the specification and recommendation of themanufacturer; in such cases the Technical Sheets of the products have to be submitted. In case of two andmore inputs into one joint distribution system of the object a reverse flap is installed before the water meter. Themeasuring contour has to be separated by a shut-off valves (flaps) and the measuring instrument has to beequipped with a bypass for easy dismantling. The turbine water meters are equipped by an impulse transmitter withthe constant of 1 impulse per 10, 100 or 1,000 litres. The water meter constant should be chosen in such a way thatthe frequency of pulses would not exceed 3 Hz limit with maximum flow. With big dimensions (above DN100) forindustrial and demineralized water consider use of induction or possible ultrasound flowmeters.

Usable Types of Measuring Instruments- Joint water meters – for consumption with big maximum-minimum ration (such as lavatories, objects with fire

hydrants, etc.)- Single water meters of the MeiStream type (SENSUS) for technological consumption with more-or-less

constant flow- Water meters of the 420 SENSUS type for objects with low water consumption

Manufacturers – RecommendationSPANNER POLLUX – PREMEX, SENSUS, ITRON, KROHNE, Prema - Meinecke,

2.2.4. Cooling water

The cooling energy is measured by the combined measurement of the flow and temperatures of the intake andreturn heated branches of the cooling water.

Technical Design of the Measuring Point




In the intake branch of the cooling water is installed an induction or possibly ultrasound flowmeter, In caseof invoicing measuring instruments the minimum killing sections have to be installed before and after theflowmeter always in accordance with the specification and recommendation of the manufacturer; in such casesthe Technical Sheets of the products have to be submitted (induction flowmeter min 5D and 3D, ultrasoundflowmeter 10D and 5D). The minimum speed of the flow have to be maintained, 0.25 m/s for an induction flowmeterand 0.5 m/s for an ultrasound flowmeter, and the maximum speed of 4 m/s. Reductions are used to ensure theoptimum flow speed of the cooling water. Analog flowmeter output has the value of 4-20 mA, set up the impulseoutput for maximum frequency of 3 Hz. The gas meter has to be separated by shut-off fixtures (shut-off valvesBoax) on both sides and equipped with a bypass for easy dismantling.

Manufacturers – RecommendationKROHNE, Siemens, E+H other pending the approval of the responsible ŠKO-Energo employee in writing

2.2.5. Oiled Waters

The pumping station is always realized according to the project, but in principle it should have a cistern (or cisterns)with a mixer and two (or more) of pumps (100% redundancy with an automated trigger).

Technical Design of the Measuring PointThe surface level is registered by an ultrasound sensor (output 4-20 mA, power outage warning). Reaching

the operational maximum first triggers the mixer (or mixers) in the cistern and after ca 15 minutes the lifting pumpstarts operating. Recommended type of the sensor: OPTIFLEX. When the surface lowers to the “blocking mixers”level, the mixer stops. The decrease to the operational minimum switches off the pump. The emergency max. leveltriggers the pump immediately, as well as an optical and acoustic signalization. The maximum blocking level willshut down the pump (even when switched to manual control) as well as an optical and acoustic signalization. Shallthe level rise above the “blocking mixers” level, the mixers start running in accordance with the timetable eventhough the lifting pump is not operating at the moment. Trigger to pump (before reaching the operationalmaximum) can be sent from the control system of the sewage treatment plant Z25. The amount of water pumpedto the sewage treatment plant Z25 is measured using an induction flowmeter.

Manufacturers – RecommendationPROBE, KROHNE – such as Krohne UFM 3400.

2.2.6. Measuring Electrical Energy

The electrometers have to be equipped with an RS485, M-Bus or Ethernet interface. In case of serial communicationit is necessary to take into consideration installing a converter, such as RS485/Ethernet. Use of individual electrometers(e.g. electronic) has to be consulted with the ŠE.

Direct MeasuringDirect measuring can be used up to the current value of 100 A. The electrometers are connected directly to

the distribution line with a ballast fuse with the same current value as the electrometer.

Indirect MeasuringIndirect measuring can be used from the current value of 63 A. The electrometers are connected using

measuring current transformers (MTP) with the ratio of x/5A. The measuring current transformers can be installed inthe construction design as a slide-on or integrated in the devices (fuses, load-break switches). The secondaryoutlets always have to be equipped with a short-circuit terminal box to prevent injury by electric current generatedby the high voltage upon disconnection of the electrometer. The voltage entrance is secured by a load-breakswitch.

To measure the electric energy consumption in networks with joint voltage higher than 400V, it is necessary touse on the voltage entrances measuring voltage transformers MTN with the transformer ratio on the secondaryside of 400 V.

The electrometer constant is defined by the ratio of current and voltage transformers as per the formula




= ∗. /

U - transformer ratio of the voltage transformer

I - transformer ratio of the vibrator

! In case a current or voltage transformer is not used the value equals 1!

Recommended parameters of measuring devices

Class 1 (kWh) in accordance with the ČSN EN 62053-21 standardClass B (kWh) in accordance with the ČSN EN 50470-3 standardClass 2 (kVA) in accordance with the ČSN EN 62053-23 standardAccuracy 0.5-2%In case of use as an invoicing measuring instrument the measuring device has to be MID-certified

Measuring on the VN Side

Measurement of the electric energy consumption in the VN main is done using electrometers with the transferto the Ethernet network connected directly or, in case of higher quantity, using a converter. The electrometers areconnected through appropriate measuring transformers of both voltage and current.

