Distributed Control Systems Theory & Implementation

ISA Lunch and Learn
Ken Carfagno November 6, 2013
Agenda
Theory & Practice - Basic control (e.g., regulatory control, feedback, etc) - Discrete control (e.g., relay logic, Boolean algebra) - Sequential control (e.g., (e g batch) - Typical Configuration and Programming - Input/output termination and wiring Implementation - HMI (e.g., graphics, alarm management, trending, historical
data) - Network security
HONEYWELL - CONFIDENTIAL
File Number
Page 1
Basic Control
Control Loop Types & Components
Types of Control Loops

Simple Feedback Control Loop Cascade Control Loops
Components of Control Loops

Basic Elements
File Number
Page 2
Basic Feedback Control Loop
FR
FIC FIC
FY
FV FT
Most commonly used process control loop
File Number
Basic Loop Components
PID Controller
Controller Output (0-100%)

I P
Recorder
Transducer
FR
FIC FIC
FY Pneumatic Signal
Transmission Signal FV Transmitter FT Final Control Element (control valve)
Primary Element
Detailed description of instrument symbols are on the legend
File Number
Page 3
E Assembly-Double Block/Bleed w Bypass Valve
Bypass Valve
Block Valve
Block Valve
Control Valve I/P Transducer
Bleed Valve
File Number
Cascade Control Loops

Why incorporate a cascade system? To minimize outside load variables resulting in increased process stability Examples Condensate control
FV
TR
Primary Controller
TT
TIC FIC
Secondary Controller
I
FR
FIC FIC
FY
FT
Fuel gas/oil burner pressure control Quick and frequent hydraulic changes
File Number
Page 4
Cascade Control
TT TIC
Process
I/P
Basic Loop
TY
Steam
Condensate
TT
TIC
Load Variable Changes

(P1 or P 2 is variable)
Process
FIC
Steam, P 1 FY
FT
I/P
P2 Condensate
File Number
Basic Control Implementation Function Blocks

Cascade from Primary
Input from the transmitter
PID Controller
Output to Valve
10
File Number
Page 5
Discrete Control
Simple Process
Automate simple process Push a button to start The value should open automatically When the valve is open, the pump should start automatically The operator watches the level indicator. When the tank is full the operator pushes another button The pump should stop and the valve should close. Valve with actuator IN OUT Float level indicator
Water level
Water Pump
Water Tank
12
File Number
Page 6
Honeywell Proprietary & Confidential
Since I am using relays and pushbuttons to do my remote control, I need an electrical diagram to use as my guide for connecting all of the electrical wires so I create the following pushbutton / relay wiring schematic diagram. 120 VAC PB-2 (Start)
(Stop) PB-1
(Open Valve) R1
R1 (Valve Opened) (Run Pump) R2 ZSO-2 R1
120 VAC H PB-1 R1 PB-2 N
R1 R2 ZSO-2 R1
Closed
Stopped
Here is how it works: - Press normally open pushbutton PB-2 and relay R1 is energized.
14
File Number
Page 7
R1 R2 ZSO-2 R1
Open
Stopped
Here is how it works: - Press normally open pushbutton PB-2 and relay R1 is energized. - R1 seals in PB PB-2 2 so that when I remove my finger from the button button, R1 stays energized energized. - A contact from R1 relay is wired to my valve actuator. A closed R1 contact opens the valve. Note R1 is also close in the second rung.
15
File Number
R1 R2 ZSO-2 R1
Open
Start
Here is how it works: - Press normally open pushbutton PB-2 and relay R1 is energized. - R1 seals in PB PB-2 2 so that when I remove my finger from the button button, R1 stays energized energized. - A contact from R1 relay is wired to my valve actuator. A closed R1 contact opens the valve. Note R1 is also close in the second rung. - Valve open contact ZSO-2 is wired from the valve (the contact is closed when the valve is fully open). A closed ZSO-2 contact along with the closed R1 contact energizes relay R2. - A contact from R2 relay is wired to the pump. A closed R2 contact starts the pump.
16 HONEYWELL - CONFIDENTIAL
File Number
Page 8
R1 R2 ZSO-2 R1
Open
Start
Once the tank is full, I can stop the pump and close the valve. Here is how you do it: - Press normally closed PB-1 and relay R1 is de-energized.
17
File Number
R1 R2 ZSO-2 R1
Closed
Stopped
Once the tank is full, I can stop the pump and close the valve. Here is how you do it: - Press normally closed PB-1 PB 1 and relay R1 is de de-energized. energized - When R1 is de-energized, the contact from R2 stops the pump and the contact from R1 closes the valve. - Valve open contact ZSO-2 returns to the open state as the valve goes to the closed position.
18
File Number
Page 9
R1 R2 ZSO-2 R1
Closed
Stopped
Once the tank is full, I can stop the pump and close the valve. Here is how you do it: - Press P normally ll closed l d PB PB-1 1 and d relay l R1 i is d de-energized. i d - When R1 is de-energized, the contact from R2 stops the pump and the contact from R1 closes the valve. - Valve open contact ZSO-2 returns to the open state as the valve goes to the closed position. - We are back at the beginning of our sequence when I remove my finger from PB-1.
File Number
Typical Connection and Wiring

