DCS Architectures

 

DCS EVOLUTION-CENTRALISED CONTROL

 

DCS EVOLUTION-DISTRIBUTED CONTROL

 

DCS EVOLUTION-FIELDBUS CONTROL

 

DCS EVO EVOLUT LUTION ION-- WEB CON CONTRO TROL L

 

DCS EVOLUTION-WEB CONTROL APPLICATION

 

ABB DCS ARCITECTURE

 

ABB DCS HARDWARE

 

CONTROL SYSTEMS TREND 1) PLC 2) DCS 3) PC PC - Ba Base sed d Con Contr trol ol.. •

PLC : Introduced in the late 1960 to replace Relays and Hard-wired Programming.

 

DCS : Introduced in the to replace  pneumatic controls by Mid-1970 using computers. •

PC-Based Control : Introduced by the early 1980s to avoid the  proprietary PLC & DCS systems.

 

DCS EVOLUTION •

 LOCAL CONTROL

: Initially control was performed local to the equipment control.

The ADVANTAGE was low& wiring costs .DISADVANTAGES we were re - no nott m muc uch h control, monitoring, alarming history. • •

CENTRALISED CONTROL:

With the advent of minicomputer, sensors and actuators

were into the Central Control (Computer). With the advent of microcomputer, Distributed control systems were installed in the plants near to the control room via proprietary digital communications lines called as Data Hiway. First DCS was developed by

 DISTRIBUTED CONTROL:

Honeywell,U.S in 1975. The ADVANTAGES were greatly reduced wiring costs, much more limited failure and less cost to add more points. The DISADVANTAGES were that wiring costs were that wiring costs were still significant and there was lack of interoperability among controllers of various manufacturers due to the proprietary protocols. Hence the user was locked into a single vendor.

 

DCS System Installations in RCF 1. Yoko Yokogawa gawa - CS 3000

:

Ammo Ammonia nia II

2. Yoko Yokogaw gawaa - CS 3000

:

ANP

3. Yoko Yokogaw gawaa - CS 3000

:

NNAP

4. Moor Mooree - APA APACS CS

:

Met Methyl hyl ami amine ne

5. Fis Fisher her - Ros Rosema emant nt - Del Delta ta V fie field ld Bus 6. Honeywe Honeywell ll - GUS

: :

STP Ammonia I Synthes Synthesis is

7. Yokogawa - Centum Excel

:

Steam Genera Generation tion Plant

8. Mo Moor oree - AP APAC ACS S 9. Yokogawa - Micro Excel

: Su Suph phal alaa : Methanol

10. Yokogaw Yokogawaa - Micro Excel

:

11. ABB - Fre Freela elance nce 2000

: ABC

12. Hon Honeywe eywell ll - TDC 3000 13. Hon Honeywe eywell ll - GUS

: Ammo Ammonia nia I : Ammo Ammonia nia/Ur /Urea ea - Tha Thall

14.. Fo 14 Fox x bo boro ro - I/ I/A A se seri ries es

:

D M A C - Th Thal al

15. Fis Fisher her - Ros Roseman emantt RS3 16. Fis Fisher her - Ros Roseman emantt RS3

: :

P G R  Ste Steam am Gene Generat ration ion - Tha Thall

17. Moor Mooree - APA APACS CS

:

Wat Water er Treatme Treatment nt Pla Plant nt - Tha Thall

S A P/C N A

 

DCS • • •

Th The e im impor porta tance nce of D DCS CS ssys yste tems ms tto o in incr crea ease se gl globa oballpharmaceutical co compe mpeti titi tive ve d dyna ynami cs iin n food and beverage, specialty metals, pulp andaasspaper, andmics fire chemical processing. Th Thee D DCS CS has net netwo worki rking ng ca capab pabil ilit itie iess w whi hich ch are us usefu efull ffor or b bus usine iness ss management. Th Thee D DCS CS has ca capac pacit ity y ffor or proce process ssing ing large large num numbe berr o off II/O /O poi points nts..

TYPES OF DCS

1) Conventional DCS . 2) PLC based DCS. 3) Hybrid DCS. 4) Open DCS System

:

 

CONVENTION CONVENTIONAL AL 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.

•

Mediu edium m - Grea Greate terr tha than n$ $10 100, 0,00 000 0 & Le Less ss tha than $50 $500, 0,00 000. 0.

•

Large - Greater than $500,000.

PLC Based DCS. This is a network of PLC’s 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.

   

Honeywell TDC 3000 DCS Architecture

US#1

US#2

HM LCN

A B

HG AMC EC Link 

AMC Data Hiway

A

B

Field  Field 

Hiway Gateway (HG)

 

•

LCN Modu dulle. Provid vides a two way commu muni niccation link between the Lo Loccal Control Network and data hiway.

•

68020 based high performance intelligence module.

•

Conv nveert rtss d daata aand nd pro rottoc oco ol b beetween L Lo ocal C Co ontro roll N Neetwork and d daata h hiiway.

• •

Scans the hiway for alarm conditions. Syn yncchr hro oniz nize time keepin ping fo forr hiwayy-ba bassed pr proc oceess conn nneected bo boxe xess.

•

On Onee HG is re requ quir ired ed for for ea each ch da data ta hi hiwa way y that that is co conn nnec ecte ted d to the the LC LCN. N. Up to 20 da data ta hiway pairs can be connected to an LCN.

•

Connects following hiway resident boxes to LCN 1.

AMCs

2.

CPC ( critical p prrocess cco ontroller ))..

3. 4.

D H P. Hiway traffic director etc…

HG Functions : 1. Data aacccess ::-- gets b bo ox d daata rreequ queested ffrrom LCN m mod odu ules. 2.

Ev Even entt pr proc oces essi sing ng :- sen ends ds pr proc oces esss an and db box ox al alar arm m to LC LCN N mo modu dule less

3.

Da Data taba base se co conf nfig igur urat atio ion n :- 30 3000 00 po poin ints ts pe perr hg ca can n be co conf nfig igur ured ed..

Data Hiway

 

Data hiway provides communication link between hiway gateway,  preferred access access devices and process connecting box. Da Data ta hiway operates aatt 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. 2. 3.

Resp Respon ond d onl only dev eviices ces Ex:Ex:- A-MC A-MC (Adv (Advan ance ced d Mul ulttif ifun uncction tion con ontr tro oller ller)) Polled devices Ex:- PIU’s (Process interface unit) Preferred access devices

 

History Module

•

LCN LCN Modu Module le.. St Stor ores es p pro roce cess ss and and sy syst stem em info inform rmat atio ion n ttha hatt ca can n be displayed.

•

Based sed o on nm miicroprocess sso ors 68 68020.