For monitoring, controlling, and automatization of the VN switching stations at the Mladá Boleslav plant, theABB MicroSCADA PRO system is installed with an internal Ethernet communication without connection to the ŠkodaAuto a.s. network. The individual REF 6xx ABB terminals are connected to the closed system using communications.All interventions and extensions of the systems have to be consulted with the network administrator (ŠKO Energo).

Measuring on the NN SideMeasurement of the electric energy consumption on the NN switching stations is done using electrometers on

the DIN bar in the distributors. The electrometers have to be equipped with an RS485, M-Bus or Ethernet interface. Itis possible to use the existing communication lines in the individual objects and connect the electrometers to them.This is understood to mean connecting electrometers in the order of magnitude of single units (1-5).

When installing higher number of electrometers (6 and more), it is requested to connect them to the Ethernetnetwork using converters (such as TRITON – manufacturer Papouch). The converter has to be able to forward thedata to the Energis system for monitoring energies.

The voltage coils of electrometers are connected directly, the current coils with vibrators with the output of 5 Aor directly (based on the maximum possible consumption values).· The voltage is measured using a voltage-current converter with the output of 4-20 mA, type NC 220, 100V, 4-20

mA accuracy class 0.5· The frequency is measured using a frequency-current converter with the output of 4-20 mA, type NC 200, 100V,

4-20 mA, accuracy class 0.2.The necessity of voltage and frequency measurement always has to be consulted with the ŠE-ES/2 andEI/4 departments.

At the switching stations without the current converters is monitored the condition “switching station undervoltage” or “switching station without voltage” using an installed relay. Shall the voltage decrease under the 85 % ofthe nominal voltage, the switching station is considered without voltage and the relay shuts off. The maintenance consists of tightening the bolts and checking the voltage which should shut off the relay (85 %of the Unom). Is done at the same time as the switching station maintenance. Calibrating the devices is done onlywhen there is a suspicion of incorrectly measured values. It is always necessary to verify the compatibility of theelectrometer and the data concentrator. In case it is required to measure frequency, power factor, symmetry, etc.,multifunction measuring devices (multimeters) will be installed – especially at shops with high emphasis on thecondition and quality of energy. The request should be originated by or approved by the responsibledepartment of ŠE-ES or ŠE-EI/4.

Recommended electrometer manufacturers

AEG, ABB, Schneider Electric, SAIA, ZPA, Siemens, KMB, ACEAN




For NN e.g. ACEAN DVH 5261 (direct measuring)SAIA-BURGESS AWD3D5WD00C3A00 (indirect measuring)always incl. RS485/Ethernet (Papouch)

For VN e.g. ABB A44 352-100 incl. RS485/Ethernet (Papouch)Multimeter e.g.: Siemens SENTRON PAC3200

2.3. Pressure MeasurementPressure is measured by sensors with current output of 4-20 mA, double wired connection. Every sensor is

separated from the pipeline by a manometric valve and in case of medium temperature higher than 100°C, also by asteam loop. Sensor ranges have to be proposed based on the specific application (operational pressure), we offer thebasic recommended range below:

hot water – primary 0 - 1600 kPa

hot water – secondary 0 - 1000 kPa

hot water central heating –secondary

0 - 600 kPa

drinking, industrial, cooling, demiwater

0 - 1000 kPa

pressurized air 6 bar 0 - 1000 kPa

pressurized air 12 bar 0 - 1600 kPa

natural gas 20 kPa 0 - 40 kPa

natural gas 170 kPa 0 - 250 kPa

Table 5: Recommended Ranges of Pressure Sensors in Energy Measurement

2.3.1. Manufacturers – Recommendation

JUMO, BD Sensors, Cressto, REM, SENZIT, E+H, JSP, ZPA

2.3.2. Measuring Differential Pressures

Differential pressure is measured by sensors with current output of 4-20 mA, 24V/DC power supply, IP67, doublewired connection. The sensor is connected to the pipeline using a manometric valve allowing for replacement of thesensor, desludging the supply impulse pipe, and maintenance (five-way valve set).

2.3.2.1. Manufacturers – Recommendation

differential pressure sensors: BD – Sensors, ZPAfive-way fixture: ZPA, Huba Control, REM, SENZIT, E+H, JSP, ZPA

2.3.3. Temperature Measurement

Temperature is measured by temperature sensors Pt 100 or Pt 1000 with converter either separate or in the head.Length of the stem 50, 100, 150, 200, 250 mm. It is possible to use the NTC termistory 20kΩ at 25°C in the air-conditioningapplications.

We recommend to use in the heating machinery rooms programmable two-wired temperature converters with adigital indication type PT-02(020), possible programmable range -30 to 200 °C. The converters have the current output of4-20 mA, double-wired connection. Sensor ranges have to be proposed based on the specific application, we offer thebasic recommended range below:

hot water – primary 0 - 150 °C

heating water for the central heating –secondary

0 - 130 °C

hot industrial water (TUV) – secondary 0 - 100 °C

area temperature – interior 0 - 50 °C




outside temperature -30 - +50 °C

pressurized air 6, 12 bar 0 - 50 °C

natural gas 0 - 50 °C

Table 6: Recommended Ranges of Temperature Sensors in Energy Measurement

2.3.3.1. Manufacturers – Recommendation

ZPA EKOREG, JSP, SENZIT, REGMET, COMET, E+H




3. Specifications of Individual Subsystems – Substations, Communication, VisualizationIn case the technological network is not available at the place in question it is necessary to purchase further equipmentin accordance with the requirements of the FIO/34, i.e. this has to be included in the list of activities already during thedesigning stage!!!

