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Dcsbasics 110629044133 Phpapp02 PDF
Dcsbasics 110629044133 Phpapp02 PDF
DCS EVOLUTION
LOCAL CONTROL : Initially control was performed local to the equipment
control. The ADVANTAGE was low wiring costs .DISADVANTAGES were not much control, monitoring, alarming & history.
:
:
:
:
Ammonia II
ANP
NNAP
Methyl amine
: STP
: Ammonia I Synthesis
: Steam Generation Plant
: Suphala
: Methanol
: S A P/C N A
: ABC
: Ammonia I
: Ammonia/Urea - Thal
: D M A C - Thal
: PGR
: Steam Generation - Thal
: Water Treatment Plant -
DCS
The importance of DCS systems to increase as global competitive
TYPES OF DCS :
1) Conventional DCS .
2) PLC based DCS.
3) Hybrid DCS.
4) Open DCS System
CONVENTIONAL DCS
This is a pure Process only control system. Usually purchased from
one vendor. This DCS arranged into three categories:
Small - Less than $ 100,000.
Medium - Greater than $100,000 & Less than $500,000.
Large - Greater than $500,000.
PLC Based DCS.
This is a network of PLCs used to perform the task of
conventional DCS and programmable functionality when required.
Hybrid DCS.
Performs both process and sequential control.
Open DCS System.
This is Field-Bus Control. Advantages are lower wiring cost and
less failure, smaller expansion costs and multi vendor interoperability
DCS and PLC can be more closely and efficiently interconnected.
US#1
US#2
HM
LCN A
B
HG
AMC
Field
EC Link
AMC
Data Hiway
Field
LCN Module. Provides a two way communication link between the Local
Control Network and data hiway.
68020 based high performance intelligence module.
Converts data and protocol between Local Control Network and data hiway.
Scans the hiway for alarm conditions.
Synchronize time keeping for hiway-based process connected boxes.
One HG is required for each data hiway that is connected to the LCN. Up to
20 data hiway pairs can be connected to an LCN.
Connects following hiway resident boxes to LCN
1. AMCs
2. CPC ( critical process controller ).
3. DHP.
4. Hiway traffic director etc
HG Functions :
1. Data access :- gets box data requested from LCN modules.
2. Event processing :- sends process and box alarm to LCN modules
3. Database configuration :- 3000 points per hg can be configured.
Data Hiway
History Module
Universal Station
Universal station (US) communicates with all modules on the
LCN, process
connected devices on the hiway via hiway gateway and UCN via network
interface module
(NIM).
The following are the features of US,
Intelligent man/machine interface in the TDC 3000 system.
Stands on the LCN. Communicates with all Modules on LCN, process
connected devices on the Hiway via Hiway Gateway.
Provides comprehensive facilities to the process operator, process
engineer and maintenance technician on the Universal Window.
US provides comprehensive facilities to the following people,
Process engineer
Process operator
Maintenance technician.
AMC
HONEYWELL - GUS
Printer
Drives
Printer
Universal
Station
US#1
US#2
US#3
US#4
HM
History Module
A
Local Control Network
NIM
HPM
HPM
HPM
Processor
Memory
Cache
Storage
Cartridge Drive
Video
Pixels
Colours
Keyboard
PIN Connection
Cursor Control
:
:
:
:
:
:
:
:
:
Peripherals supported
Printer
8 * CD-ROM
1/4 Steamer Tape
3.5 Floppy Drive
100 Mb ZIP Drive
Annunciator relay on the console-based keyboard
Operating System
Base System
:
:
exchange
between the network and all GUS
functions.
History Modules
The History Modules is the bulk module that can be utilized by all module
connected
to the Local Control Network. It is as the name implies the mass memory of the
TPS
System. The memory components of this module are one 1.8 gigabyte
Winchester discs.
It is controlled by an M68040 microprocessor. This provides the module with
significant
computing power that this used to structure much of the incoming data and
format it into
a form for easy retrieval.