• •

Win inch cheeste ster disk disk for for dat ataa st stor orag age. e. Comm Commun unic icat ates es wi with th al alll Modu Module less on th thee LC LCN. N.

•

Stor Stores es hist histor ory y and and gene genera rall info inform rmat atio ion. n.

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, Inte Intell llig igen entt ma man/ n/ma mach chin inee iint nter erfa face ce iin n th thee TD TDC C 30 3000 00 ssys yste tem. m.

•

St Stan ands ds on th thee L LCN CN.. Co Commu mmuni nica cate tess wi with th all all M Modu odule less o on nL LCN CN,, p proc roces esss conne connect cted ed devices on the Hiway via Hiway Gateway.

•

Pr Provi ovides des ccomp ompre rehe hensi nsive ve fa faci cili liti ties es tto o the p proc roces esss ope operat rator or,, pro proce cess ss engi enginee neerr 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.

Based o on nM Mo otorola 68000 M Miicroprocessor.

2.

Fa Fasste terr eexe xecu cuti tion on an and d ccon ontr trol ol with ith 5 500 00 ms pr proc oces essi sing ng ra rate te..

•

Multifunction – Modulating, sseequence, lo logic, II//O m mo onitoring communication and diagnostic.

•

Faster peer to p peeer communication over EC link ( 50 500 kbits/sec ).

•

Proven control techniques

•

1.

Full function algorithms.

2.

Process o orriented p prrogramming.

Configured as a box on TDC 3000 Data Hiway. Supported by 1.

LCN devices – US, AM, HM.

 

HO HONE NEYW YWEL ELL L - GU GUS S Printer 

Drive’s

Printer 

Universal Station

US#1

US#2

US#3

US#4

HM History Module A Local Control Network 

 Network Interface Module

 NIM

   k   r   o   w    t   e    N    l   o   r    t   n   o    C    l   a   s   r   e   v    i   n

HPM HPM HPM

High Performance Manager 

B

   U

 

Honeywell System Description

•

Global User Station

• •

History Modules Network Interface Modules

•

Comm Commun unic icat atio ion n Sub Subsy syst stem em - Loca Locall Con Contr trol ol Ne Netw twor ork k & Un Univ iver ersa sall C Con ontr trol ol

 Network  • High igh Perf Perfor orm man ancce Proc Proces esss Mana Manage ger  r 

Global User Station

 

Overview The TPS system provides an integrated interface between the process and the end user. This interface is named as the Global User Station (GUS). GUS is an important part in the Honeywell Total plant Solutions offerings. It  provides access to plant wide process network, plant or organization organizatio n wide intranet or even Internet. The following hardware is available to enhance the functionality of the GUS: •

In Inte tegr grat ated ed Ke Keyb yboa oard rd for for O Ope pera rato tors rs as we well ll as En Engi gine neer er..

• •

Ma Matr trix ix pr prin inte terr sup uppo port rted ed by Wi Wind ndow owss NT NT.. 8 * CD-ROM

•

100MB ZIP Drive

•

3.5” Floppy Drive

•

GUS has following functionality's : Th Thee “H “Huma uman n ” in inter terfa face ce aall llow owss ef effec fecti tive ve iint nter eract action ion o off th thee Op Opera erato torr thr throug ough h the u use se of operating displays

•

En Engi ginee neeri ring ng fu funct nctio ions ns ssuch uch aass da data ta p poi oint nt bu buil ildi ding, ng, d dis ispl play ay bu buil ildi ding ng an and d rep report ort  building are available.

•

Co Comm mmun unic icat atio ion nw wit ith h ot othe herr L LCN CN mo modu dule less iiss aacc ccom ompl plis ishe hed. d.

•

Communication on Ethernet.

Honey well GUS Hardware:

 

•

Processor

:

Pentium Pro / 200MHZ

•

Memory

:

64MB RAM ECC

•

Cache

:

256KB ECC

•

St Stor orag agee

:

2 GB ha hard rd di disk sk dr driv ive, e, CD ROM OM,, Car artr trid idge ge Dr Driive

• •

Vi Vide deo o Colours

: :

21 21”” hi high gh reso resolu luti tion on sc scre reen en 12 1280 80 * 10 1024 24 Pi Pixe xels ls 256 color palette

•

Ke Keyb yboa oard rd

:

Int Integ egra rate ted d ke keyb yboa oard rd wi with th mo mous usee

•

PIN Conne necction

:

Built in Etherne nett

•

Cu Curs rsor or Con ontr trol ol

:

QW QWER ERTY TY & Mo Mous use/ e/To Touc uch h Sc Scre reen en

Peripherals supported  • •

Printer   8 * CD-ROM

•

1/4” Steamer Tape

•

3.5” Floppy Drive

•

100 Mb ZIP Drive

•

An Annu nunc ncia iato torr re rela lay yo on n th thee co cons nsol olee-ba base sed d ke keyb yboa oard  rd 

 

Honeywell GUS software

•

Op Oper erat atin ing g Sy Sysste tem m

:

Wi Wind ndow owss NT ve vers rsio ion n 4. 4.0 0

•

Ba Base se Sy Syst stem em

:

Pr Prov ovid ides es re real al time time da data ta ex exch chan ange ge  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 controlled by an M68040 microprocess microprocessor. or. This provides the module with sign significant ificant 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 modules have acce access ss to data in the His History tory Modules for their functions. functions. The History Module Module provides two funct functions, ions, stora storage ge only and data struct structuring uring and storage.. The data structuri storage structuring ng and storage funct function ion provides much of the historica historicall data of  the process to which the system is connected.

 

HM functions and Historization parameter HM functions : It can automatically backup the control databases in the HG, AM, CG. HM can store, •

Continuous process history.

•

Event journal (history).

•

Active system ffiiles.

•

Static system files.

•

On p pro roce cess ss an anal alys ysis is pr prog ogra ram m ((ma main inte tena nanc ncee aaid id))

HM Historization parameters : There can can be up to 10 HM’s o on n the LCN. T There here can be m maximum aximum of 150 groups p per  er  HM. Each group can have up to 20 points. All points in the group must be in the same unit.

 

Network Interface Module (NIM)

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 redund ant 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 eac communicate each h other. The LCN is a bro broadcast adcast ty type pe of LAN. It is high spee speed  d  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  up. Local Control Control Network Network provides ti time me synchroni synchronization zation for al alll modules modules..