3.1. Measuring Energies – Mladá Boleslav Production Plant

3.1.1. Information measurement system Control Web

!!! THE CONTROL WEB SYSTEM WILL BE EXPANDED NO MORE!!! ANY AND ALL NEW TECHNOLOGICALDEVICES, SUCH AS REGULATING HOT INDUSTRIAL WATER AND CENTRAL HEATING, PUMPING OILEDWATER, COOLING CONOURS, NEUTRALIZATION STATIONS, ETC. HAVE TO BE COMMUNICATING DIRECTLYINTO THE ENERGIS EVALUATING SYSTEM. DESCRIPTION OF THE CONTROL WEB SYSTEM IS INCLUDEDHERE IN CASE OF ANY POSSIBLE EXTENSION/REPAIR OF EXISTING SOLUTIONS.

System DescriptionMeasuring and regulating system of energies is realized based on the SAIA PLC substations (currently ca 130 pcs)

connected to the data concentrator using the primary wiring network. Currently the priority is using the ethernetinterface. In case of already implemented communication structures, the S-BUS communication protocol can be used inexceptional cases.

The PLCs are intended for collection and calculation of data for the information system of energy consumption(electric energy; natural gas; pressurized air; technical gasses; drinking, industrial, demineralized, oiled, and sewagewater; heat) but also for regulation (regulation of the hot industrial water - TUV, and the central heating - ÚT; regulationof pumping the oiled water; regulation of cooling contours; regulation of neutralization stations).

The PLCs are connected to the data points (sensors, actuators) using the secondary wiring network. The PLCs canoperate independently without a superordinate level (in case of communication outage). The measurement itself is doneusing the measuring instruments as necessary with the output in the form of a current loop (4-20 mA), pulses orcommunication interface.

All current branches of the S-BUS network (+ethernet) from the PLC SAIA flow into the data concentrator for thecontrolling station (ŠE), which is a communication and information server operating in an MS cluster. Using the MSclustering are backed up two NT servers connected by data fields. In case of an outage of the active server the secondserver immediately takes up its function (with no data loss). An SW Windows 2000 Advanced server, MS SQL Server 2008Enterprise is used on the server, visualization uses the Control Web v6. The server receives the data from all SAIA PLCs,stores them in the database files at an external disk fields where they are archived for 3 months, and allows visualizationof data on the controlling computers. The controlling computers connected to the network of the communication andinformation server visualize real data and allow controlling. Other computers (including computers in the companynetwork) allow, according to user authorizations, visualization of both real and historic data. Trending of the measuredvalues is possible from all computers with access to the data concentrator. The server also ensures transfer of the datato the External superstructural system ENERGIS. The server allows remote access through modem (remote monitoringand maintenance).




Figure 2: The Topological Diagram of the Control Web System

Hardware Specification and VisualizationIt is recommended to use the SAIA PLC stations PCD2.M5XXX and PCD3 in the Control Web system (ethernet

communication, exceptionally using the S-BUS in connecting to the old solutions).The number and type of input and output cards depends on the number and type of sensors connected (signalization

contacts) and the type of the regulated values or controlling. The basic SAIA unit is installed on two DIN bars vertically inthe MaR distributor.

The displaying and controlling industrial terminals have to be equipped with a graphic display (type e.g. WEINTEK6051iP) installed on the MaR distributor door (use bigger diagonal for more complicated adjustments).· The contracting party for the hardware and software function is the ŠE in cooperation with the designer and supplier

of the control system.

In exceptional cases PLCs of other manufacturers may be included in the system. Connecting any PLC has to beconsulted with the system administrator at the ŠE – department ES/2 and EI/4.

Visualization of technologies (compressor station, cooling station, heating machine room, …) is in the ControlWeb6environment. For data collection (reading them from the PLC) is necessary to use the virtual server IP 10.220.111.27. Everynew “display” has to be visible also from other existing clients of the ControWeb v6 at the Mladá Boleslav plant.ControlWeb v6 also has to communicate data on energy consumption (heat, electricity, pressurized air, water, natural gas,…), which are sent to the Energis system.

Network for Energetic Device Communication:Activate the device in the technological network: see Annex 1

The ControlWeb6 application is registered under the ID 182654 (information on the Škoda Auto Intranet):https://ums.skoda.vwg/SkoNetInfo/Application.aspx?appId=182654

Virtual server Skdambscw6.fw.skoda.vwg 10.220.111.27

SQL DatabaseENERGO_MAR

skdambvsql08d01.mb.skoda.vwg (development) 10.217.144.42

skdambvsql08p05.mb.skoda.vwg (production) 10.217.144.29

Table 7: Network for Control Web Communication

https://ums.skoda.vwg/SkoNetInfo/Application.aspx?appId=182654




Operator Guarantor:Mr. Brabec, Oto 2 (ŠE ES/3) [email protected]; +420 326 812 702

Service Organization ContactTesyco - Mr. Zdeněk Křížek; [email protected]; +420 605 245 666