The history in the model is provided by the History Module. Process
variables are
available for hourly, shift, daily and monthly average calculation and recording.
All system event history such as process alarms, system status changes,
and error
messages are stored into the History Modules.
Other modules have access to data in the History Modules for their
functions.
The History Module provides two functions, storage only and data structuring
The Network Interface Module (NIM) provides the link between the local Control
Network and the Universal Control Network. As such it make the transition from
the
transmission technique and protocol or the Local Control Network to the
transmission
technique and the protocol of the Universal Control Network. The NIM provides
access
by LCN modules data from UCN resident devices. The NIM is available in the
redundant
configuration to provide continued operation in the event of the primary failure. It
can
also do event processing.
There can be up to 10 redundant NIM pairs per LCN. A NIM can host upto
8000 tag
names and supports a data transfer rate of 2400 parameters per second.
Communication Subsystem
Local Control Network (LCN)
Communication Subsystem
EOPS
/1
EOPS
/2
ENGG.
STATION
Micro-XL
A
B
HF BUS
(1 Mbps)
EFCD
EFMS
EFGW
I/O #1
ncst
Closed loop
control signal
Through I/O NEST
I/O #2
ncst
Monitoring signals
Through I/O NEST
I/O #3
I/O #5
ncst
I/O #4
A B
NIO Bus
INTERPLANT
NETWORK PC
(OPTIONAL)
OPERATOR/ENGINEERING
STATION
HIS
DM
Printer
PRT
HIS
HIS
PRT
Inkjet
Printer
DUAL V NET
10 Mbps
FCS
RIO BUS
NIU
NIU
INTERPLANT
NETWORK PC
(OPTIONAL)
OPERATOR/ENGINEERING
STATION
HIS
DM
Printer
PRT
HIS
HIS
PRT
CGW
Inkjet
Printer
V NET
10 Mbps
FCS
BCV
RIO BUS
NIU
NIU
CS, CS 1000
Centum XL, -V, -MXL
HIS Human Interface Station.
FCS Field Control Station.
NIU Node Interface Unit.
RIO Bus Remote I/O Bus.
CGW Communication gateway unit
BCV Bus Converter
HIS
HIS
HIS
V net
FCS
FCS
FCS
1,00,000
256
16
64
16 NOS
:
:
:
:
256 / system
16 / system
1 to 64
1 to 16
64
:
:
:
:
17 to 64
1 to 64 in descending
1 to 64 in ascending order
16
:
8
:
40
( Max. 5/ IOU)
:
20 Km
:
20 Km (750m ~
10BASE2 cable
V net Communication
HIS
HIS
V net
Protocol
: IEEE802.4
Access Control : Token Passing
Trans. Speed : 10 Mbps
Trans. Distance: 500m to 20Km
Media
: Coaxial/optical fiber
FCS
FCS
V net specification
ITEM
SPECIFICATION
Transmission route
Type
Communication rate
10 Mbps
Transmission Distance
Redundancy
Dual-redundant
Proto type
Token passing
V- net Features
comp. )
Communication speed : 10 Mbps.
High reliable token passing communication
( performance guaranteed )
Std. max. length : 185 m.
Max. length : 20 Km ( with optical fiber )
1.6 Km ( with coax. Repeater )
BNC Connector
VL net
cable
VL net I/F card ( PCI )
Ethernet
HIS and ENG, HIS and supervisory systems can be
connected by an
Ethernet LAN; supervisory computers and personal
computers on the Ethernet
LAN can access messages and trend data in the CS 3000
system. The Ethernet
can also be used for sending trend data files from the HIS
to supervisory
computers, or for equalizing the data in the two HIS station
( rather than using
the V net control bus to do this ). A system with only one
HIS with engineering
functions installed, does not need Ethernet but in general
Ethernet ( and
corresponding network engineering ) is required.