 

Communication Subsystem

Universal Control Network (UCN) The Universal Control Network is a high speed, high security process control network network based on open system inte interconnect rconnection ion standar standards. ds. It features a 5 megabit/second, megabit /second, ccarrier arrier band band,, token bus netw network ork compati compatible ble with IEEE and ISO standards. standar ds. It is used as the re real al time redund redundant ant Communic Communications ations backbone for   process connected devices such as the High Performance Process Pro cess Manager  (HPM), Advanced Process Manager . The UCN supports peer-to-peer  communication for sharing data and allowing greater co-ordination of control strategies among network devices. The UCN uses redundant co-axial cables and can support up to 32 redundant devices UCN supports 2 types of devices - Pr Proce ocess ss ma manag nager er.. - Lo Logic gic man manage ager. r.

High Performance Process Manager (HPM)

 

The High Performance Process Manager is the latest in the Progression of High Performance control products offered by Honeywell for the application to Improve controlling of existing and new industrial processes. High Performance Process Manager is a fully integrated membe memberr of the TPS family. It is capable of : • •

perf perfor ormi ming ng da data ta acqu acquis isit itio ion n an and d cont contro roll func functi tion onss full fully y comm commun unic icat atin ing g wi with th ope opera rato tors rs aand nd eng engin inee eers rs aatt th thee GU GUSs Ss aand nd un univ iver ersa sall Work stations.

•

Suppor Supportin ting gh high igherer-lev level el strate strategie giess avai availab lable le on the Loc Local al Con Contro troll Netw Network ork through the Application Module and Host Computers.

 

High Performance Process Manager Overview The High Performance Process Manager uses a powerful multi-processor architecture architecture with separate microprocessors dedicated to perform specific tasks. The HPM consists of two modules Communication and Control Module (CCM) and the I/O subsystem the I/O subsystem consist of up to 40 Smart I/O Modules (SIOM). All control operation are performed within the communicati communication on and control module. The process engineer has complete flexibility of choice within the maximum HPM design limits. These selections are implemented using the interactive interactive tools provided by both the GUS and Universal Work Station. The I/O processors, for example, provide such functions as engineering unit conversion and alarm limit checking independent of the communication and control modules. communication The communication process is optimized to provide high performance network communications. communicatio ns. The control processor is HPM resource dedicated to executing regulatory,logic and sequence functions, including a powerful user programming facility. Since Since communi communication cation and I/O proce processing ssing are provided provided by separate ded dedicated  icated  hardware.

YOKOGAWA CENTUM EXCEL ARCHITECTURE

 

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

Third party system with PLC, Gas Analyser Analyser etc. thr RS 232C 232C port At the rate of 9600 bps

I/O #3 I/O #5 ncst I/O #4

HF BUS : High frequency frequency Bus: n no. o. of station on HF Bus are 32 EOPS : Extended Operator station: Hard disk capacity of EOPS is 80 MB EFCD : Extended Extended field control station : 80 laps per controller : Extended field mauture station Max 255 inputs EFGN : Extended field gateway unit ENGS : Engineering station EFMS

A B NIO Bus

NIO

: Nest I/O bus.

   

Windows NT Based Centum CS Configuration

INTERPLANT  NETWORK PC (OPTIONAL)

Ethernet Connectivity (optional)

OPERATOR/ENGINEERING STATION

OPERATOR STATION SUB-SYSTEM

HIS

DM Printer 

PRT

HIS

HIS

PRT

Inkjet Printer 

DUAL “V NET” 10 Mbps FCS

RIO BUS

 NIU

 NIU

HIS – Human Interf Interface ace Sta Station. tion. FCS – Field Control Control Station Station..  NIU – Node Interface Unit. RIO Bus Bus – Remote Remote I/ I/O O Bus. Bus.

 

Centum CS 3000 System Overview Centum CS 3000 is an integrated production control system for medium and large control applications. This system is a synthesis of the latest technology with Yokogawa’s experience and specialist know-how.

Centum CS 3000 system features : • Sy Synt nthe hesi siss o off D DC CS w wit ith hP Per erso sona nall ccom ompu putters ers. •

Online D Do ocumentation.

•

Po Powe werf rful ul Op Oper erat atio ion n an and d Mo Moni nito tori ring ng Fu Func ncti tion ons. s.

•

Two Types of Control Station.

•

Compact I/O Modules.

•

Po Powe werf rful ul Co Cont ntro roll an and d Co Comm mmun unic icat atio ion n Fu Func ncti tion ons. s.

• •

Efficient Engineering. Vi Virt rtual ual Te Test st fun funct ction ionss d don’ on’tt rrequ equire ire Con Contr trol ol St Stat ation ion ha hardw rdwar are. e.

•

Full-Featured B Baatch P Paackage.

•

CE CENT NTUM UM CS mi micr croo-XL XL Inte Integr grat atio ion n ( to be rele releas ased ed ).

 

Centum CS 3000 System Overview Centum CS 3000 is an integrated production control system for medium and large control applications. This system is a synthesis of the latest technology with Yokogawa’s experience and specialist know-how. Centum CS 3000 system features :

•Synthesis of DCS with Personal computers. •Truly open system for integrating multi-vendor solutions. •High Reliability of computed process data by the unique fault tolerant control processor. •Powerful built in “RISC PROCESSOR” with high speed and dynamic error correcting code. •Remote I/O concept enables geographically distribution of I/O Modules thereby reducing cabling cost. •1:1 Redundancy at almost all the system levels except for control processor which employs a special Redundancy with 4 identical CPU’s. •Powerful Control Tools and Communication Functions. •Virtual Test functions don’t require Control Station hardware. •Full-Featured Batch Package. •Built in security features to prevent mal-operations. •CENTUM CS micro-XL Integration ( to be released ).

 

 

CS300 000 0 – Sys System tem Con Config figura uratio tion n CS3

INTERPLANT  NETWORK PC (OPTIONAL)

Ethernet Connectivity (optional)

OPERATOR/ENGINEERING STATION

OPERATOR STATION SUB-SYSTEM

Remote Domain System

HIS

DM Printer 

PRT

HIS

HIS

PRT

Inkjet Printer 

CGW

V NET 10 Mbps FCS

BCV

RIO BUS

 NIU

 NIU

CS, CS 1000 Centum Cen tum – XL, -V, -V, -M -MXL XL HIS – Huma Human n Inte Interface rface S Statio tation. n. FCS – Field Control Control Sta Station. tion.  NIU – Node Interface Unit. RIO Bus Bus – Remote Remote I/O Bus. CGW – Comm Communicat unication ion gate gateway way uni unitt

BCV – Bus C Conv onvert erter  er 

 

CENTUM CS 3000 NETWORK

HIS

HIS

HIS

V net

FCS

FCS

FCS

 

