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Introduction
The control system was completely pneumatic complete with multitube bundles,
pneumatic transmitters, pneumatic SLCs, relays, chart recorders (even pneumatic
square root extractors!). On top of this there was a very proprietary minicomputer
(8080 based) for APC (advisory only) for P-Xylene & DMT section of the plants.
Barring that the alarm annunciation system was the highest form of electronics
(discrete components based).
The advancement in measurement and control have been so fast and multi-
dimensional that it was most challenging to keep pace and appears surreal that in
1984-85 I was working in design engineering for NTPC Singrauli 2X500 MW
(Indias first super thermal) with exotic electronic systems like SIEMENS Teleperm
M and Westinghouse WDPF systems ! We worked and studied for minimum14
hrs/day but were so excited that we wished the earth rotate a little slower.
The communication between field devices to the control system evolved from
pneumatic to electric signals to digital signals, field buses and now wireless !
Till 1970s, control of process plant was mainly LOCAL. The drives were
started/stopped by local PB stations or from MCC, while analog controls were
achieved by local pneumatic controllers. Although such systems had the advantage of
less cabling, no common failure; there was no central control, alarms, reports or
history and required more operating manpower and hardware. I still remember
struggling with the pneumatic chart-recorders!
From mid-1970s, centralized computer based systems (CCS) began to emerge. Such
systems could perform the complete analog controls and data monitoring centrally by
means of a shared mini-computer. Pioneer in this regard was the IBM-360 mainframe
mini-computer. Of course this was made possible by advancement in the sensor
technology. New electronic (discrete components) transmitters came into the market
and some even started retrofitting their pneumatic transmitters with P/I convertors
and multitubes by cables in field! I still remember in 1983 we were quite suspicious
about these new-fangled devices and attended argumentative seminars when the
OEMs tried to push the new electronic transmitters!!
Form 1980s the ICs started entering the electronics field and miniaturization started.
A host of IC based modules like AI, AO, DI, AO, LVM, PID controllers, signal
amplifiers/distributors
The binary control, on other hand, moved from eletromagnetic relays to solid state
electronic logic cards (ISKAMATIC-B of Siemens) and then to programmable
systems with UVROMs, EPROMs and EEPROMs...
The result was, till 1990s, the process control arena had surrendered to the electronic
solid state systems, whereas the ESD, BMS etc., considered necessary for safety
systems still remained in the clutches of the electromagnetic relays. It is only since
2000s that these systems started trusting the electronics and the programmable
systems.
What were the advantages in the good old days ?
1. Extensive use of instrument air called for large compressor, air drying plants,
contaminated air damaging instruments.
2. Very large control rooms due to dedicated panel instruments.
3. Handling mathematical algorithms and complex PID loops.
4. Slow control response
5. No configurability of hardware (software was unknown)
6. Maintaining tedious log books
7. It was a nightmare attending to alarms during process upsets.
8. Deployment of large manpower in field and CCR.
But the demand kept on increasing from the process industry on the other fronts. Industry
wanted :-
The earliest predecessor of modern DCS was a mini-computer (mainframe) based system
which assimilated all the field analog data converted by ADC and processed to execute
the controls, perform mathematical calculations and display the same to the operator on a
CRT based display. Such a system was based on UNIX platform and was known as
Centralized Computer Control System (CCCS). Such system suffered from several
issues:-
Such alarming qualities rang the death knell for mainframe based system for basic
control. But such systems were still being used till 2000 for Advanced Process Control
Applications (but at Level-3 automation), when the Level-2 was already under the grip of
modern DCS.
Let us now ponder some time over the acronym DCS. It means Distributed Control
System. (Interestingly, some of the pioneers started calling it DDCS, i.e., Digital
Distributed Control System and even DDCMIS i.e., Digital Distributed Control and
Measurement Information System. Earlier, we were so suspicious of these systems.
First DCS was developed by 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 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. Yokogawa - CS 3000 : Ammonia II2. Yokogawa - CS
3000 : ANP3. Yokogawa - CS 3000 : NNAP4. Moore - APACS : Methyl amine5.
Fisher - Rosemant - Delta V field Bus : STP6. Honeywell - GUS : Ammonia I
Synthesis7. Yokogawa - Centum Excel : Steam Generation Plant8. Moore -
APACS : Suphala9. Yokogawa - Micro Excel : Methanol10. Yokogawa - Micro
Excel : S A P/C N A11. ABB - Freelance 2000 : ABC12. Honeywell - TDC 3000 :
Ammonia I13. Honeywell - GUS : Ammonia/Urea - Thal14. Fox boro - I/A
series : D M A C - Thal15. Fisher - Rosemant RS3 : PGR16. Fisher - Rosemant
RS3 : Steam Generation - Thal17. Moore - APACS : Water Treatment Plant - Thal
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
13. 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.
