ABB - Symphony

Rakesh Y, Ahmed, Abdul-Aziz

:DCS
Remote
Location
Monitoring the Process .1
Control the process .2

DCS Problem Analysis .3

Process Automation .4
Process parameters data storage .5
Plant Operation &
Process
Reports & Reviews .6
:DCS

Engineering
Work Stations Station

Controller Controller
I/O Modules I/O Modules

Plant Operation & Process

Main Steam Damper Motor

Pressure, Tank
Open Run
Flow Level
Feedback Cmd
ABB Symphony DCS
Tnore NT Stations Composer Tnore NT Stations

C-Net Bridge C-Net

PCU PCU PCU PCU

Controller Controller Controller Controller
I/O Modules I/O Modules I/O Modules I/O Modules

Symphony DCS contains Control Net & Nodes (PCU, Tenore NT, Composer, Bridge)
Control Net: C-net is unidirectional, high speed serial data network. Each C-net supports 250
node connections.
PCU: Receive the input from field & process the function & gives the output to field control
devices.
Tnore NT: It is an operator station HMI to monitor & control the process.
Composer: It is an engineer station HMI, which contains engineer applications.
Bridge: To connect one C-net with other C-net.
:Communication Interface

Loop – 4(STG-4)
NTCL NTCL
NTCL
Loop - 1

NTCL

N I I
P C I
M T T
Bridge Node

PCU Node
Tnore NT Node

NTCL & NIS

• They are common in every loop.
• NTCL connect the node with others nodes.
• NIS is the front end of every C-net communication interface
• NIS has LED, each LED has different error code which you can devein it in the manual.
:PCU (Process Control Unit) NTCL NTCL

N N
I I
S S
NPM
Filtering the signals, if the signals has the N
P N
same address it will pass them to the MFP. M P
Control Way
M
MFP
It is the main equipment for controlling and M M
processing of the plant F M F M
P F P F I/O Expander Bus
I/O slaves P P
• Used to Connect the Field signals with
A A D D A A D D
MFP S S S S S S S S
• Digital (0 or 1) I O I O I O I O
• Analog 4-20 MA – resistance - MV
TU TU
TU (Termination Unit)
• Each Slave Module have one termination TU
TU
unit
• It use to assemble the signals together. TU TU

TU TU
:Tnore NT C-Net

Loop – 4(STG-4)
NTCL
NTCL
NTCL

I
C I I
T C C
T T
Tnore NT Tnore NT Tnore NT
Client-1 Client-2 Tnore Tnore Composer Client-3
Server1 Server2

O-Net

Root Switch Printer

Tnore NT Station: Composer:

• It provide Human –Machine Interface for
plant monitoring and control.
• Process supervision .
• Data historian and archiving.
• Analog trending, Alarm management .
• Report generation
• It is an engineering station.
• It provides all engineering applications like
Automation Architect, Graphic Designer.
• Composer performs important tasks like Controller
configuration, New points configuration.
 :Bridge
Bridge Node I
I
T

• To connect one C-net with other C-net

we use bridge.
• It is used to import and export the
NTCL
process data from one node to another NTCL

node.
• It accept the control commands from Loop – 4 Loop –1
operators . (STG-4) CCB

