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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.
DCS
The importance of DCS systems to increase as global competitive
dynamics in food and beverage, specialty metals, pulp and paper, pharmaceutical and fire chemical processing. The DCS has networking capabilities which are useful for business management. The DCS has capacity for processing large number of I/O points.
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
EC Link
Field Field
Data Hiway
Data hiway provides communication link between hiway gateway, preferred access devices and process connecting box. Data hiway operates at 250 kbps. It is redundant pair of 75 ohm coax cable connected to box. It may be 20,000 feet long. There are 3 kinds of devices on the data hiway, 1. Respond only devices Ex:- A-MC (Advanced Multifunction controller) 2. Polled devices Ex:- PIUs (Process interface unit) 3. Preferred access devices
History Module
information that can be displayed. Based on microprocessors 68020. Winchester disk for data storage. Communicates with all Modules on the LCN. Stores history and general information.
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
TDC 3000 controller
1. 2. Based on Motorola 68000 Microprocessor. Faster execution and control with 500 ms processing rate.
Multifunction Modulating, sequence, logic, I/O monitoring communication and diagnostic. Faster peer to peer communication over EC link ( 500 kbits/sec ). Proven control techniques
1. 2. 1. Full function algorithms. Process oriented programming. LCN devices US, AM, HM.
HONEYWELL - GUS
Printer
Drives
Printer
Universal Station
Global User Station History Modules Network Interface Modules Communication Subsystem - Local Control Network & Universal Control Network High Performance Process Manager
Processor Memory Cache Storage Cartridge Drive Video Pixels Colours Keyboard PIN Connection Cursor Control
: : : : : : : : :
Pentium Pro / 200MHZ 64MB RAM ECC 256KB ECC 2 GB hard disk drive, CD ROM, 21 high resolution screen 1280 * 1024 256 color palette Integrated keyboard with mouse Built in Ethernet QWERTY & Mouse/Touch Screen
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
: :
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)
The backbone of every TPS system is a communication network, known as Local Control Network. The LCN is a LAN through which TDC 3000 modules communicate with each other. The LCN is a broadcast type of LAN. It is high speed redundant communication bus that connect all the control room equipment. All information is transferred on the network at 5 million bits per sec.,serially. It is based on the IEEE 802.4 Token passing and Bus Standard. Each LCN device that is connected to the Local Control Network is called a module. Up to 64 modules may be connected to the Local Control Network in a TPS system. The Local Control Network is designated as the primary and the other as the back
Communication Subsystem
EOPS /1
EOPS /2
ENGG. STATION
A B
HF BUS (1 Mbps) EFCD I/O #1 ncst I/O #2 ncst I/O #3 I/O #5 ncst I/O #4 A B NIO Bus
HF BUS : High frequency Bus: no. of station on HF Bus are 32 EOPS : Extended Operator station: Hard disk capacity of EOPS is 80 MB EFCD : Extended field control station : 80 laps per controller EFMS : Extended field mauture station Max 255 inputs EFGN : Extended field gateway unit ENGS : Engineering station NIO : Nest I/O bus. Closed loop control signal Through I/O NEST Monitoring signals Through I/O NEST Third party system with PLC, Gas Analyser etc. thr RS 232C port At the rate of 9600 bps
EFMS
EFGW
OPERATOR/ENGINEERING STATION
HIS
DM Printer
PRT
HIS
HIS
PRT
Inkjet Printer
RIO BUS
NIU
NIU
HIS Human Interface Station. FCS Field Control Station. NIU Node Interface Unit. RIO Bus Remote I/O Bus.
CGW
HIS
DM Printer
PRT
HIS
HIS
PRT
BCV
RIO BUS
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
NIU
HIS
HIS
HIS
V net
FCS
FCS
FCS
NO. OF TAGS MONITORED TOTAL NO. OF STATION NO. OF DOMAINS NO. OF STATIONS IN A DOMAIN NO. OF HIS / DOMAIN
10BASE2 cable
used by HIS, maximum segment length = 185 m 10BASE5 cable used by stations other than HIS(FCS,CGW etc.) maximum segment length = 500 m
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
Transmission route Type Communication rate Transmission Distance Redundancy Proto type
SPECIFICATION
Coaxial or fiber optical cable Bus type or Multi-drop type 10 Mbps 500M 20Km Max Dual-redundant Token passing
V- net Features
Real time control bus. ( Dual redundant possible ) Cable : 50 ohm coax. cable with BNC connector ( 10Base2
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 )
VL net cable VL net I/F card ( PCI )
BNC Connector
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
Transmission Route Type Communication Rate Transmission Distance Redundancy Proto type
SPECIFICATION
Coaxial or Fiber optical cable Bus type or Multidrop type 10 Mbps 500m 2.5 Km max. Not available CSMA/CD Type
TYPES OF HIS
Console type HIS Desk top type HIS PHIS Yokogawa brand OPS
HIS Hardware
CPU Main memory
monitoring only) Hard disk Display Pentium 166 96MB or larger(for op & 1 GB or larger 256Colors min. resolution 800*600 1024*768 recommend(1280*1024 best) RS232C*1 or more (for operation 1 port for printer or more Windows NT 4.0 Workstation Max. 8 stations
Serial port
keyboard) Parallel port OS Operator stations
HIS
HIS
HIS
V net
Sub system
Node
Sub system
Compact FCS
Standard FCS
Ethernet
Exapilot client (engineering, operation)
HIS
ENG
Exaopc
Exapilot server (engineering, operation)
V-net
Features of Exapilot
Standardize and Automate Manual Procedures Improve Plant Operating Efficiency Improve safety of Plant Operation
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 Traditional Field bus Savings Savings % Savings $ Wire (pair) 3500 640 2860 82% Screw Terms 168 64 104 63% I/O Cards 2 1 1 50% IS Barriers 2 1 1 50%
$ 3000 Material $ 2000 Labor $ 5000 Total Typically comments from a plant personal : Easy to identify whats out there. Consistent calibration procedure. Two days versus four days to commission system. Familiar with twisted pair wiring comfortable.