CENTUM CS3000 SYSTEM SPECIFICATION

• NO. OF TAGS MONITORED

1,00,000

• TOTAL NO. OF STATION

256

• NO. OF DOMAINS

16

• NO. OF STATIONS IN A DOMAIN

64

• NO. OF HIS / DOMAIN

16 NOS

 

CENTUM CS3000 SYSTEM SPECIFICATION • •

Max. no. of stations Max. no. of Domains

: :

256 / system 16 / system

•

Numbering of Domains

:

1 t o 64

•

Domain No. CS3000 Domain :

1 t o 16

:

64

:

17 t o 64

(V net Domain) •

Max. no. of stations/Domain

•

Domain No.Virtual Domain (Non V net Domain)

•

Stat Statio ion n NO NO.. HIS HIS

:

1 to 64 in de desc scen endi ding ng or orde derr

•

Station NO. FCS

:

1 to 64 in ascending order  

•

Max. No. of ICS / Domain

:

16

•

Max. No. of NIU / FCS

:

8

•

Max. Max. No No.. of IO IOU U / FCS FCS

:

40

•

Max. length of Vnet

:

20 Km

•

Max. Max. leng ength of RIO RIO bus bus

:

20 Km

( Ma Max. x. 5/ IO IOU) U) (7 (75 50m ~ 20K 20Km)

Centum CS-3000 Communication

 

V net

V net is 10 mbps real time control bus which links station such as FCS , HIS , BCV and  CGW. It can be dual redundant. It can be up to 500m using coaxial cable alone, or up to 20 Km when repeater are used or optical fiber is used. •

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. to 20Km fiber Media Distance:: 500m Coaxial/optical

FCS

FCS

 

V net specification

ITEM

SPECIFICATION

Transmission route

Coaxial or fiber optical cable

Type

Bus type or Multi-drop type

Communication rate

10 Mbps

Transmission Distance

500M –20Km Max

Redundancy

Dual-redundant

Proto type

Token passing

 

Feat atu ure ress V- net Fe • Re Real al ti time me cont contro roll b bus us.. ( D Dua uall rred edun unda dant nt po poss ssib ible le ) • Ca Cabl blee : 50 oh ohm m ccoa oax. x. cab cable le with with B BNC NC con conne nect ctor or ( 1 10B 0Bas ase2 e2 co comp mp.. ) • Commun munication ssp pee eed d:1 10 0 Mbps. • Hi High gh re reli liab able le toke token np pas assi sing ng co comm mmun unic icat atio ion n ( performance guaranteed ) • Std. max. length : 185 m. • Ma Max. x. le leng ngth th : 2 20 0K Km m(w wit ith ho op ptica ticall ffib iber er )

BNC Connector 

1.6 Km ( with coax. Repeater )

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 equalizi equalizing ng the da data ta in the two HIS station station ( rather than using the V net control bus to to do this )).. A system wi with th only one HIS with engineering engineering functions installed, installed, does no nott need Ethe Ethernet rnet – but in ge general neral Ether Ethernet net ( and corresponding network engineering ) is required.

 

Ethernet Specification ITEM

SPECIFICATION

Transmission Route

Coaxial or Fiber optical cable

Type

Bus type or Multi–drop type

Communication Rate

10 Mbps

Transmission Distance

500m – 2.5 Km max.

Redundancy

Not available

Proto type

CSMA/CD Type

 

TYPES OF HIS

• Console type HIS • Desk top type HIS • PHIS Yokogawa brand OPS

HIS Hardware

 

• •

CPU Main memory

Pentium 166 96MB or larger(for op & monitoring only)

•

Hard disk

1 GB or larger  

•

Display

256Colors min. resolution 800*600 1024*768 recommend(1280*1024 best)

•

Serial port

RS232C*1 or more (for operation keyboard)

• •

Parallel port OS

1 port for printer or more Windows NT 4.0 Workstation

•

Operator stations

Max. 8 stations

Field Control Station Configuration

 

 

Ethernet

HIS

HIS

HIS V net

I/O Unit RIO Bus  Node

Sub system

 Node

Interface Unit I/O Unit

Sub system

Compact FCS

Standard FCS

   

Connection to Centum CS 3000 System

Exapilot client (engineering, operation)

Ethernet Exapilot client (engineering, operation)

HIS

E NG

Exaopc Exapilot server (engineering, operation)

V-net

Exapilot communication data Process data read/write FCS

FCS

 

Features of Exapilot • •

St Stan anda dard rdiz izee aand nd Au Auto toma mate te Ma Manu nual al Pr Proc oced edur ures es Impr prov ovee P Pllant O Op pera ratting E Effficienc ncy y

•

Impr prov ovee safety of Plant Operat ration

Features of Event Analysis Package •

An Anal alys ysis is DCS DCS Ev Even entt Hi Hist stor ory y to He Help lp Y You ou E Enh nhan ance ce Ef Effi fici cien ency cy..

•

En Enhan hance ce P Proc roces esss St Stab abil ilit ity: y: B Bal alanc ancee Pr Proc oces esss Ev Even ents ts aand nd O Ope pera rator tor Ac Acti tions ons..

•

Whe When, n, Wh Where ere,, W Wha hatt ((3W) 3W) Fi Filt lter erss H Hel elp pY You ou Na Narr rrow ow Fo Focu cuss o off A Anal nalys ysis is..

 

OPEN DCS SYSTEM Ethernet Field Bus Power Supply

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 : •

Dra Drasti sticc rreduc eductio tion n iin n ca cable ble,, ccondu onduits its cab cable le tra trays, ys, mars marshal hallive live rac racks, ks, and conn connect ectors ors etc etc..

•

Dr Dras asti ticc rred educ ucti tion on in ins install tallat atio ion n ccos ost. t.

• •

Fewer non field devices. Mo More re re reli liab abil ilit ity yd due ue to the the ssma mall ller er nu numb mber er of de devi vice ces. s.

•

Mor Moree ef effi fici cient ent ope opera rati tion on d due ue tto o be bett tter er aacc ccura uracy cy ((no no A A/D /D aand nd D D/A /A cconv onver ersi sion) on)..

•

Ea Easy sy inte integr grat atio ion n iint nto o plan plantt ma mana nage geme ment nt sy syst stem em..

•

Fl Flex exibi ibili lity ty ffor or di diffe ffere rent nt ssupp uppli lier erss ar aree in inte terop ropera erabl blee an and d int inter ercha change ngeab able le..

•

Major reduc ucttion in m maainte ntenanc ncee ccos ostt.

Field-bus Benefits

 

Wiring

Wire (pair)

Screw Terms

I/O Cards 2 1

Traditional Field bus

3500’ 640’

168 64

Savings Savings %

2860’ 82%

104 63%

Savings $

$ 3000 Material

$ $ 2000 5000 Labor  Total Typically comments from a plant personal : •Easy to identify what’sprocedure. out there. •Consistent calibration •Two days versus four days to commission system.