15. Hiway Gateway (HG) LCN Module. Provides a two way communication link
between the Local Control Network and data hiway. 68020 based high
performance intelligence module. Converts data and protocol between Local
Control Network and data hiway. Scans the hiway for alarm conditions.
Synchronize time keeping for hiway-based process connected boxes. One HG is
required for each data hiway that is connected to the LCN. Up to 20 data hiway
pairs can be connected to an LCN. Connects following hiway resident boxes to
LCN 1. AMCs 2. CPC ( critical process controller ). 3. DHP. 4. Hiway traffic
director etc HG Functions : 1. Data access :- gets box data requested from LCN
modules. 2. Event processing :- sends process and box alarm to LCN modules 3.
Database configuration :- 3000 points per hg can be configured.
16. Data Hiway Data hiway provides communication link between hiway
gateway, preferred access devices and process connecting box. Data hiway
operates at250 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 LCN Module. Stores process and system 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.
18. 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.
19. AMC TDC 3000 controller 1. Based on Motorola 68000 Microprocessor. 2.
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. Full function algorithms. 2. Process oriented programming.
Configured as a box on TDC 3000 Data Hiway. Supported by 1. LCN devices
US, AM, HM.
20. HONEYWELL - GUSPrinter Drives Printer - - US#1 US#2 US#3 US#4
Universal Station HM History Module A B Local Control Network Network
Interface Module NIM Universal Control Network HPM High Performance
Manager HPM HPM
21. Honeywell System Description Global User Station History Modules
Network Interface Modules Communication Subsystem - Local Control Network
& Universal Control Network High Performance Process Manager
22. 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 wide intranet or even Internet. The following hardware is
available to enhance the functionality of the GUS: Integrated Keyboard for
Operators as well as Engineer. Matrix printer supported by Windows NT. 8 *
CD-ROM 100MB ZIP Drive 3.5 Floppy Drive GUS has following
functionalitys : The Human interface allows effective interaction of the
Operator through the use of operating displays Engineering functions such as
data point building, display building and report building are available.
Communication with other LCN modules is accomplished. Communication on
Ethernet.
23. Honey well GUS Hardware: Processor : Pentium Pro / 200MHZ Memory :
64MB RAM ECC Cache : 256KB ECC Storage : 2 GB hard disk drive, CD
ROM, Cartridge Drive Video : 21 high resolution screen 1280 * 1024 Pixels
Colours : 256 color palette Keyboard : Integrated keyboard with mouse PIN
Connection : Built in Ethernet Cursor Control : QWERTY & Mouse/Touch
ScreenPeripherals supported Printer 8 * CD-ROM 1/4 Steamer Tape 3.5
Floppy Drive 100 Mb ZIP Drive Annunciator relay on the console-based
keyboard
24. Honeywell GUS software Operating System : Windows NT version 4.0 Base
System : Provides real time data exchange between the network and all GUS
functions.
25. 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
26. 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 files. Static
system files. On process analysis program (maintenance aid)HM Historization
parameters : There can be up to 10 HMs on the LCN. There can be maximum of
150 groups per HM. Each group can have up to 20 points. All points in the group
must be in the same unit.
27. Network Interface Module (NIM) The Network Interface Module (NIM)
provides the link between the local ControlNetwork and the Universal Control
Network. As such it make the transition from thetransmission technique and
protocol or the Local Control Network to the transmissiontechnique and the
protocol of the Universal Control Network. The NIM provides accessby LCN
modules data from UCN resident devices. The NIM is available in the
redundantconfiguration to provide continued operation in the event of the primary
failure. It canalso do event processing. There can be up to 10 redundant NIM pairs
per LCN. A NIM can host upto 8000 tagnames and supports a data transfer rate of
2400 parameters per second.
28. 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 modulescommunicate 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
29. Communication Subsystem Universal Control Network (UCN) The Universal
Control Network is a high speed, high security processcontrol network based on
open system interconnection standards. It features a 5megabit/second, carrier
band, token bus network compatible with IEEE and ISOstandards. It is used as the
real time redundant Communications backbone forprocess connected devices such
as the High Performance Process Manager(HPM), Advanced Process Manager .