Ethernet Specification
ITEM
SPECIFICATION
Transmission Route
Type
Communication Rate
10 Mbps
Transmission Distance
Redundancy
Not available
Proto type
CSMA/CD Type
TYPES OF HIS
HIS Hardware
CPU
Main memory
monitoring only)
Hard disk
Display
Pentium 166
96MB or larger(for op &
Serial port
1 GB or larger
256Colors min. resolution 800*600
1024*768 recommend(1280*1024 best)
RS232C*1 or more (for operation
keyboard)
Parallel port
OS
Operator stations
HIS
HIS
HIS
V net
I/O Unit
RIO Bus
Sub system
Node
Node
Interface
Unit
I/O Unit
Sub system
Compact FCS
Standard FCS
Exapilot client
(engineering, operation)
Ethernet
Exapilot client
(engineering,
operation)
HIS
ENG
Exaopc
Exapilot server
(engineering, operation)
V-net
FCS
Features of Exapilot
Flow Trans.
Terminator
HMI
Control Valve
Safety Barrier
Pressure TX.
Field bus
It is a standardized digital communication protocol between a process
Control field devices
and the Control room. It is a simple pair of wires to power and carry the
communication
signal between the field devices and the Control room.
FEATURES :
Drastic reduction in cable, conduits cable trays, marshallive racks, and
connectors etc.
Drastic reduction in installation cost.
Fewer non field devices.
More reliability due to the smaller number of devices.
More efficient operation due to better accuracy (no A/D and D/A
conversion).
Easy integration into plant management system.
Flexibility for different suppliers are interoperable and interchangeable.
Major reduction in maintenance cost.
Field-bus Benefits
Wiring
Wire
(pair)
Screw
Terms
I/O
Cards
IS
Barriers
Traditional
3500
168
Field bus
640
64
Savings
2860
104
50%
50%
Savings %
82%
63%
$ 3000 Material
$ 2000 Labor
$ 5000 Total
Typically comments from a plant personal :
Savings $
Transducer
(Servo)
Block
Function
Function
Block(s)
Block(s)
FOUNDATION
fieldbus
Transducer
Block
Temperature
Transmitter
Function
Function
Block(s)
Block(s)
FOUNDATION
fieldbus
H1 Segment
Moderate speed
Use existing wiring
Bus powered
Can be intrinsically
safe
Low power 2 wire
devices
4 wire devices
Replace analog &
proprietary digital
H2 Segment
High speed
Link multiple H1
Segments
I/O subsystem bus
Replace
proprietary
networks
New wiring
H1/H2
Bridge
PLC
H1 Segment
H1/H2
H1/H2Bridge
Bridge
Replaces
Replaces
Traditional
TraditionalI/O
I/O
H1 Segment
H1 Segment
IEC
International Electro-technical Commission
ISA
International Society for Measurement and Control
(formerly: Instrument Society of America)
SP50
CENELEC
European standards body
Parallel (competitive?) Working Groups to IEC
Reduced
H1 I/O
ReducedWiring
Wiring
Interface
Junction
Box
H1 I/O
Terminations
FewerTerminations
FewerTerminations
H1 Fieldbus
all-digital
Marshaling
Fewer
FewerTerminations
Terminations
Fewer
FewerIS
ISbarriers
barriers
IS (Ex i)
Barriers
Cost
Costsavings:
savings:
wiring
wiring
I/O
I/Ocards
cards&&
cables
cables
terminations
terminations
IS
ISbarriers
barriers
marshaling
marshaling
H1 Fieldbus
all-digital
Barriers
Operator station
Printer
Printer
8 port Hub
primary
8 port Hub
Redundant
1
Serial
P
S
Contr.
Contr.
A AA DDD
I I O I I O
Power supply
Controller
H1
Connector
Blank
Blank
Blank
Blank
Blank
Blank
PLC For
8 DI &
8 DO
H
I
Fieldbus Transmitter
3244MVF1NAB4
Fieldbus Power
Pressure Transmitter
3051TG2A2B21AB4M5FF
Smart valve positioner
FSDVC0400-201
MIS
High
Level 4
Scheduling
SCHED.
Low
Level 3
Supervisory control
Level 2
Direct digital
Control (DDC)
Level 1
Sensors (S)
& Actuators (A)
High data rates
Low responsibility
SUP.