1 50%

IS Barriers 2 1

1 50%

•Familiar •Famil iar with ttwiste wisted d pair wiri wiring ng – comforta comfortable. ble.

     

FOUNDATION™ fieldbus Vocabulary Blocks Basic Ba sic Components omp onents Valve

Resource Resource Block Block

Transducer  (Servo) Block

Function Function Block(s) Block(s)

FOUNDATION™ fieldbus

   

FOUNDATION™ fieldbus Vocabulary Blocks

Basic Ba sic Compone omp onents nts

Resource Resource Block Block

Transducer  Block

Function Function Block(s) Block(s)

Temperature Transmitter 

FOUNDATION™ fieldbus

 

FOUNDATION™ fieldbus Vocabulary • H1 Segment

H1 and H2 • H2 Segment

 – speed   – Moderate Use existing wirin wiring g  – Bus powered 

 – High speed   – Link multiple H1 Segments

 – Can be intrinsically safe  – Low power 2 wire devices  – 4 wire devices  – Replace analog &  proprietary digital

 – I/O subsystem bu buss  – Replace proprietary networks  – New wiring

 

FOUNDATION™ fieldbus Vocabulary  New Approach for H2 • 10 100 0 Meg Meg Et Ethe hern rnet et te tech chno nolo logy gy wi with th ex exte tens nsio ions ns  – Improve time to market  – High speed   – Mandatory redundancy  – Widely available technology and silicon  – Widely available tools  – Limited incremental development  – Many suppliers  – High volume for low cost  – Works with installed equipment  – Evergreen technology

ette terr th than ANY oth other er solu luti tio on! • Bet

 

 

FOUNDATION™ fieldbus Vocabulary H1/H2 Bridges Server 

H1/H2 Bridge

H2 Se Segm gment ent 10 100 0M Meg eg Eth Ethern ernet et Control Module

PLC

H1 Segment

H1 H1/H 22Brid Br ge H1/H /H2 Bridge Brid idge ge H1/H2 Replaces Replaces Traditional TraditionalI/O I/O

H1 Segm Segment ent

H1 Segment

 

FOUNDATION™ fieldbus Standards Organizations • IEC  – International Electro-technical Commission

• ISA  – International Society for Measurement and Control (formerly: Instrument Society of America) • SP50

• CENELEC  – European standards body • Par Parall allel el ((com compet petiti itive? ve?)) Worki Working ng Group Groupss to IIEC EC

   

 

FOUNDATION™ fieldbus Topography H1 Fieldbus Installations Controller  Simi Similar lar Cards ards Simi Similar larI/O I/OC Card Ca rds s

Reduced H1 I/O ReducedWiring Wiring Interface

Junction Bo x

H1 I/O Terminations

FewerTerminations FewerTerminations

H1 Fieldbus Fieldbu s all-digital Marshaling

Fewer FewerTerminations Terminations

Fe Fewer wer barriers iers Fewer werIS ISbarr barri barriers ers Fe

IS (Ex (Ex i) i) Barriers

Cost Costsavings: savings: • wiring • wiring • I/O I/I/O OOcards • I/ cards&& cables • • terminations cables terminations • IS barriers barri ers • IS barri barriers ers • marshaling • marshaling

H1 Fieldbu Fieldbus s all-digital

 

FOUNDATION™ fieldbus Topography Intrinsic Safety

Barriers

 

DeltaV System Architecture

 

Engineering station

Operator station

Printer 

Printer 

8 port Hub  primary

8 port Hub Redundant 1

2 wide carrier for  Power/Controller  P S

 C        o      n      t .  r         

P S

 C        o      n      t .  r         

 S    e  r   i       a  l     

8 wide carrier for  I/O subsystem

A AA DDD I

I O I I O

Power supply Controller 

I/O extension cable

H1 Connector 

RS232 Modbus PLC For  8 DI & 8 DO

D O

B       B        al             al            n     n     k       k      

B        al            n     k      

B       B       l        al             a     n     nk      k            

B        al            n     k      

H I

Fieldbus Transmitter  Pressure Transmitter 

3244MVF1NAB4

3051TG2A2B21AB4M5FF Smart valve positioner  FSDVC0400-201

Fieldbus Power   

DCS communication system Hierarchy

 

Level 5 Management Low data rates Superior responsibility

MIS High

Level 4 Scheduling

SCHED. Low

Level 3 Supervisory control

Level 2 Direct digital Control (DDC)

SUP.

SUP.

DDC

DDC

DDC

DDC

Level 1 Sensors (S) & Actuators (A) High data rates Low responsibility

S

A

A

S

A

S

S

S

A

S

S

A

PLANT

 

History of Process Control Signal Around 50 years ago, most plant used 3-15psi pneumatic signal to control their process. The last change change change in signal standa standard rd was the open protocol HART digit digital al communica communications tions format. The HART protocol provides simultaneous digital communications with the 4-20 mA output. The next protocol change will be fieldbus. Fieldbus is entirely digital-there is no analog Signal. Fieldbus also allows migration of control functions to field devices. Process ss control control Timeline – The Evolution Evolution of Signal Signal Standard Proce

Signal standards have evolved over the years, starting with the 3-15 psi standard. There are also other communication methods, but they have not gained widespread acceptance. With many standard there is typically a slow transition period as plant engineers and  managers test period does gain widespread acceptance. However, once the benefits of the Fieldbus become tested and proven, more plant will install Fieldbus because of its benefit and  economic cost.

Digital: Fieldbus Digital plus Analog: HART with 4-20mA Analog: 4-20mA

Pneumatic: 3-15 psi

1940

1950

1960

1970

1980

1990

2000

2010

 

I/O Bus Network Protocol I/O Bus Network Device bus network

Analog

Discrete

Byte-wide Data

Process bus network  

Bit-wide data

Several Hundred Data Bytes

 

Protocol Standard Field Bus Foundation (Field Bus std.)

Process bus network Profibus Trade Organization (Profibus std.)