3.1.2. Information Measurement System EMI (Air-Conditioning Units)

System Description and General RulesIn case of realization of air-conditioning units, two basic types have to be distinguished by the output:1) AC device up to and including 10,000m3/hr2) AC device above 10,000m3/hrAutonomous MaR control units can be used with the air-conditioning devices of the Group 1). Nevertheless,

these systems have to allow for connection of signals of overall defect and operation into the visualization system.For the devices above 10,000 m3/h the controlling will be done using freely programmable controllers

(regulators) of HONEYWELL, SIEMENS or SAIA manufacturers. The overall concept of the events with bigger scope willalways be consulted with the Ško-Energo department – department ES/2. All requisites and specific requirements forthe AC units (including MaR) are included in the ITS 1.21 Air Conditioning

Figure 3: The Topological Diagram of the EBI System

Hardware Specification and VisualizationThe system is mainly based on the PLC Honeywell Eagle (Excel 5000). Communication of data to server runs using

the serial lines (C-Bus) terminated by a converter to the ethernet, so-called BNA (Building Network Adapter). Data arecommunicated to the server using the Škoda Auto network.

A new PLC can be included into communication either by including to the existing serial lines or by direct connectionto the Škoda Auto ethernet network using the BNA.

In exceptional cases PLCs of other manufacturers may be included in the system. Connecting any PLC has to beconsulted with the system administrator at the ŠE-ES department.

mailto:Oto.Brabec2:@sko-energo.cz

mailto:krizek:@tesyco.cz




Visualization of the AC units is realized in the EBI Honeywell system. A virtual server EBI2 IP 10.220.119.56 has to beused for data collection. Every new “display” has to be visible also from other existing clients of EBI at the Mladá Boleslavplant. Within the EBI system it will be necessary to purchase a database extension for the appropriate number of datapoints.

Network for Energetic Device Communication:Activate the device in the technological network: 172.29.2.0/24

Application: https://ums.skoda.vwg/SkoNetInfo/Application.aspx?appId=129849

List of the EBI Honeywell system servers

Server M6 SKDAMBSEBI1 172.29.2.11

Server M2 SKDAMBSEBI2 172.29.2.12

Server TC SKDAMBSEBI3 172.29.2.13

Table 8: List of the EBI Honeywell System Servers

Operator Guarantor:Mr. Slavik, Vladimir (ŠE ES/3) [email protected]; +420 734 264 508

Service Organization ContactHoneywell – Mr. Luboš Chasák; [email protected]; +420 602 382 821

Distribution System Protection System (microSCADA MB)

The “Distribution System Protection” system ABB MisroSCADA PRO is intended for monitoring, controlling, andautomatization of switching stations at the Mladá Boleslav plant. The data communication occurs on the closed localethernet network. The system is not connected to the Škoda Auto company network. Into the system are communicateddata from individual REF 54x ABB Vaasa Finland terminals.The specific extensions of the system have to be consulted with the system administrator at the ŠE-ES.

3.2. Measuring Energies – Kvasiny Production Plant

3.2.1. Information measurement system RC Ware

System DescriptionThe measuring and regulating system of energies is realized based on the PLC substations SAIA (280 pcs) and SAUTER

(20 pcs) connected to a server by a data network. This network transfers data to the server and back using the S-BUS,RS323 communication protocols, and an optical network with MOXA converters.

The overall topological diagram and function of the whole system is clear from the Figure 1 (below). The PLCs areintended for collection and calculation of data for the information system of energy consumption (electric energy; naturalgas; pressurized air; technical gasses; drinking, industrial, demineralized, oiled, and sewage water; heat) but also forregulation (regulation of the hot industrial water - TUV, and the central heating - ÚT; regulation of pumping the oiledwater; regulation of cooling contours – AC technology).

The PLCs are connected to the data points (sensors, actuators) using the secondary wiring network. All current datanetwork branches flow into the RCWare server and further to the controlling station (ŠE). The server receives the datafrom all PLCs, stores them in the database files at an external disk field where they are archived for 3 months, and allowsvisualization of data on the controlling computers. The controlling computers connected to the network of thecommunication and information server visualize real data and allow controlling. Other computers (including computers inthe company network) allow, according to user authorizations, visualization of both real and historic data. Trending of themeasured values is possible from all computers with access to the server. The server also ensures transfer of the data to


mailto:Vladimir.Slavik:@sko-energo.cz

mailto:lubos.Chasak:@honeywell.com




the external superstructural system ENERGIS. The server allows remote access through modem (remote monitoring andmaintenance).

Figure 4: The Topological Diagram of the MaR Kvasiny System

Hardware Specification and VisualizationText terminals: PCD7.D8xxx, PCD7.D7xxx, PCD7.D2xxx

Touch terminals: MT61.00, MT81.00

There is no independent DMZ network for energetics so far at the Kvasiny production plant. The devices insingle numbers are handled individually by the FIO. In case of systematic increase of individual communicationdevices creating an independent DMZ would be a necessity.