Local C-Net Central C-Net

MARAFIQ – UCS(Unified Control System) with Symphony

STG1 STG2 STG3 STG4 Desal-

1,2,3,4,5

PCU PCU PCU PCU PCU

Polish
1&2 Desal-7,8

PCU
PCU
CCR – Loop 1

GTG/
HRSG Desal-9

PCU
PCU

Tank Desal-
SWPH Polish 3&4 BWRO
Farm 10,11

PCU PCU PCU PCU

PCU
:Works executed in Team

• PM of STG-1 PCU’s
 Remove all the filters and clean them with instrument air.
 Clean the cabinet from inside using air vacuum and brush.
 Checked the redundancy for communication modules NIS/NPM.
 Checked the redundancy for controller modules MFP.
 Remove all the modules one by one and clean them with air
duster and brush.
 Checked the Input & Output supplies of PSU-Power Supply Unit
with multi meter.
 Checked the input voltages of Termination Units
 Check the green light on NTCL when switch over.
 Check if you get alarm when switch over.
 • Replacement of PSU in HRSG-2
 DI signal failure happened which  Finally, we found that the DSI
tripped the HRSG-2. Termination Units are getting only
16vdc instead of 24vdc.
 In trouble shooting the problem, we
 Because of Power Supply Unit is
measured the contact and found that it
is close from field. showing the 24vdc at output but not
driving the same voltage to
 We suspected that channel is failed, so
Termination Units, which is the root
we changed the module to rectify the
cause for the problem.
problem.
 It causes the modules unable to read
 After changing the module, it
the contacts.
measured the contact.
 So, we replaced the Power Supply
 But when contact is open and closed
Unit & found no signal failures in that
again the module is unable to read the
PCU.
contact.
 We tried all the possibilities to find the
signals failure, but still problem is
persist.
• Some Other Activities

 Finding the I/O signal’s hardware channel addresses in

composer.
 Troubleshooting the channel failure of signals.
 Troubleshooting the problems in Master modules NPM,MFP.
 Replacement of the faulty modules with new modules.
 Error code study of all master & slave modules.
 Replacement of NTCL without fail the communication.
Conclusion:
In last 2 months span we gained this and in future we are seeking
to get experience by -
• Utilizing this knowledge & practical experience to give
professional output.
• Troubleshooting the problems in different ways to keep the
operation safe.
• Executing the jobs in team with all safety procedures.
• Improving the knowledge on symphony system
1) Problem analysis and resolving skills.
2) Controller Configuration
3) Logics Study, Modification
4) Graphics Creation, Modification
5) DCS Applications(Trends, Alarms, Reports, etc)
NPM (Network Processor Module)
• It is a communication module that makeup the C-net to PCU node
communication.
• NPM connects with control module(MFP) via control way in PCU. It is the
gateway between C-net & Control Way.
• Filtering the signals, if the signals has the same address it will pass them to
the MFP.
• It is responsible for a) Write command to NIS
b) Requesting NIS status
c) Writing data to NIS
d) Read data from NIS
• Backup/Secondary NPM continuous monitor the Primary NPM through
direct cable connection, if Secondary detects Primary failure then it
becomes primary.
MFP (Multi Function Processor)
• It is a multiple loop analog, sequential, batch & advanced controller.
• It provides powerful solutions to process control problems.
• The set of function codes in this module handles most complex strategies.
• This controller uses analog, control, digital I/O modules to communicate
with the process.
• It communicates with 64 I/O modules maximum.
• It operates in 3 modes 1) Execute Mode
2) Configure Mode
3) Error Mode
• Backup/Secondary MFP continuous monitor the Primary MFP through
direct cable connection, if Secondary detects Primary failure then it
becomes primary.
 I/O Slave Modules

• These modules are used by controller to monitor & control the process.
• These modules are interface between controller & field signals.
• I/O modules are commonly 4 types 1) Analog Input
2) Analog Output
3) Digital Input
4) Digital Output
• Each module contains its own address.
• Each modules contains 16 channels.
• Analog Signals : 4-20 ma, MV, Resistance
Example: Pressure, Flow, Level, Temperature, Vibration, Speed
• Digital Signals : 0 or 1
Example : Open/Close feedbacks, Switches, Motor Running feedbacks
TU (Termination Unit)
• Each Slave Module have one termination unit
• It use to assemble the signals together.
• We use the jumper to identify type of signal
and type of power supply ( system power -
external power ).
C-Net

• Control Net (C-net) is unidirectional, high speed serial data network.

• Each C-net supports 250 node connections.
• One C-net can connect with other C-net as a node.
• Group of C-net can connect with one C-net which is called Central C-net
(CC-net).
• So, the capacity of nodes in a system are 62500
• Redundant Communication is main feature in C-net.