Device net Byte-Wide Data

CAN Bus SDS Inter Bus-S

Device bus network Bit-Wide Data

Seriplex ASI Inter Bus Loop

 

Fieldbus Architecture Fieldbuss is more than just a new ssignal Fieldbu ignal commu communicatio nications ns protocol protocol,, but a whole new way to control the process. process. With the rele release ase of the low fieldbus (H1), the entire fiel fieldbus dbus will be defined.. Most of the recent publish defined published ed literat literature ure has focused on the intrica intricate te details of the fieldbus architecture, especially those layers that have not been released. However, except  physical layer and the user layer, these layer are transparent to the engineers en gineers and the manager. Maintenance information

Workstation

system

User Layer

Application Layer

Data Layer

Physical Layer

   t   n   e   m   e   g   a   n   a    M    k   r   o    t   w   e    N

   t   n   e   m   e   g   a   n   a   m   m   e    t   s    S   y

       k      c      a       t      s

Multivariable Valve Transmitter

Level

Pump

Transmitter

   

Open System Interconnected Reference Model

Application

MBAP, SMB, FTP, SMTP, FMS, IEC 61158, ANSI/ISA S50.2,IEEE 1451

Presentation Session Transport

TCP, SPX, UDP

Network

IP, IPX, NetBeui

Data link

HDLC, ETHERNET, ANSI/ISA S50.02

Physical

Physical – Provides the standard for transmitting raw electrical signals over the communication channels. Data link – Contains the rule for interpreting electrical

signals as data, error checking and physical addressing Network – Describes the rule for routing messages through a complex network and deals with congestion. Transport – Establishes a dependable end-to-end connection between two host.

Session – provides Management and Synchronization of complex data transaction. EIA-485, ETHERNET,ANSI/ISA S50.02 Presentation – Establishes protocol for data format conversion, encryption and security. Application – Contains protocol that accomplish task  such as e-mail, file transfer or reading a set of registers from a PLC.

For the purpose of Process control, the top and bottom four layers are used. Layers 5 and 6 are important to t o large commercial networks.

 

Field Bus Field Bus is a bi-directional bi-directional digital communication communication that interc interconnects onnects sma smart rt 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 Communication network. Layer

Function

7

Application

Provides formatted data

6

Presentation

Converts data

5

Session

Handles the dialogue

4

Transport

Secures the transport connection

3

Network

Establishes network connections

2

Link

Establishes the data link

connection 1

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 considered since the they y deal with tran transferenc sferencee of data among networks 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 how data is specified, its addresses and its representation.

The Fieldbus was invented by an Indian engineer Mr. Ram 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 utilizes existing existing wi wires. res. H2 has high sp speed eed and may require in independent dependent 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 o f the frame and one end delimiter  at the end delimiter at the end of the of the frame.

DATA LINK LAYER

 

The Data Link Layer will assure the integrity of the message by using the frame check sequence: Two bytes added to the frames and a polynomial calculation of all frame data. The Data Link Link Layer also chec checks ks to see that the data data reaches th thee devices co correctly rrectly.. Technical characteristics

Medium Access: There are three forms to access the network: •

Token passing: Token is the right to initiate a transaction on the bus. A device must have the token to initiate a conversation. As soon it finishes it will return the token to the LAS (Link  Active Scheduler). The LAS send the token to the unit that requested in either in a  pre-configured way or via scheduling. sched uling.

•

Immediate response: A master station will give an opportunity to the station to reply with one frame.

•

Requested token: a device request a token by using a code in any of the response sent to the bus. The LAS will hear this request and will then send a token to the device when there is time

available in the aperiodic traffic scheduling phase.

 

APPLICATION LAYER AND MANAGEMENT The Application Layer provides a simple interface to the end user’s application. Basically , it defines how to read, write , interpret and execute a message or command. A big part of this job is to define the message syntax. The contents include the requested message, action taken, and  the response message. The management defines how to initialize the network : tag assignment, address assignment, clock assignment, clock synchronization, distributed application scheduling across the network or association of the input and output parameters of the function blocks. It also controls the operation operat ion of the network with stat statistic istic of fault faultss and detection of the addition of the new element or the absence absence of a station. Th Thee system always always look for the new station stationss on the bus by polling the possible station addresses.

 

Digital Communication Protocol ISO

- Interna International tional Standar Standard dO Organizat rganization. ion. Respons Responsible ible for developi developing ng the model that the communication specification are based upon as well as standards for each layer of communication specification.

IEEE

- Institu Institute te of Electri Electrical cal and Elect Electronics ronics Engi Engineers. neers. For Formed med the IEEE 802  project for defining standards for network media and access methods.

SP72

- Instit Institute ute Society of Ameri America, ca, Standa Standards rds and Practic Practicee committee Numbe Numberr 72

SP50

Developing EIA1393 companion standard for process control messaging. - Instit Institute ute Society of Ameri America, ca, Standa Standards rds and Practic Practicee committee Numbe Numberr 50 Developing standards for digital communication between field devices.

F.I.P

- Factory Inf Information ormation Pr Protocol, otocol, ap approved proved Frenc French h National S Standard. tandard.

Profibus WorldFIP

- Process Fieldbus Fieldbus,, approved G German erman Nat National ional Sta Standard. ndard. - A U.S./ U.S./French French con conglomerat glomeratee of instr instrument ument manuf manufacturer acturers. s.

ISP

- Interope Interoperable rable Syst Systems ems Proje Project, ct, a multin multinational ational gro group up of some 80 manufacturers spanning U.S/Europe and Japan.

 

HART COMMUNICATION PROTOCOL Why HAR HART T proto protocol col ? 4-20 ma is tried, tested tested and widely widely used standard standard but only limited limited amount of information information is sent by a 4-20 ma signal. HART (Hiway Addressable Remote Transducer) protocol enhances these operations by

transmitting digital transmitting digital data along with the 4-20 ma signal – without interferin interfering g with it ! HART permits two-way communications. It also has all digital mode that allows instrument to be connected to a single cable, cutting installation costs dramatically. Features : 1. Fiel Fi eld d pro prove ven n con conce cept pt th that at is ea easy sy to un unde ders rsttan and d and and us use. e. 2. Compatible wi with ex existing 44-20 ma ma sy systems.

3. 4. 5.

Simult Simu ltan aneo eous us po poin intt-to to-p -poi oint nt 44-20 20 ma an and d di digi gita tall co comm mmun unic icat atio ion. n. Alternative multi-drop mode. Meas Me asur ured ed var varia iabl bles es,, tag tag no no.. , ran range ge an and d spa span n set setti ting ngs, s, de devi vice ce in info form rmat atio ion, n, diagnostics and simple messages transmitted.

6. 7.

Digita Digi tall res respo pons nsee tim timee of of 500 500 ms msec ec;; bur burst st mo mode de re resp spon onse se of 30 300 0 mse msec. c. Open Op en ar arch chit itec ectu ture re;; fr free eely ly av avai aila labl blee to an any y ve vend ndor or an and d ev ever ery y us user er..