SUP.
DDC
DDC
DDC
PLANT
DDC
Discrete
Byte-wide
Data
Analog
Bit-wide
data
Several Hundred
Data Bytes
Protocol Standard
Field Bus Foundation
(Field Bus std.)
Device net
Byte-Wide
Data
CAN Bus
SDS
Inter Bus-S
Seriplex
ASI
Inter Bus Loop
Fieldbus Architecture
Fieldbus is more than just a new signal communications protocol, but a whole new way
to
control the process. With the release of the low fieldbus (H1), the entire fieldbus will
be
defined. Most of the recent published literature has focused on the intricate details of
the
fieldbus architecture, especially those layers that have not been released. However,
Maintenance
except
Workstation
information
physical layer and the user layer, these layer aresystem
transparent to the engineers and the
manager.
Data Layer
Physical Layer
Multivariable Valve
Transmitter
Level
Pump
Transmitter
stack
System management
Application Layer
Network Management
User Layer
For the purpose of Process control, the top and bottom four layers are used.
Layers 5 and 6 are important to large commercial networks.
Field Bus
Field Bus is a bi-directional digital communication that interconnects smart field
devices to
control system or to instrument located in the control room.
Field Bus is based on the OSI (Open System Interconnect), which was developed by
the ISO
(International Standard Organization) to represent the various functions required in
any
Layer
Function
Communication network.
7
Application
Provides formatted
data
Presentation
Converts data
Session
Transport
Network
Establishes network
connections
Link
Physical
Connects the
equipment
Field Bus
The OSI model consists of seven layers. However for real time application
layers 3 to 6 are
not considered since they deal with transference of data among networks.
For such
application following layers are used:
LAYER 1 - PHYSICAL LAYER
Defines the type of signal, transmitting medium, data transmission
speed, etc.
LAYER 2 DATALINK LAYER
Define the interface between the physical layer and the application layer.
It establishes
how the messages shall be structured and normalizes the use of
multiple masters.
LAYER 3 APPLICATION LAYER
Defines
howwas
data
is specified,
its addresses
andRam
its representat
ion.
The Fieldbus
invented
by an Indian
engineer Mr.
Ramchandran
( M.S in Comp. Tech , Texas)
PHYSICAL LAYER
The Physical layer defines the medium that transport the messages frames, the signal
shape and
amplitude limits, data transfer rate, and power distribution.
Technical Characteristics:
Physical Medium
Three types are defined: wires, optic fiber, and radio signals. The
specification for
wire has been already approved.
Bit rate for wire media
31.25 Kbps (H1)
1 megabits and 2.5 megabits (H2).
H1 and H2 are classification of the two hanks of Field Bus target applications.
H1 has
low speed and utilizes existing wires. H2 has high speed and may require
independent
wires to power up field devices.
Number of devices per link (31.25Kbps)
2 to 32 devices, without power and no IS (intrinsic safety).
2 to 6 with power and IS.
Maximum distance
Up to 1900 meters for 31.25Kbps, without repeaters. Up to 750 meters for 1
megabits. Up to 500 meter for 2.5 megabits.
PHYSICAL LAYER
Signal Modulation
Manchester bi phase L synchronous.
Physical layer preamble
on transmissions, the physical layer will add to the data sent by the layer
above a
preamble and one start delimiter in the beginning of the frame and one end
delimiter
at the end delimiter at the end of the of the frame.
well as
IEEE
802
methods.
SP72
Number 72
messaging.
SP50
Number 50
devices.
F.I.P
Profibus
LAYER
FUNCTIONS
HART
Application
Presentation
Converts data
Session
Handles the
dialogue
Transport
Secures the
transport
connection
Network
Establishes
network
connections
Link
Establishes the
data link
connection
HART protocol
regulations
Physical
Connects the
Bell 202
AD
CD
BC
Statu
s
Dat
a
Parity
SD start character.
AD display terminal and field
addresses.