Transducer Block
Temperature Transmitter
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
H1/H2 Bridge H1/H2 Bridge Replaces Replaces Traditional I/O Traditional I/O
H1 Segment
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
Junction Box
Cost savings: Cost savings: wiring wiring I/O cards & I/O cards & cables cables terminations terminations IS barriers IS barriers marshaling marshaling FewerTerminations FewerTerminations
H1 Fieldbus all-digital
IS (Ex i) Barriers
Barriers
P S
A AA DDD I I O I I O
Contr.
Serial
Contr.
H1 Connector
D O
H I
Fieldbus Transmitter 3244MVF1NAB4 Pressure Transmitter 3051TG2A2B21AB4M5FF Smart valve positioner FSDVC0400-201
Fieldbus Power
MIS
High
Level 4 Scheduling
SCHED.
Low
SUP.
SUP.
DDC
DDC
DDC
DDC
PLANT
Discrete
Analog
Byte-wide Data
Bit-wide data
Protocol Standard
Field Bus Foundation (Field Bus std.)
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 system physical layer and the user layer, these layer are transparent to the engineers and the manager.
User Layer
Application Layer
Network Management
System management
Data Layer
Physical Layer
stack
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 6 5 4 3 2 1 Application Presentation Session Transport Network Link Physical Provides formatted data Converts data Handles the dialogue Secures the transport connection Establishes network connections Establishes the data link connection 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 invented by an Indian engineer Mr. Ramrepresentation. The Fieldbus data is specified, its addresses and its 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.
HART Protocol Structure : HART follows the basic Open Systems Interconnection (OSI) reference model, developed by the International Organization for Standard (ISO). The HART protocol uses a reduced OSI model, implementing only layers 1,2 and 7
LAYER
7 6 5 4 Application Presentation Session Transport
FUNCTIONS
HART
Provides formatted HART instructions data Converts data Handles the dialogue Secures the transport connection Establishes network connections Establishes the data link connection Connects the HART protocol regulations Bell 202
Network
Link
Physical
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 is an asynchronous communication network. Normally, a binary system is used to transmit data in ASCII (American Standard Code for Information Interchange) format. This code translates human readable code (letter/numbers) into computer readable code(1s and 0s). There are 2 types of RS-232 devices. The first is called a DTE (Data Terminal Equipment) device and a common example is a computer. The other type of device is called DCE (Data Communication Equipment) device and a common example is a modem. In RS-232 the first thing a terminal send is start bit. This start bit is a synchronizing bit added just before each character being send. The last thing send is a stop bit. This stop bit informs to the receiving terminal that the last character has just being send.
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
1 2 3 4 5 6 7 8 9
PURPOSE
Frame ground Receive data (RD) Transmit data (TD) Data terminal ready (DTR) Signal ground (GND) Data set ready (DSR) Request to send (RTS) Clear to Send (CTS) Ring indicator (RI) *only for modems*
01 02 03 04 05 06 07
08 CTS 09 RI
9-Pin D Connector
PC-to-Phone
The Internet PC Local ISP Local ISP Voice Gateway Phone
Phone-to-Phone
Phone
Operator Console
Engineer Console
Operator Console
Console Level
Controller Module
Controller Level
I/O Modules
Transmitter
Interlock
I/P Valve
HMI 1 2 3
-----------------------
Planning HMI 4 5 6
Drivers
HMI 2 3
----------------------------------
Planning HMI
Windows NT
Control network
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.
However, Windows NT has the following disadvantages : Needs a lot memory and processing power. Optimized for office, not control, requirements. Requires a disk drive which may fail. Depends on single vendor. Reboots at unexpected times Unstable operating system.
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
1 2 3 4 5 6 7 8
Function
Transmit Transmit Receive
Colour
White/Orange Orange/White White/Green Blue/White White/Blue
Receive
RJ45
1 2 3 4 5 6 7 8
Ethernet Topology
Segmented (star) topology Bus topology
Workstation
Workstation
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.
OP Client
OPC server
SCADA server
Real-time database
opc ABB
Modbus
comli
Allen Bradley
Protocol Protocol xx yy
GE Fanuc
Siemens
The open, manufacturer-independent programming standard for automation is IEC 61131-3. You can thus choose what configuration interface you wish to use when writing your application :
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
TY UCTIVI e-PROD
ASSET
ION OPTIMIZAT
Distribution
Plant