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DeltaV Process Control System CM4120 Unit Operations Lab January 2011 1
DeltaV Process Control
System
CM4120
Unit Operations Lab
January 2011
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Outline Evolution of Process Control Layout and Architecture of the DeltaV system in the PSCC
Outline
Evolution of Process Control
Layout and Architecture of the DeltaV system in
the PSCC
Physical connections between process
instrumentation and the DCS
What the engineers and operators see
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Evolution of Controllers 1930’s – Pneumatic Controllers • air pressure w/ flappers, bellows, and valves
Evolution of Controllers
1930’s – Pneumatic Controllers
• air pressure w/ flappers, bellows, and valves
adjust valve position based on measured
process variable for P, PI, later PID control
1950’s – Electronic Controllers
• transistors, resistors, and capacitors for P, PI,
PID control
• capable of remote installation
1960’s – Mainframe Computer Control
• Refineries were typical users
• Alarming capability and supervisory control
• Single point of failure, no user-friendly
graphical interface
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Evolution of Controllers Late 1970’s – Distributed Control Systems (DCS) • Networked computers distributed thru
Evolution of Controllers
Late 1970’s – Distributed Control Systems
(DCS)
• Networked computers distributed thru plant
• Pre-configured controllers
• Data archival capabilities
• Included an operator console
• Hardware was proprietary
Late 1990’s – DSC’s built on commodity
hardware platforms (COTS)
• Better scalability
• Affordable
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Distributed Control System (DCS) Functionality Continuous control of processing equipment Pre-programmed control
Distributed Control System (DCS)
Functionality
Continuous control of processing equipment
Pre-programmed control software – needs
only to be configured
Control functions are distributed throughout
redundant, deterministic networked computer
architecture
◦ I/O interface and level 1 (basic) control
functions
◦ advanced control functions
◦ interactive graphical interface (HMI)
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DeltaV Architecture: ProPlus server Plant Area – valves, xmitters MD Controller and I/O Cards ProPlus
DeltaV Architecture: ProPlus server
Plant Area – valves, xmitters
MD Controller
and I/O Cards
ProPlus
Server
PSCC_DeltaV
Redundant Hub
• Stores/serves configuration
• Archives data
• Displays information
• Allows control of process
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DeltaV Architecture: Operator Stations Plant Area – valves, xmitters MD Controller and I/O Cards ProPlus
DeltaV Architecture: Operator Stations
Plant Area – valves, xmitters
MD Controller
and I/O Cards
ProPlus
Server
PSCC_DeltaV
Redundant Hub
• Archive data
• Display information (HMI)
• Allows process changes
Operator Stations
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Communication paths… Redundant Control network MD Controller Windows XP Workgroup – PSCC_DeltaV Windows
Communication paths…
Redundant Control network
MD Controller
Windows XP Workgroup –
PSCC_DeltaV
Windows Networking and
TCP/IP protocol
PSCC_DeltaV
Redundant Hub
ProPlus
Server
Operator Stations
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DeltaV’s MD Controller and I/O – How it connects to the process… Plant Area –
DeltaV’s MD Controller and I/O –
How it connects to the process…
Plant Area – valves, xmitters
MD Controller
and I/O Cards
I/O cards are specific to device requirements
•4-20 mA input, 4-20 mA output
•24 VDC input, 24 VDC output, etc.
•Foundation Fieldbus Interface
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Emerson’s DeltaV System – Current State of the Technology PID control Discrete logic control Signal
Emerson’s DeltaV System –
Current State of the Technology
PID control
Discrete logic control
Signal conversions
Alarming
Fuzzy control, etc.
are continuously executed
by the “MD” controller
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Wiring Systems Connect Transmitters to DCS – at the Instrument End: Level transmitter Wiring to
Wiring Systems Connect Transmitters
to DCS – at the Instrument End:
Level transmitter
Wiring to field
junction cabinet
RTD or T/C head
Wiring from
transmitter to temp
measuring element
Temperature
transmitters
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Wiring Systems Connect Transmitters to DCS – at a Marshalling Cabinet: Single pairs from field
Wiring Systems Connect Transmitters
to DCS – at a Marshalling Cabinet:
Single pairs
from field
devices
8 pr. Cables to
controller
cabinet
8-pr. cables run from Field Junction Box (Marshalling
Cabinet) to Distributed Control System
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Wiring Systems Connect Transmitters to DCS – in the Controller Cabinet: DeltaV “MD” controller I/O
Wiring Systems Connect Transmitters
to DCS – in the Controller Cabinet:
DeltaV “MD” controller
I/O cards
Power-limiting
Zener barriers
8 pr. cables from
field junction cabinet
2 nd I/O chassis w/4-20
mA Output cards
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Wiring Systems Connect DCS to Transducers – at Marshalling Cabinet: 8-pr. cable from controller cabinet
Wiring Systems Connect DCS to
Transducers – at Marshalling Cabinet:
8-pr. cable from
controller cabinet
Current to pneumatic
transducers
Air lines to
control valves
Wire prs. to transducers
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Regulatory Control Valve Air line from I/P transducer Actuator w/ positioner Control valve Block valves
Regulatory Control Valve
Air line from I/P transducer
Actuator w/ positioner
Control valve
Block valves
Bypass valve
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Output Signals from Control System to Control Solenoids Solenoids for 2-position air-actuated ball valves 8-pr.
Output Signals from Control System
to Control Solenoids
Solenoids for 2-position
air-actuated ball valves
8-pr. cable from
controller cabinet
Air lines to
ball valves
Wire prs. to solenoids
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Installed Field Devices: Ball Valve w/ Actuator Air line from solenoid Ball valve body Actuator
Installed Field Devices:
Ball Valve w/ Actuator
Air line from
solenoid
Ball valve body
Actuator
Process line
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DeltaV & Foundation Fieldbus (4) mass flows, (4) densities, and (4) RTD temps (3) 8-multiplexed
DeltaV & Foundation Fieldbus
(4) mass flows, (4) densities,
and (4) RTD temps
(3) 8-multiplexed RTD temps
(2) temp-only transmitters
(1) wire
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The directory tree for our DeltaV system… Control modules ProPlus server MD controller w/ I/O
The directory tree for our DeltaV
system…
Control modules
ProPlus server
MD controller w/ I/O
cards and controllers
Fieldbus I/O card
w/instruments
Operator Stations
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A typical PID Control Module… Analog Input function block PID function block Analog Output function
A typical PID Control Module…
Analog Input
function block
PID function block
Analog Output
function block
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Configuring a PID Control Module… Alarm configuration PID tuning configuration Configuration for I/O signals
Configuring a PID Control Module…
Alarm
configuration
PID tuning
configuration
Configuration for
I/O signals
Configuration of
operating
parameters
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What an operator might see… 22
What an operator might see…
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References www.emersonprocess.com/rosemount/, Rosemount, Inc., Oct. 2006. www.emersonprocess.com/micromotion/, Micro
References
www.emersonprocess.com/rosemount/,
Rosemount, Inc., Oct. 2006.
www.emersonprocess.com/micromotion/, Micro
Motion, Inc., Oct. 2006.
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