CD HART instruction.
BC Byte count.
Status Field device and communication status (only from field device to
master)
The individual characters are : 1 start bit, 8 data bits, 1 bit for odd parity and 1
Layer 7, the application layer, brings the HART instruction into play. The master
sends
messages with requests for specified values, actual values and any other data or
parameters
available from the device. The field device interprets these instruction as defined
in the
HART protocol. The response message provides the master with the status
information
and data from the slave.
For slave devices, logical uniform communication is provided by the following
command
sets:
Universal commands understood by all field devices.
Common practice commands provide functions which can be carried out by
many,
though not all, field devices.
Drive-specific commands provide functions which are restricted to an
individual
DATA INTEGRITY
Physical layer
: Error rate destination circuit : 1/(10^5)
Link layer
: Recognizes : all groups up to 3 corrupt bits and
practically all longer
and multiple groups.
Application layer : Communication status terminated in a response
message.
MODBUS
The MODBUS protocol describes an industrial communication and
distributed
control system developed by Gould-Modicon. MODBUS is a Master/Slave
communications protocol, whereby one device (Master), controls all serial
activities by
selectively polling one or more slave devices. The protocol provides for one master
device
and up to 247 slave devices on a common line. Each device is assigned an
address to
distinguish it from all other connected device.
Only a master initiates a transaction. Transactions are either a
query/response type,
or a broadcast/no-response type. A transaction comprises a single query and
single
response frame or a single broadcast frame.
Certain characteristic of a MODBUS protocol are fixed such as frame
format, frame
sequences, handling of communication errors and exception conditions, and the
functions
performed.
RS-232 Communication
RS-232 Communication
RS-232 communication is done through Serial port which usually has a 9-pin
configuration. The pin and their purposes are shown below.
9-PIN
PURPOSE
Frame ground
CD 10
01
CD
RXD 20
02
RXD
TXD 30
03
TXD
DTR 40
04
DTR
GND 50
05
GND
DSR 60
06
DSR
RTS 70
07
RTS
CTS 80
08 CTS
09 RI
RI 90
9-Pin D Connector
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
PC
Dial-up or Local ISP
Leased Line
Local ISP
PC-to-Phone
The
Internet
PC
Phone
Local ISP
Voice Gateway
Local ISP
Phone-to-Phone
Access
Code
The
Internet
Phone
Phone
Local ISP
Voice Gateway
Local ISP
Voice Gateway
Operator Console
Engineer Console
Operator Console
Controller Level
Controller Module
I/O Level
I/O Modules
Transmitter
Interlock
Console Level
I/P Valve
TAGS
Range
Engineering Unit
Diagnostics
Drivers
-----------------------
HMI
1
Planning
HMI
4
Devices
I/O
PLC
DCS
OPC Client
Application
OPC
Server
HMI
----------------------------------
Planning
HMI
Devices
I/O
PLC
DCS
Windows NT
Corporate
IT Network
Windows NT
Server
Control
network
Embedded
Real System
Windows NT Interconnectivity
Transparent inter-connectivity to typical business systems in plants:
1) ODBC : It provides access to most SQL databases.
2) ActiveX/OLE : Supports data access between application and
embedding of
one applications function within another.
3) DDE : Dynamic Data Exchange supports simple data exchange
between
applications such as plant data populating an Excel spread
sheets.
Windows NT features
Windows NT is gaining ground in open control because of the following advantages :
User acceptance.
Corporate interoperability
Ease of use.
Connectivity.
Scalability for small and large application.
Ethernet
Ethernet was originally designed by Digital, Intel and Xerox (DIX) in the early
1970s
and has been designed as a broadcast system. The original format for Ethernet was
developed
in Xerox Palo Alto Research center (PARC), California in 1972. The two inventors
were
Robert Metcalf and David Boggs.
Ethernet version 1.0 and 2.0 followed until the IEEE 802.3 committee rejigged the
Ethernet II packet to form the Ethernet 802.3 packet. Nowadays you will see either
Ethernet II (DIX) format or Ethernet 802.3 format being used.