 

HART COMMUNICATION PROTOCOL Method of Operation : The Hart protocol operates using the FSK principal. The digital data is made up from two

frequencies –1200 Hz and 2200 Hz representing bits 1 and 0 respectively. Sinusoidal waves of these frequencie frequenciess are superimpos superimposed ed on the DC analog signal cabl cables es to give simultaneous analog and digital communications

HART Protocol Structure :

HART follows the basic Open Systems Interconnection (OSI) reference model, developed   by the International Organization for fo r Standard (ISO). The HART protocol uses a reduced  OSI model, implementing only layers 1,2 and 7

 

HART COMMUNICATION PROTOCOL OSI reference model Open Systems Interconnections

LAYER

FUNCTIONS

7

Application

Provides formatted data

6

Presentation

Converts data

5

Session

Handles the dialogue

4

Transport

Secures the transport

3

Network

connection Establishes network connections

2

Link

Establishes the data link connection

HART HART instructions

HART protocol regulations

1

Physical

Connects the equipment

Bell 202

 

HART PROTOCOL LAYERS Layer 1, the physical layer, operates on the FSK principle Data transfer rate: 1200 bit/s Logic “0” frequency: 2200 Hz Logic “1” frequency: 1200 Hz the vast majority majority of exist existing ing wiring is us used ed for this type of digital co communicat mmunication. ion. Layer 2, the link layer establishes the format for a hart message. HART is a master/slave  protocol. the structure of these messages is given below:

Preamble SD

AD

CD

BC

Status

Data Parity

SD – sta start rt cha charact racter. er.

AD – disp display lay ter termina minall and fie field ld addr address esses. es.

CD – HAR HART T ins instruc tructio tion. n.

BC – Byt Bytee coun count. t.

Status – Field devic devicee and communicati communication on status (onl (only y from field device to master master))

The individual individual ccharacte haracters rs are : 1 start bit, 8 d data ata bit bits, s, 1 bit for o odd dd parit parity y and 1 st stop op bit.

 

HART PROTOCOL LAYERS

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, m any, though not all, field devices. Drive-specific commands – provide functions which are restricted to an individual

device.

 

HART PROTOCOL COL – TEC TECHNI HNICAL CAL DAT DATA A HART PROTO DATA TRANSMISSION Types of data transmi transmission ssion

:

Frequen Frequency cy shift keying (FSK)

Transfer rate

:

1200 bit/s.

‘0’ bit information frequency ‘1’ bit information frequency

: :

2200 Hz 1200 Hz

Signal struct structure ure

:

1 start bit, 8 data bits, 1 bit for odd parity, 1 stop bit.

Transferr rate for simple variable Transfe variabless :

Approxim Approximately ately 2/s (poll/r (poll/response esponse))

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. Other characteristics are user selectable. These include a choice of transmission media, baud rate, character parity, no. of stop bits and the transmission modes. The user  selected parameter are set at each station. These parameter cannot be changed while the system is running

RS-232 Communication

 

RS-232 is an asynchronous asynchronous communic communication ation netwo network. rk. Normall Normally, y, 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(1’s and 0’s). There are 2 types of RS-232 devices. The first is called a DTE (Data Terminal Equipment)) device and a common ex Equipment example ample is a comput computer. er. The othe otherr type of device iiss called  DCE (Data Communication Equipment) device and a common example is a modem. In RS-232 the first first thing a termi terminal nal send is st start art bit. This sstart tart bit is a synchron synchronizing izing  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-P1IN

PrU F amR e gProO unS dE  

2

Receive data (RD)

3 4

Transmit data (TD) Data terminal ready (DTR)

5

Signal ground (GND)

6 7

Data set ready (DSR) Request to send (RTS)

8

Clear to Send (CTS)

9

Ring indicator (RI) *only for modems*

   

PC-to-PC Communication through Serial Port

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

RI 90

09 RI

9-Pin D Connector  

 

PC-to-PC Communication through LPT1 Port 1

1

2 3 4 5 6 7 8 9 10

2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19

11 12 13 14 15 16 17 18 19

20 21

20 21

22 23 24

22 23 24

25

25

 

Flavours of Internet Telephony PC-to-PC The Internet PC

PC Dial-up or Local ISP Leased Line

Local ISP

PC-to-Phone The Internet PC

Phone Local ISP

Phone-to-Phone

Local ISP Voice Gateway

Access Code The Internet

Phone

Phone

Local ISP Voice Gateway

Local ISP Voice Gateway

APACS Operat ration ion Pla Platfo tform rm APACS - Ope Database Ownership

  

Operator Console

Engineer Console

Operator Console

Console Level

Controller Level

Controller Module

I/O Level

I/O Modules Transmitter

Interlock

I/P Valve

•TAGS •Range •Engineering Unit •Diagnostics

 

TODAYS INDUSTRIAL SYSTEMS Application

Drivers

Planning ----------------------HMI

HMI 1

2

3

4

5

Devices I/O PLC

DCS

6

   

PC Based Industrial Systems

OPC Client Application

OPC Server 

HMI

1

2

----------------------------------

Planning HMI

3

Devices PLC

DCS

I/O

 

Enterprise Automation Schemes

Windows NT

Corporate IT Network  Windows NT

Server 

Control

network 

 

Embedded Real System

Windows NT (“New technology”) FEATURES:: FEATURES • A true 3 32 2b biit processing. •

A very re relliable oper perating system.

•

Real operating sy system.

ASPECT:: TECHNICAL ASPECT •

Mu Mult ltipr iproc oces essi sing, ng, Mul Multi tith thre readi ading ng an and dp par arti titi tione oned dm memo emory ry sp spac ace. e.

• •

Security - C2 compliance. In-built networking.

•

Internationalization .

•

Human iin nterface as W Wiindows 95.

•

Object - based : DCOM/OLE - ActiveX.

•

for for sp spec ecia iall ne need ed o off th thee pr proc oces esss iind ndus ustr trie ies. s. D DCO COM M an and d OL OLE E ar aree no nott robu robust st,, deterministic and secure.

•

Client - Server architecture.

 

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. Sc Scal alab abil ilit ity y fo forr ssma mall ll an and d la larg rgee aapp ppli lica cati tion on..

However, Windows NT has the following disadvantages : Ne Need edss a lot lot me memo mory ry an and d pr proc oces essi sing ng po powe wer. r. Op Opti timi mize zed d for for of offi fice ce,, no nott ccon ontr trol ol,, rreq equi uire reme ment nts. s. Require uiress a disk d dri riv ve w wh hich m maay ffaail. Depends on single vendor. Reboots at unexpected times Unstable operating system.