Network for Energetic Device Communication:Kvasiny – RCWare System individually with the FIO

Operator Guarantor:Mr. Kubec, Martin (ŠE ES/4 – MaR and IS Technology); [email protected]; +420 734 783 516Service Organization Contact:ENERGOCENTRUM PLUS, s.r.o. - Mr. Muchna, Luboš; [email protected]; +420 606 166 279

3.3. Measuring and Controlling – Vrchlabí Production Plant

3.3.1. VRCHLABÍ – Energetics Information and Controlling System – Johnson Controls

The system is intended for monitoring and controlling of energetic devices at the Vrchlabí plant. The systemconsists mainly of DX8451 and DX8454 controllers by the JC company, which are connected into individual serial lines (thesystem has currently 9 lines) communicating with the control units NAE35 using a communication protocol (N2-Bus).These network control units then communicate through the Š-A ETH connection also among themselves and with avirtual server, which is physically located at the Š-A data centre at MB.

mailto:martin.kubec:@sko-energo.cz

mailto:lubos.muchna:@energocentrum.cz




Figure 5: The Topological Diagram of the JCI Vrchlabí System




Network for Energetic Device Communication:Vrchlabí – Metasys system 10.221.161.117

Operator Guarantor:Mr. Štefan, Jaromír (ŠE ES/5); [email protected]; +420 734 264 525Service Organization Contact:PMNP - Mr. Petr Mach; [email protected]; +420 603 894 946

Technological partNetwork control units: NAE 1 – NAE 9IP addresses and DNS names of network control units: UPON REQUEST

Virtual server skdavrsemetasys.fw.skoda.vwg 10.220.111.66

Table 9: IP Address of the Metasys - Vrchlabí System Virtual Server

User work stations: UPON REQUEST

3.4. Direct Energy Measuring – ENERGIS

3.4.1. Direct Energy Measuring Using the Energis System

Energis is a superstructural system used mainly for evaluation and invoicing of energies and also for archiving ofselected data from other systems. Data from the ControlWeb6 systems are received through the SQL DatabaseENERGO_MAR. Data from other systems are communicated in a different, agreed-upon way.

Measurement of energy consumption (electricity, heat, natural gas, water. …), which are not directlyrelated with the visualization of the AC technology at MB, visualization in the Metasys or RC Waresystems, are required to be communicated using an Ethernet interface directly into the Energis system,server IP 10.220.111.4x. The method of transfer has to be consulted with the system administrator at theŠE-ES department.

Network for Energetic Device Communication:Activate the device in the technological network: 10.220.111.0/24 ID 3066

Application: https://ums.skoda.vwg/SkoNetInfo/Application.aspx?appId=114541

Energis data collection HLIXMB msehlix1.fw.skoda.vwg 10.220.111.41

IS ENERGIS Škoda Auto a.s. 10.220.111.46

IS ENERGIS Ško-Energo, s.r.o. 10.220.111.42

Virtual server for Energis Škoda Auto a.s. application migration (2017) 172.29.2.15Virtual server for applications replacing the Control Web Ško-Energo(2017) not defined

Table 10: IP Addresses of Energis System Servers

Operator Guarantor – Mladá Boleslav plantMr. Vrba, Premysl (ŠE ES/1) [email protected]; +420 326 819 318

Operator Guarantor – Kvasiny plantMr. Krassek, Petr (ŠE ES/4); [email protected]; +420 734 264 547

Operator Guarantor – Vrchlabí plant

mailto:jaromir.stefan:@sko-energo.cz

mailto:mach:@pmnp.cz


mailto:Premysl.Vrba:@sko-energo.cz

mailto:petr.krassek:@sko-energo.cz




Mr. Vrba, Premysl (ŠE ES/1) [email protected]; +420 326 819 318Mr. Štefan, Jaromír (ŠE ES/5); [email protected]; +420 734 264 525

Service Organization Contact:Instar - Mr. Michael Hahn; [email protected]; +420 737 208 029

mailto:Premysl.Vrba:@sko-energo.cz

mailto:jaromir.stefan:@sko-energo.cz

mailto:michael.hahn:@instar.cz




4. Basic Installation ConditionsWith the electric installation it is necessary to comply with all current safety regulations and binding provisions of ČSNincluding electromagnetic compatibility (EMC).

4.1. Electric Distributor Hardware· Lighting with a switch (door contact) – at all sections, min. 1 service socket 230V/16A per section – power supply

to the service socket in front of the main switch (safety has to be maintained)· Signalization of opened distributor door by the door contact with connection to the PLC – in all sections· Signalization of circuit break to the PLC· By the selected MaR distributors placed at the VN switching stations the continuous power supply has to be

handled as well.· For power supply of the MaR devices use the TN-S 1+N+PE 230V/50Hz set.· The MaR distributor has to be equipped by a safety CENTRAL STOP button (emergency shut-off), placed on the

distributor doors. At closed and locked machine rooms it is possible to use a STOP button of XAL-K174E -SCHNEIDER type with protective basket arresting device against accidental shut-off. If the distributors areplaced in unlocked places, a STOP button under glass will be used, of the type GW 42201 GEWISS. Under thiscabinet has to be provided a yellow frame with an overlap of 5 cm. An overall defect signalization will be placedon the distributor door.

· Protection against dangerous touch voltage should be done using automated power shut-off or by a small PELVor SELV voltage in accordance with ČSN 33 2000-4-41 ed. 2.