The Ether part of Ethernet denotes that the system is not meant to be
restricted only to
one medium type, copper cables, fiber cables and even radio waves can be used.
Briefly, stated Ethernet what is referred to as the Physical layer and the Datalink layers
protocols. The physical layer defines the cable types, connectors and electrical
characteristics.
The Data link layer defines the format an Ethernet frames, the error checking
method and the
Ethernet
10Base5
Traditionally, Ethernet is used over thick coaxial cable called 10Base5 (
the 10
denotes 10 Mbps, base means that the signal is baseband i.e, takes the whole
bandwidth
of the cable, 5 denotes 500m maximum length ). The minimum length
between stations
is 2.5m.
The cable is run in one long length forming a Bus Topology. The
segments are
terminated by 50 ohm resistor and the shield should be grounded at one end
only.
10Base2
Thin Ethernet (Thinnet) uses RG-58 cable and is called 10Base2 (the 2
denotes
200 mtr maximum length cable). Each station connects to the Thinnet by way
of
Ethernet
10BaseT
Nowadays, it is becoming increasingly important to use Ethernet across
Unshielded
Twisted Pair (UTP) or Shielded Twisted Pair (STP), this being called 10BaseT (the T
denotes twisted pair). UTP is installed in star wire format and Ethernet Hubs with
UTP ports
(RJ45) centrally located. Also there should be no more than a 11.5db signal loss and
the
minimum distance between devices is 2.5 meters.
The advantages of the UTP/STP technology are gained from the flexibility of
the
system, with respect to moves, changes, fault finding, reliability and security.
10BaseF
10BaseF standard developed by IEEE 802.3 committee defines the use of Fiber
for
Ethernet. 10BaseFB allows up to 2 Km per segment and is defined for Backbone
Ethernet
The following table shows the RJ45 pin outs for 10BaseT :
RJ45 Pin
Function
Colour
Transmit
White/Orange
Transmit
Orange/White
Receive
White/Green
Blue/White
White/Blue
Receive
Green/White
White/Brown
Brown/White
RJ45
Ethernet Topology
Segmented (star) topology
Workstation
Workstation
Bus topology
Workstation
Workstation
Switched Hub
Controller
Controller
Controller
Controller
Wireless LAN
Wireless LAN is based on standard IEEE 802.11b which throughput of up to 11Mbps in
the
2.4 Ghz band. Similar Wireless Personal Area Network (WPAN) are Bluetooth and
Infrared.
Ethernet works on the CSMA/CD technology but wireless LAN has difficulty of
detecting
collision in Radio frequency. Therefore they are using CSMA/CA (Collision Sense Multiple
Access / Collision Avoidance) technology to transmit data. Physical Layer is either
Photonic or
Radio frequency.
History &
Trend
Alarm &
Events
SCADA
configuration
editor
Other Aspect
system
SCADA Control
Aspect
OP Client
OPC server
SCADA
server
Real-time
database
opc
Modbus
comli
Protocol Protocol
xx
yy
ABB
Siemens
Allen
Bradley
GE
Fanuc
Ladder Diagram
Instruction List
Function Block Diagram
Sequential Function Chart
Structured Text
All users, be they plant electrician or computer scientists, thus have
a configuration interface in which they can feel at home.
Industrial IT Trends
The availability of information is becoming increasingly crucial in the view of growing
global
competition. In future, a decisive competitive edge can only be achieved by providing
the
right information at the right time, in the right place and in the right form for the right
person.
these leading- edge application are continuously optimized and repositioned.
Industrial IT consists of five components:
1.
2.
3.
4.
5.
Engineering IT
Operation IT
Production IT
Optimization IT
Evolution / Information
Industrial IT Trend
Business
Systems
Sales &
Marketing
Plant &
Process Eng.
Operation &
Maintenance
Real-time
Automation &
Information
ASSET
TY
UCTIVI
e-PROD
Planning &
Scheduling
ION
OPTIMIZAT
Distribution
Plant