 

Embe Embedded dded contr control ol Operat Operating ing System System - QNX QNX real-time operating system, has evolved from the first-ever micro-kernel operating system for PCs into one of the best selling and most trusted operating systems for mission critical application. Today, QNX is the real time operating system in industrial automation, hand held devices, controllers and soft PLCs QNX is recognized as : •

Th Thee fa fast stes estt an and d mo most st d dep epen enda dabl blee re real al ttim imee op oper erat atin ing g sy syst stem em..

•

Th Thee mo most st p pro rove ven n hi high gh sspe peed ed,, de dete term rmin inis isti ticc re real al ttim imee ke kern rnel el..

•

Ha Havi ving ng a ha hard rd rrea eall time time eeng ngin inee th that at g giv ives es PL PLCC-st styl ylee co cont ntro rol. l.

•

En Enab abli ling ng d dat ataa ac acqu quis isit itio ion n wi with th m mil illi lise seco cond ndss re reso solu luti tion on..

•

Prov Providin iding g a faul fault-t t-tole olerant rant arc archit hitect ecture ure on whic which h yo you u ccan an run cont control, rol, even events, ts, ala alarms rms in a virtually crash-proof environment.

Window dowss NT - for Proc Process ess cont control rol Win

 

Windows NT features : • • • •

A true 32 bit processing. A ve verry reliable ble op opeerating system. Real operating system. Mul Multi tipro proce cess ssin ing, g, Mul Multi tithr threa eadin ding g aand nd pa parti rtiti tione oned dm mem emory ory spa space ce..

• • • • •

Security - C2 compliance. In-built networking. Internationalization. Human interface. Object-based DCOM/OLE : The sending object is shown as client and receiving object is known as server. The MS technology allows any developer to produce small, self contain objects that have “packaged” visual component specific action. These components are called  “ActiveX” objects. NT’s OLEand technology is part of Microsoft’s Distributed  Component Object Model (DCOM) operating across networks. Anyone can develop ActiveX Object using VC++ or even VB on a PC. For special needs of the process control industries DCOM and OLE are not secure, deterministic and robust enough. OPC is a process industry consortium that is working to make extension to

DCOM\OLE

 

Ethernet Ethernet was origina Ethernet originally lly design designed ed by Digital Digital,, Intel and Xerox (DIX) in the ea early rly 1970’s 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 re-jigged 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 Data-link layers  protocols. The physical layer defines the cable types, connectors con nectors and electrical characteristics. The Data link layer defines the format an Ethernet frames, the error checking method and the  physical addressing method. As Ethernet is only a Physical/Data link layer other protocols need to be added on top of it to address address the issu issues es of routing, end-toend-to-end end data inte integrity grity and house specific network task are carried out.

 

Ethernet 10Base5 Traditionally, Traditional ly, 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 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   Network Interface Card (NIC). At each station station the Thinnet Thinnet terminates at a T-piece and at each end of the Thinnet run a 50 ohm terminator is required to absorb stray signals

thereby preventing signal bounce.

 

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 twisted pair) pair).. UTP is installe installed d in star wire format and Ethernet Hub Hubss 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 application such as cascading repeaters. 10BaseFL describes the standards for the Fiber optic links

 between stations and repeaters allowing up to 2 Km per segment segm ent on multimode Fiber.

Ethernet

 

The following table shows the RJ45 pin outs for 10BaseT :

RJ45 Pin

Function

Colour

1

Transmit

White/Orange

2

Transmit

Orange/White

3 4

Receive

White/Green Blue/White

5 6

White/Blue Receive

Green/White

7

White/Brown

8

Brown/White

 

PC-to-PC Communication through Ethernet

RJ45

RJ45

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

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. Ethernett works on the CSMA/CD tec Etherne technology hnology but wirel wireless ess LAN has difficu difficulty lty 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.

 

Process control Software characteristics The most important feature of process control system is that it needs to be reliable. The  process control system used has to be completely crash-proof crash-p roof and any changes in the system need to be made on-line. The process control needs to be made real time, which means that it can update the I/O data table and and process the co control ntrol progra program m in the time requir required ed by the proces process. s. A process control system that is deterministic refers to whether the operating system allows the highest priority task to work without interruption from task with lower priority. Software offerings in the automation and the process control fields must be versatile and  open enough to address the needs of different applications.

Finally the chosen solution must deliver tangible, quantifiable values such as : 1.

Reducing project implementation time and cost.

2. 3.

Improving time-to-market. Achieving higher production and quality.

4.

Cutting maintenance and training cost.

5.

Increasing profits.

 

PC-based control system features Unlike the other systems, systems, PCs provide provide a more open architect architecture ure making them idea ideall for improving, optimizing and integrating the overall automation process, as well as conducting control task. In addition PCs offer the following features : •

Lower cost.

•

Ease of use.

•

Graphical u usser iin nterface.

• •

Ea Easy sy inte integr grat atio ion no off llog ogic ic,, m mot otio ion n aand nd p pro roce cess ss co cont ntro rol. l. Si Simp mpli lifi fied ed ap appl plic icat atio ion n de deve velo lopm pmen ent. t.

•

Software portability

•

Inde Indepe pend nden ence ce fr from om prop propri riet etar ary y co cont ntro roll sy syst stem em.. Using PCs enable the following functions,

•

Mi Mill llis isec econ ond d ttim imee stamp stampin ing gw whi hich ch is esse essent ntia iall to util utilit itie ies. s.

•

Real time control.

•

Sequence of events.

•

Alarming.

•

Data collection.

   

PLC conceptual overview Process Graphics

History & Trend 

Alarm & Events

SCADA configuration editor 

Other Aspect system

SCADA Control Aspect

OP Client

OPC server 

SCADA server 

Modbus

Real-time database

Protocol Protocol

opc

comli Siemens

ABB

xx

Allen

GE

Bradley

Fanuc

yy

….

PLC Programming Standards

 

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 L Liist Function Block Diagram

•

Sequential F Fu unction C Ch hart

•

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 availability of informa information tion is becoming inc increasing reasingly ly crucial in the view of growing global competition. competi tion. In future, a deci decisive sive compet competitive itive edge can only be achiev achieved ed by providing the right information at the right time, in the right place and in the right form for the right person. these leadingleading- edge applic application ation are conti continuously nuously optimized optimized and repositioned. repositioned. Industrial IT consists of five components: 1. 2.

Engineering IT Operation IT

3.

Production IT

4.

Optimization IT

5.

Evolution / Information

Industrial IT Trend

 

Business Systems

Sales & Marketing

Planning & Scheduling

Plant &

e    -P        

Real-time Automation & Information

Process Eng.

Operation & Maintenance

Distribution

ASS E T 

R      O      D      U      C      T      IV            IT            Y     

A T IO N O P T I M IZ

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