120 VAC H PB-1 R1 PB-2 N R1 Contact
Here is how we would wire our control circuit.
120 VAC
R1 R2 R1 R2 Contact
120 VAC
ZSO-2
20
File Number
Page 10
Control Via PLC, Ladder Logic

DI DO
Here is how we would wire our devices to the PLC I/O.

DI 1 DI 2 DI 3 DI 4 DI 5
PB-1 PB-2 ZSO 2 ZSO-2
DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8
Valve Pump
PB-1 Stop
DI 6 DI 7 DI 8
PB-2 Start
ZSO-2
File Number
PB-1 PB-2 ZSO-2
Valve Pump
R1 R2 ZSO-2 R1
DI 6 DI 7 DI 8
This is what our PLC programming language looks like. DI 1 DI 2 DO 1 DI 3 DO
( )
1
We take all of our wiring information and I/O module information create this program program.
DO 1
DO
( )
22
Notice the relationship between our I/O point numbers and the programming.
File Number
Page 11
PB-1 PB-2 ZSO-2
Valve Pum p
R1 R2 ZSO-2 R1
DI 6 DI 7 DI 8
DI 1
DI 2 DO 1 DI 3
DO
( )
1
Also take note that my DI-1 logic contact is normally open. This is because it will be held close by PB-1 when the PLC power is on.
DO 1
DO
( )
File Number
PB-1 PB-2 ZSO-2
Valve Pum p
R1 R2 ZSO-2 R1
DI 6 DI 7 DI 8
DI 1
DI 2 DO 1 DI 3
DO
The programming is done on a laptop PC.
( )
1
DO 1
DO
( )
File Number
Page 12
Control via DCS, Function Blocks

H PB-1 R1
PB-2
120 VAC
R1 R2 ZSO-2 R1
25
File Number
Sequential Control
Page 13
Sequential Control
Time ordered control Series of step to meet control objective - Examples:
Equipment Startup or shutdown Non-continuous (batch) process
Sequential Control follows a common pattern - Take action which will cause a change in the process - Wait for the desired change to complete - Repeat
27
File Number
SCM Example
Embedded Operator Instructions
Step Blocks
Transition Blocks
Configured Handlers
28
File Number
Page 14
Basic Wiring
Analog Inputs
Analog Inputs: Questions

Where does the signal power come from? Where does the transmitter power come from? Where is the signal ground?
30
File Number
Page 15
Analog Inputs, 2 wire, System Powered
31
File Number
AI, Current Signal, Self Power
32
File Number
Page 16
Human Machine Interface
HMI
HMI Example of Non-Conforming Graphic

T200 FRAC OVRHD CSR FI226 400.312 MSCFD TI202 281.53 DEGF CW S PI201 18.71 PSI TI201 280.03 F 15% E209 TI203 200.09 DEGF E210 PC105 18.70 PS IG PC106 15 73 15.73 PS IG PI115 10.77 PSIG FI204 000.00 MSCFD FUEL GAS LI224 95 % T203 0% FC234 13.29 KBPD TI223 440.06 F TI213 89.03 F LC204 25 % SOUR W TR 50% SL OP 100% P209 P211 FL ARE
FC201 4608.23 BPD D200
85% LI214 85 %
65%
T200 TEM PS
1-281.53 DEGF 2-280.03 DEGF 3-271.89 DEGF 4-266.00 DEGF 5-255.44 DEGF 6-254.99 DEGF 7-266.92 DEGF
T200
VRU
C205
AI241 320.78 AMPS FC214 1308.29 BPD
NAP HT HA
P210
P212
35
File Number
Page 17
HMI Example of ASM Graphic
36
File Number
Abnormal Situation Management Study