· Distributor design RAL 7035, in unlocked places RAL 9010

4.2. PLC Installation Principles Including Viewpoint of Electric SafetyIn case installation of PLC (controller) is necessary, all information stated here has to be followed. The PLC is installed

into a MaR distributor, which has to meet the following requirements:· Cover minimum IP54, distributor MaR – BA marking, heavy-current distributors – RM marking

o Kvasiny distributors marking: RA xxx – number of the device (MaR) per objectRM xxx – number of the device (ET or ET/MaR) per object

· Bigger application distributor dimensions: 800(600) x 400 x 2000 mm (floor-mounted cabinet including a 100 mmstand),

· Smaller application distributor dimensions: 800 x 600 x 800 mm (wall-mounted),· In case of including the distributor into the same block of cabinets as the heavy current, use the side separating

metal sheet· The distributor has to be equipped by a universal lock cylinder for the whole system (lock 1333)· The distributor has to be marked in accordance with the project and TDB· The cabinet distributor has to be equipped with a stand· The descriptions have to be in the form of engraved labels, marking and connection of the distributor mandatory· In case of danger of mechanical damage to the distributor, steel barriers have to be installed· The distributor has to be opened to the 95° angle. After the distributor doors are opened, there has to be at

least 1 m of space in front of the distributor from the closest live part.

4.2.1. Manufacturers – Recommendation

Rittal – The System, Schrack Technik, OEZ

4.2.2. Power supply leads:

Power supply of the PLC system has to be backed up by two independent sources (two different switching rooms,transformer stations or using an emergency power or UPS) – necessity and form of power supply back-up always has tobe consulted with the ŠE-ES department. On the supply voltage input of the PLC it is always necessary to install at theMaR distributor a power filter and an overvoltage protection. The live parts of the circuit behind the supply transformermust not be connected to a PE or N wire. Power supply leads behind the power filter and transformer also cannot have anyovertravel with power supply leads before the filter. The PLC cover has to be conductively connected to a PE cable with theminimum cross section of 4 mm2. In case of UPS request, the UPS has to be connected to the TOTAL STOP circuit of the




object under the provisions of ITS 2.11, ČSN 73 0802, ČSN 730804. The PLC memory has to be backed-up with its ownbattery due to danger of data loss in case of UPS outage.

4.2.3. Binary Inputs:

Shielded leads can be only used when the input leads are thoroughly separated from the power and supply wires; if thiscannot be ensured, shielded wires have to be used with the earthing at the entry to the distributor. The other side ofshielding stays unconnected.

4.2.4. Binary Outputs:

The inductive loads always have to be equipped with an interference suppression element. Semiconductor parts on theoutput are especially sensitive to breakdown during the switch peak.

4.2.5. Analogue Inputs and Outputs:

Only shielded leads may be used. Shielding outside the distributors should be earthed at the entry to the distributor, theshielded wire in the distributor should be grounded at the PLC terminal box. No overtravel with the power or supply wiresallowed. For measurement use preferably sensors with current output.

4.3. CablingWhen installing the MaR components, the ITS 1.11 Electrics and 5.11 Electric Assembly and Installation have to be

observed. For correct MaR cable installation it is necessary to adhere to the following principles.· Measurement cables from sensors to the subswitchboard – shielded double wire 2 x 1 mm2, shielding earthed at

the subswitchboard side only (JYTY cable).· For communication bus RS 485 (S-BUS) – use shielded datapar cable (LAM DATAPAR 2 x 2 x 1 mm2). The cable

cannot be extended.· In case of overtravel of several cables longer than 50 m it is possible to join the cables using a concentrator into

one shielded multiple cable, so-called multicable (cable JYTY X x 1 mm2). The S-Bus cable cannot be combined withany cables. Analogue and pulse signals have to be combined separately and lead through two cables.

· The cables are installed in troughs made of galvanized sheet metal / wire (e.g. troughs MARS and MERKUR 2) oralso in plastic in case of interior lines

· The cable runs of measuring and controlling cables are strung separately from power supply cable runs (minimumdistance 250 mm)

· Upon consultations with the ŠE-ES departments it is possible to use for the measuring and controlling cables ajoint trough MARS with a partition

· On the sections of cable run between the trough and the sensor the cables have to be protected by a steel wiringpipe (protection of the cable against damage) – request specific for production halls only. In administrative spacescables run in a plastic pipe or bar inside the walls.

· Cable shielding cannot be conductively connected to live or un-live parts of the systems outside the MaRdistributor, cannot be connected to constructions. Cable shielding is connected at the MaR distributor to a specialterminal box connected to the PE with a cable with the cross section at least 4 mm2.

· Conductors leading to he sensors cannot be conductively connected to constructions. Shall the system requireconnection to PE, this shall be done at the distributor only by leading out the PE conductors from sensor to aspecial bar where they will get connected, and this bar will be connected to the PE using only one sufficientlydimensioned wire (minimum 4 mm2).

· After placing all the cables the individual strands will be checked (rang), terminated at the terminal boxes andmarked with permanent description tags.

4.4. Rules for Connecting to the ŠKODA AUTO, a.s. NetworkThe controllers (PLC), data concentrators, converters, and other devices transferring data to the servers of appropriate

measuring systems have to be connected to the Škoda Auto ethernet network. An ethernet socket has to be created forthe connection. Creation of the socket is monitored by the FIO/34 department (financial coverage has to be provided by theinvestor), which will entrust the realization to the appropriate authorized company. Every data socket has a unique numberassigned after it has been created. After the socket has been created it is necessary to request its activation. The requestis sent by e-mail to the call centre.




If possible the sockets have to be activated into the technological network, then no firewall penetration has to berequested for the network. Individual network numbers for communication of energetic devices are stated in the chapter 5.