The UCN supports peer-to-peercommunication for sharing data and allowing
greater co-ordination of controlstrategies among network devices. The UCN uses
redundant co-axial cables and cansupport up to 32 redundant devices UCN
supports 2 types of devices
30. High Performance Process Manager (HPM)The High Performance Process
Manager is the latest in the Progression of HighPerformance control products
offered by Honeywell for the application toImprove controlling of existing and
new industrial processes. High PerformanceProcess Manager is a fully integrated
member of the TPS family. It is capable of : performing data acquisition and
control functions fully communicating with operators and engineers at the GUSs
and universal Work stations. Supporting higher-level strategies available on the
Local Control Network through the Application Module and Host Computers.
31. High Performance Process Manager OverviewThe High Performance Process
Manager uses a powerful multi-processor 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
controloperation are performed within the communication and control module.
The processengineer has complete flexibility of choice within the maximum HPM
design limits. These selections are implemented using the 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.
DELTA V SYSTEM
DeltaV System Architecture: Engineering station, Operator station, Printer
Printer 8 port Hub 8 port Hub primary Redundant 12 wide carrier for 8 wide
carrier forPower/Controller P P A AA DDD I/O subsystem.
Contr. Serial S S I I O I I O Power supply H1 Controller I/O extension cable
Connector RS232 Modbus PLC For Blank H Blank Blank Blank D Blank Blank 8
DI & 8 DO O I Fieldbus Transmitter Pressure Transmitter 3244MVF1NAB4
3051TG2A2B21AB4M5FF Smart valve positioner FSDVC0400-201 Fieldbus
Power
63. DCS communication system Hierarchy Level 5 Management MIS Low data
rates High Superior responsibility Level 4 Scheduling SCHED. Low Level 3
Supervisory control SUP. SUP. Level 2 Direct digital Control (DDC) DDC DDC
DDC DDCLevel 1Sensors (S)& Actuators (A)High data rates S A A S A S S S A S
S ALow responsibility PLANT
HISTORY
History of Process Control Signal Around 50 years ago, most plant used 3-15psi
pneumatic signal to control their process. The last change in signal standard was
the open protocol HART digital communications 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 control Timeline The Evolution of Signal Standard 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 Digital:
Fieldbus acceptance.
Digital plus Analog: HART with 4-20mA With many standard there is typically a
slow transition period as plant Analog: 4-20mA engineers and Pneumatic: 3-15
psi 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 I/O Bus Network Protocol, I/O Bus Network Device bus
network Process bus network Discrete Analog Byte-wide Bit-wide Several
Hundred Data Bytes
66. Protocol Standard Field Bus Foundation (Field Bus std.)Process bus network
Profibus Trade Organization (Profibus std.) Device net Byte-Wide CAN Bus Data
SDS Inter Bus-SDevice bus network Seriplex Bit-Wide Data ASI Inter Bus Loop
67. Fieldbus ArchitectureFieldbus 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, except Maintenance
Workstation information physical layer and the user layer, these layer are
transparent to the engineers and the system manager. User Layer System
management Network Management Application Layer stack Data Layer Physical
Layer Multivariable Valve Level Pump Transmitter Transmitter
68. Open System Interconnected Reference Model MBAP, SMB, FTP, SMTP,
FMS, Physical Provides the standard for transmitting rawApplication electrical
signals over the communication channels. IEC 61158, ANSI/ISA S50.2,IEEE
1451Presentation Data link Contains the rule for interpreting electrical signals
as data, error checking and physical addressing Session Network Describes the
rule for routing messages Transport TCP, SPX, UDP through a complex network
and deals with congestion. Transport Establishes a dependable end-to-end
Network IP, IPX, NetBeui connection between two host. HDLC, ETHERNET,
ANSI/ISA S50.02 Session provides Management and Synchronization Data link
of complex data transaction. Physical 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
large commercial networks.
69. Field BusField 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 FunctionCommunication network. 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
70. 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 how was invented by an Indian engineer Mr.
Ramre presentation. The Fieldbus data is specified, its addresses and its
Ramchandran ( M.S in Comp. Tech , Texas)
71. PHYSICAL LAYERThe 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.
72. PHYSICAL LAYERSignal 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.
73. DATA LINK LAYERThe 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 Layer also checks to see
that the data reaches the devices correctly.Technical characteristicsMedium
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. 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
74. APPLICATION LAYER AND MANAGEMENTThe Application Layer
provides a simple interface to the end users 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 of the network with statistic of faults and detection of the
addition of the new element or the absence of a station. The system always look
for the new stations on the bus by polling the possible station addresses.
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