Comparing ASM designed operator interface (multiwindow) vs standard operator interface (single window)
- 21 Operators - Matching process upsets on

simulator
>38% improvement in recognizing process deviations before an alarm 26% improvement in their ability to successfully resolve problem p 35-48% improvement in overall operator response time to deviations
Source: ASM Meeting report Oct. 2004

File Number
Page 18
Context-sensitive Access to Information

Context-Sensitive Menus
Alarm help Operating procedures
Trends and analysis tools Alarm management tools Maintenance management tools
Quicker response & Less errors

File Number
Alarm Management
Filtering Sorting Alarm Shelving Alarm Commenting Custom Views Alarm Details Links to Detail & Associated Displays Alarm Help p Dynamic Alarm Suppression
39
File Number
Page 19
Trending
Trending - Events Integration - Custom Trend - 32 Pens - Resizable views - Save on demand - Improved User Interface - Easy to use time range
selections
Operators can invoke the Operators can invoke the Location Pane to quickly Location Pane to quickly filter event data to filter event data to specific process areas. specific process areas.
40
File Number
Trending Examples
Trend Navigation Bar Chart
Trend with Events
Trend with Numerics
42
File Number
Page 20
Secure Network Architectures
Manufacturing automation architecture

ISA99 functional hierarchical model
Level 4
Business Planning & Logistics

Plant Production Scheduling, Operational Management, etc
4 - Establishing the basic plant schedule production, material use, delivery, and shipping. Determining inventory levels. Ti Time Frame F Months, weeks, days 3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process. Time Frame Days, Shifts, hours, minutes, seconds
Level 3
Level 2 Batch Control Level 1 Level 0 Continuous Control
2 - Monitoring, supervisory control and automated control of the production process Time Frame Discrete Hours, minutes, seconds, subseconds
Control
1 - Sensing the production process, manipulating the production process 0 - The actual production process
ISA99
File Number
Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...
44
Page 21
PROCES SS CONTROL DOMAIN
Manufacturing Operations Management
OFF FICE DOMAIN
Typical PCS Network Topology
Level 4
Firewall Terminal Patch Anti eServer Server Mgmt Virus Server Server RD 3 Party App Subsystem EAS Interface PHD Shadow Server
L4 to L4 Limited L3.5 to L3.5
Level l 3.5 3 DMZ

Domain Controller ESF PHD Server Experion Server
L3 to L3 Limite d L2 to L3
ESC
ESF
ACE
Experion Server
EST
Level 2 Level 1
Qualified Cisco Switches
L2 to L2
L1 to L1
45
Security levels
Level 1 - Controllers and real time control Level 2 Servers, Operator Stations and supervisory control. Level 3 - Historians and Advanced Control and connection to other Level 2 areas or units. Level 3.5 - DMZ accessed from the Business Network and the PCN. Level 4 - Is the business network with clients for Historians or Advanced Control applications. Level 3 and 3.5 utilizes standard open systems Ethernet technology and Level 4 utilizes standard open systems LAN technology.
46
Page 22
No communications betw ween L1 & L3 or L4

File Number File Number
Domain Controller
Limite d L2 to L1
Very Limited L2 to L3.5
Level 3
Router
Optional HSRP Router ESVT Safety Terminal Server Manager
No Direct communications between L4 & L3 or L2
Enterprise Switch
Comm flow
Very Limited L3.5 to L4
Level 1 Process Control

Level 4
Level 3.5 DMZ

ESC
ESF
ACE
Experion Server
EST
Level 2 Level 1
L2 to L2
L1 to L1
47
Level 1 - Process Control

Controllers and real time control Safety Systems Protected by all other levels
48
Page 23
No communications s between L1 & L3 or L4

Domain Controller
Limite 2 to d L2 L1
Level 3
Router
No Direct communica ations between L4 & L3 or L2
Enterprise Switch
Comm flow
Very L3 Limited L to L3.5
Level 2 Supervisory Control
Level 4
Level l 3.5 3 DMZ

ESC
ESF
ACE
Experion Server
EST
Level 2 Level 1
L2 to L2
L1 to L1
49
Level 2 - Supervisory Control

Connections for Servers and Operator Stations Supervisory control Connection to Level 1 Protection for Level 1 with access lists FTE capable
50
Page 24

Domain Controller
Limite d L2 to L1
Level 3
Router
Enterprise Switch
Comm flow
Level 3 Advanced Control
Level 4
Level l 3.5 3 DMZ

ESC
ESF
ACE
Experion Server
EST
Level 2 Level 1
L2 to L2
L1 to L1
51
Level 3 - Advanced Control