4.4.1. Connecting Devices to a ŠKODA AUTO, a.s. Network

Necessary for connection:· Request for assigning the device a name and SAP registration· Request for assigning an IP address in the DNS, see Škoda Auto intranet, form 9038· It is necessary to enter a MAC address or to set up an IP physically, then a location has to be entered.

Approval takes about 1 day from the request· Request for a FIREWALL penetration into the DMZ server (if necessary) form 9031. It is necessary to enter

the ports requested. It is necessary to enter the network names of clients and servers. The approval takesabout 1 week, activation is done once a week – FIO/2 department.

5. Change Management and Change RequestA change management term is understood to mean any activity the subject of which is adding/cancelling a data point at

an existing PLC. Another case is adding/removing a data point in the ENERGIS system. Naturally, a combination of bothabove-mentioned possibilities is an option. Each of mentioned options can have its own peculiarities of solution in thechange management, therefore a technical meeting where these peculiarities will be discussed and strictly explained ismandatory.

5.1. Technical MeetingThe subject of a technical meeting is clear definition of summary and content of the project documentation. Among the

present at every technical meeting has to be a representative of the investor, the technology supplier, the MaR supplier,and of the device user (ŠE – ES and ŠE-EI). The project documentation has to include all measured and controlledquantities (new, added or cancelled). All measured and controlled quantities have to be approved by the responsibledepartment of the investor (ŠE-ES/1 and ES/2).

5.2. Table of Data PointsThe table of data points (hereinafter as TDB) is a place for storing identifiers, topologies, technological constants, limits,

and requests for communication, visualization and archivation of data (measured and then calculated) for a specific datapoint. The data point is defined in the graphic part of the screen.

For creation of the project documentation and its subsequent approval, a TDB has to be filled. When filling a TDB, thedesigner works with calculation formulas and texts, with connection of the measuring point and with the table of datapoints. In case of data point cancellation the designer is obligated to delete the data on terminal box numbers at the PLCSAIA and has to ban the transfer to the SAIA monitor (including the transfer to the data central and to the superstructuredENERGIS system).

Day of the introduction of the change by solver = day of the last update.

5.3. Creation of Project DocumentationProject documentation created by the responsible designer has to be approved by a specialized ŠE department.

The specialized ŠE department establishes, which quantities will or will not be transferred to the central, authorizationfor controlling and transfer to the superstructured ENERGIS system. In case of considered visualization creation theinvestor together with the solver are the ones responsible for its proposal (is handled by a joint proposal!!!). Theapproved project documentation and visualization proposal will be submitted by the investor to the solver (Supplier).

!!! TO CHANGE THE CONTENT MEANING OF ALREADY EXISTING DATA POINTS OR CANCEL EXISTING IDENTIFIERSID_KB,EKOD IS UNACCEPTABLE. IT IS ALSO NOT POSSIBLE TO CHANGE THEIR EXISTING LINKAGE!!!

5.4. Going Live and Hand-Over of the Technological Device (including Controlling Technology HW)The Supplier can carry out the installation/dismantling, going live, and subsequent hand-over of the supplied

technology solely based on the approved project documentation. The MaR Supplier is obligated to get the controllingsystem HW live.




5.5. Controlling Programs (Systems) – Creation and Going LiveTo ensure the correctness of the creation and the result of the software proposal of controlling programs, theproject always has to include:- A complete list of controlling system input and output connections including technical parameters thereof.- Controlling algorithms including functionality description.- A complete description of communication protocols of connected devices.- A description of linkage to the cooperating controlling or measuring systems including addresses of channels

transferred.- A description of requested behaviour of the control panel, including relation to the TDB.- Implemented graphical designs of technological diagrams for visualization.- A description of connection of dynamic elements to the variables in the TDB.- A description of behaviour of non-standard dynamic elements in the visualization.- Texts of error messages with their linkage to the variables in the TDB.- A description of other non-standard visualization requirements.- The project has to be approved by the customer.- The Supplier/Solver will create a SW for the controlling system based on the project documentation and the

TDB.- The solver will get the controlling system SW live.- The Supplier/Solver has to submit all annotated source codes in non-compiled and freely adjustable form

5.6. Visualization Systems – Creation and Going LiveThe solver will create the SW visualization and then get it live.

5.7. Generating DocumentationAfter the visualization system goes live and the documentation generator is on, the current table will be saved to

the SQL server. The solver will generate “*.LST” files and (files PlatneDefiniceSA or PlatneDefiniceSE; platne definice =current definitions) will send them to the investor in a digital form.

5.8. Result of Every Change – Hand-Over of the Control System, Visualization System, and Hand-OverProtocols

The result of every change is a complete hand-over of the control system and visualization system with hand-overprotocols. Part of the SW hand-over by the Supplier are the following points:

- Functional control system on the PLC level (including all the source codes to make possible future changes ofcontroller functionality – original uncompiled source codes).

- Functional visualization system.- Documentation newly generated by the documentation generator.- Update of the measuring points table in the documentation system.- Files *.LST for the ENERGIS system (the Supplier shall copy them to the ENERGIS server disc).- Hand-over protocol proposal.- Current version of the annotated source code and executable files for PLC.

!!! The result of every change is a complete hand-over of the ENERGIS system including hand-over protocols!!!

5.9. AddendumThe complete progress of individual steps has to be carried out in accordance with the timetable approved by the

investor and partial realizations have to be approved by the investor supervisor!