Connections for Historians and Advanced Control g Routing Access List control Connect other Level 2 areas or units Can be redundant, but not FTE capable HSRP
52
Page 25

Domain Controller
Limite d L2 to L1
Level 3
Router
Enterprise Switch
Comm flow
Level 3.5 Demilitarized Zone (DMZ)
Level 4
Level l 3.5 3 DMZ

ESC
ESF
ACE
Experion Server
EST
Level 2 Level 1
L2 to L2
L1 to L1
53
Level 3.5 - Demilitarized Zone (DMZ)

Is commonly called the DMZ Typical nodes WSUS, Anti-Virus Server, etc. Provides connectivity for devices that are to be accessed from the Business Network and the PCN. Security zone between the PCN and outside networks Can be redundant, but not FTE capable
54
Page 26

Domain Controller
Limite d L2 to L1
Level 3
Router
Enterprise Switch
Comm flow
Level 4 - Business Network
Level 4
Firewall Terminal Patch Anti eServer Mgmt Server Virus Server Server RD 3 Party App Subsystem EAS Interface PHD Shadow Server
Level l 3.5 3 DMZ

ESC
ESF
ACE
Experion Server
EST
Level 2 Level 1
L2 to L2
L1 to L1
55
Level 4 Business Network

Is the business network with clients for Historians or Advanced Control applications. Untrusted Network Separated by a firewall No direct connection to Level 3 or below Managed by Business IT department Level 4 utilizes standard open systems LAN technology.
56
Page 27

Domain Controller
Limite d L2 to L1
Level 3
Router
Enterprise Switch
Comm flow
Questions?
57
File Number
Thank You
58
File Number
Page 28

Distributed Control Systems Theory &amp; Implementation

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Distributed Control Systems Theory &amp; Implementation

Uploaded by

Copyright:

Available Formats

ISA Lunch and Learn

Ken Carfagno November 6, 2013

Control Loop Types & Components

Types of Control Loops

Components of Control Loops

Basic Feedback Control Loop

Most commonly used process control loop

Basic Loop Components

Controller Output (0-100%)

Transmission Signal FV Transmitter FT Final Control Element (control valve)

Detailed description of instrument symbols are on the legend

E Assembly-Double Block/Bleed w Bypass Valve

Control Valve I/P Transducer

Cascade Control Loops

Load Variable Changes

Basic Control Implementation Function Blocks

Input from the transmitter

Honeywell Proprietary & Confidential

R1 (Valve Opened) (Run Pump) R2 ZSO-2 R1

120 VAC H PB-1 R1 PB-2 N

120 VAC H PB-1 R1 PB-2 N

120 VAC H PB-1 R1 PB-2 N

120 VAC H PB-1 R1 PB-2 N

120 VAC H PB-1 R1 PB-2 N

120 VAC H PB-1 R1 PB-2 N

Typical Connection and Wiring

Here is how we would wire our control circuit.

Control Via PLC, Ladder Logic

Here is how we would wire our devices to the PLC I/O.

PB-1 PB-2 ZSO 2 ZSO-2

120 VAC H PB-1 R1 PB-2 N

PB-1 PB-2 ZSO-2

This is what our PLC programming language looks like. DI 1 DI 2 DO 1 DI 3 DO

120 VAC H PB-1 R1 PB-2 N

PB-1 PB-2 ZSO-2

120 VAC H PB-1 R1 PB-2 N

PB-1 PB-2 ZSO-2

The programming is done on a laptop PC.

Control via DCS, Function Blocks

Embedded Operator Instructions

Analog Inputs: Questions

Analog Inputs, 2 wire, System Powered

AI, Current Signal, Self Power

Human Machine Interface

HMI Example of Non-Conforming Graphic

FC201 4608.23 BPD D200

AI241 320.78 AMPS FC214 1308.29 BPD

HMI Example of ASM Graphic

Abnormal Situation Management Study

- 21 Operators - Matching process upsets on

Source: ASM Meeting report Oct. 2004

Context-sensitive Access to Information

Alarm help Operating procedures

Quicker response & Less errors

Trend with Events

Trend with Numerics

Secure Network Architectures

Manufacturing automation architecture

Business Planning & Logistics

Level 2 Batch Control Level 1 Level 0 Continuous Control

Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...

PROCES SS CONTROL DOMAIN

Manufacturing Operations Management

Distributed Control Systems Theory & Implementation

Distributed Control Systems Theory & Implementation