6. MetrologyIn accordance with the ŠKODA AUTO Metrology Code (ON 1.018) all new measuring instruments are classified as

operational undefined measuring instruments, i.e. in accordance with the requirements of ČSN EN ISO/IEC 17025 and internalpolicies calibration protocols will be submitted (in the Palstat system; for electrometers with MID certification the protocolsare not required). External calibration of measuring instruments has to fulfil the requirements as per IS 028/11 FK from 12. 12.2011. Operation and maintenance of other measuring instruments, that are not a part of energetics measuring systems, areensured by the owner of the measuring instruments.

7. Documentation Extent

7.1. Documentation for Carrying out the Construction – Minimal Requirements:

· Technical protocol· List of devices – energy requirements· List of control system inputs and outputs· List of cabling· Regulation Diagram· Layout – including physical drawing of conductors, cables, elements of the whole· Linear one-pole distributor connection· Documentation for carrying out the construction has to be in Czech language· All documentation has to be submitted in a digital form (has to be submitted in commonly used formats – pdf., doc.,

docx., xls., xlsx., dwg., dgn. or for example EPLAN)

7.2. Documentation of the Real Execution – Minimal Requirements:

· Documentation of the real construction execution has to be in the Czech language (including annotations in the Czechlanguage at the software supplied – see 5.3 and 5.5).

· Drawing documentation adjusted in accordance with the real execution in three copies (paper copies) and 1 × digitallyon CD (pdf format of drawings).

· Current backup of SW from PLC, display, and all other programmable devices, source code annotated in detail, legiblein a text editor.

· Map of data points – created as a table (format xls), including a detailed description of communicated data points ofthe PLC program in relation to the technology controlled (ranges, ports, etc.), 1 × USB or CD medium.

· Operation Manual in general + for individual devices.· Drawings of connection of individual circuits (dwg., dgn., EPLAN P8 ver. 2.0 and higher).· Lists of items and their basic parameters in separate circuits, lists of connections and spare parts lists for two years of

operation.· Manuals for dismantling, repairs, adjustment, calibration, installation, operation for all devices in the delivery.· Protocol on training the operators.· Protocol on getting the device into operation and running the tests.· Colour scheme of the device in the A3 format, sealed in a laminating film – 1 pc.· Inspection protocol (initial electro inspection of the MaR device concerning the standards on protection against

dangerous contact voltage and others, especially from the safety viewpoint).




8. List of FiguresFigure 1: MaRSE TZB system at Škoda Auto a.s. ........................................................................................................................................................................... 8Figure 2: The Topological Diagram of the Control Web System........................................................................................................................................... 19Figure 3: The Topological Diagram of the EBI System.............................................................................................................................................................. 20Figure 4: The Topological Diagram of the MaR Kvasiny System .......................................................................................................................................... 22Figure 5: The Topological Diagram of the JCI Vrchlabí System ............................................................................................................................................. 23

9. List of TablesTable 1: List of Layers and Matching Technology/Peripherals ............................................................................................................................................... 9Table 2: Measuring and Regulating Systems ................................................................................................................................................................................ 10Table 3: Stable measurement.............................................................................................................................................................................................................. 11Table 4: Access Measuring Point........................................................................................................................................................................................................ 12Table 5: Recommended Ranges of Pressure Sensors in Energy Measurement ........................................................................................................... 16Table 6: Recommended Ranges of Temperature Sensors in Energy Measurement .................................................................................................. 17Table 7: Network for Control Web Communication ................................................................................................................................................................... 19Table 8: List of the EBI Honeywell System Servers ................................................................................................................................................................... 21Table 9: IP Address of the Metasys - Vrchlabí System Virtual Server ................................................................................................................................ 24Table 10: IP Addresses of Energis System Servers .................................................................................................................................................................... 24



Ref. No.

Annex 1Communication to the Higher CMS Systems

Communication to the higher CMS system is handled by data transfer from individual DDC stations into the server andSQL database. A TCP-IP network installed by the user is used for the data transfer. The connection method always has to beconsulted with the authorised representative of the contracting party. They will also specify the procedure of requestingconnection at the given location. Network availability and their division – see the following graphics. For data transfer to theENERGIS evaluation system

Network availability for Ško-Energo:

Mladá Boleslav:

Map of sections:

Main Plant North

Main Plant South

PTGAC

RS

SPC

Bondy

Autosalon

Uni - Na Karmeli

R&D - Česana

Kosmonosy

Server connectionMB-RZ, MB-BRZ

MB-S01O-ENRG-MB-S01

172.29.2.0/24

End appliancesarea V8-INCC

MB-A02O-ENRG-MB-A02172.29.10.0/23

End appliancesarea V1-510

TV-A03O-ENRG-TV-A03172.29.12.0/23

End appliancesarea ACE-PEN

MB-A01O-ENRG-MB-A01

172.29.8.0/23



Ref. No.

Vrchlabí:

Kvasiny:

Server connectionVR-L15, VR-L34

VR-S01

O-ENRG-VR-S01172.29.24.0/23

End appliancesVrchlabiVR-A01

O-ENRG-VR-A01172.29.26.0/23

O-ENRG-KV-S01172.29.28.0/23

Server connectionKV-M1-1, KV-M3-1

KV-S01

End appliancesKvasinyKV-A01

O-ENRG-KV-A01172.29.30.0/23

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