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DISTRIBUTED CONTROL SYSTEMS BASICS.

Ashok Kumar Barla, profile picture
Ashok Kumar Barla

This document discusses the evolution of distributed control systems (DCS). It describes how DCS have moved from centralized control to distributed and fieldbus control with the advancement of technology. It also discusses different DCS architectures like conventional DCS, PLC-based DCS, and open DCS systems. Specific DCS like Honeywell's TDC 3000 and GUS systems are outlined describing their hardware components and functions.

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DISTRIBUTED CONTROL SYSTEMS BASICS.
DCS EVOLUTIONDCS EVOLUTION--CENTRALISED CONTROLCENTRALISED CONTROL
DCS EVOLUTIONDCS EVOLUTION--DISTRIBUTED CONTROLDISTRIBUTED CONTROL
DCS EVOLUTIONDCS EVOLUTION--FIELDBUS CONTROLFIELDBUS CONTROL
DCS EVOLUTIONDCS EVOLUTION-- WEB CONTROLWEB CONTROL
DCS EVOLUTIONDCS EVOLUTION--WEB CONTROL APPLICATIONWEB CONTROL APPLICATION
ABB DCS ARCITECTUREABB DCS ARCITECTURE
ABB DCS HARDWAREABB DCS HARDWARE
CONTROL SYSTEMS TRENDCONTROL SYSTEMS TREND 1) PLC1) PLC 2) DCS2) DCS 3) PC3) PC -- Based ControlBased Control.. •• PLCPLC :: Introduced in the late 1960 to replace Relays and HardIntroduced in the late 1960 to replace Relays and Hard--wiredwired Programming.Programming.
DCSDCS :: Introduced in the MidIntroduced in the Mid--1970 to1970 to replace pneumatic controls by usingreplace pneumatic controls by using computers.computers. •• PCPC--Based ControlBased Control :: Introduced by the early 1980s to avoid theIntroduced by the early 1980s to avoid the proprietary PLC & DCS systems.proprietary PLC & DCS systems.
DCS EVOLUTIONDCS EVOLUTION •• LOCAL CONTROLLOCAL CONTROL :: Initially control was performed local to the equipmentInitially control was performed local to the equipment control. Thecontrol. The ADVANTAGEADVANTAGE was low wiring costs .was low wiring costs .DISADVANTAGESDISADVANTAGES werewere -- not much control, monitoring, alarming & history.not much control, monitoring, alarming & history. •• CENTRALISED CONTROLCENTRALISED CONTROL:: With the advent of minicomputer, sensors andWith the advent of minicomputer, sensors and actuators were into the Central Control (Computer).actuators were into the Central Control (Computer). •• DISTRIBUTED CONTROLDISTRIBUTED CONTROL:: With the advent of microcomputer, DistributedWith the advent of microcomputer, Distributed control systems were installed in the plants near to the controlcontrol systems were installed in the plants near to the control room viaroom via proprietary digital communications lines called as Data Hiway. Fproprietary digital communications lines called as Data Hiway. First DCS wasirst DCS was developed by Honeywell,U.S in 1975.developed by Honeywell,U.S in 1975. TheThe ADVANTAGESADVANTAGES were greatly reduced wiring costs, much more limitedwere greatly reduced wiring costs, much more limited failure and less cost to add more points.failure and less cost to add more points. TheThe DISADVANTAGESDISADVANTAGES were that wiring costs were that wiring costswere that wiring costs were that wiring costs were still significant and there was lack of interoperability amwere still significant and there was lack of interoperability among controllers ofong controllers of various manufacturers due to the proprietary protocols. Hence thvarious manufacturers due to the proprietary protocols. Hence the user wase user was locked into a single vendor.locked into a single vendor.
DCS System Installations in RCFDCS System Installations in RCF 1. Yokogawa1. Yokogawa -- CS 3000 : Ammonia IICS 3000 : Ammonia II 2. Yokogawa2. Yokogawa -- CS 3000 : A N PCS 3000 : A N P 3. Yokogawa3. Yokogawa -- CS 3000 : N N A PCS 3000 : N N A P 4. Moore4. Moore -- APACSAPACS : Methyl amine: Methyl amine 5. Fisher5. Fisher -- RosemantRosemant -- Delta V field Bus : S T PDelta V field Bus : S T P 6. Honeywell6. Honeywell -- GUS : Ammonia I SynthesisGUS : Ammonia I Synthesis 7. Yokogawa7. Yokogawa -- Centum Excel : Steam Generation PlantCentum Excel : Steam Generation Plant 8. Moore8. Moore -- APACS : SuphalaAPACS : Suphala 9. Yokogawa9. Yokogawa -- Micro Excel : MethanolMicro Excel : Methanol 10. Yokogawa10. Yokogawa -- Micro Excel : S A P/C N AMicro Excel : S A P/C N A 11. ABB11. ABB -- Freelance 2000 : A B CFreelance 2000 : A B C 12. Honeywell12. Honeywell -- TDC 3000 : Ammonia ITDC 3000 : Ammonia I 13. Honeywell13. Honeywell -- GUS : Ammonia/UreaGUS : Ammonia/Urea -- ThalThal 14. Fox14. Fox boroboro -- I/A series : D M A CI/A series : D M A C -- ThalThal 15. Fisher15. Fisher -- Rosemant RS3 : P G RRosemant RS3 : P G R 16. Fisher16. Fisher -- Rosemant RS3 : Steam GenerationRosemant RS3 : Steam Generation -- ThalThal 17. Moore17. Moore -- APACS : Water Treatment PAPACS : Water Treatment Plantlant -- ThalThal
DCSDCS •• The importance of DCS systems to increase as global competitiveThe importance of DCS systems to increase as global competitive dynamics in food and beverage, specialty metals, pulp and paper,dynamics in food and beverage, specialty metals, pulp and paper, pharmaceutical and fire chemical processing.pharmaceutical and fire chemical processing. •• The DCS has networking capabilities which are useful for businesThe DCS has networking capabilities which are useful for businesss management.management. •• The DCS has capacity for processing large number of I/O points.The DCS has capacity for processing large number of I/O points. TYPES OF DCSTYPES OF DCS :: 1) Conventional DCS .1) Conventional DCS . 2) PLC based DCS.2) PLC based DCS. 3) Hybrid DCS.3) Hybrid DCS. 4) Open DCS System4) Open DCS System
CONVENTIONAL DCSCONVENTIONAL DCS This is a pureThis is a pure ““Process onlyProcess only”” control system. Usually purchased fromcontrol system. Usually purchased from one vendor. This DCS arranged into three categories:one vendor. This DCS arranged into three categories: •• SmallSmall -- Less than $ 100,000.Less than $ 100,000. •• MediumMedium -- Greater than $100,000 & Less than $500,000.Greater than $100,000 & Less than $500,000. •• LargeLarge -- Greater than $500,000.Greater than $500,000. PLC Based DCSPLC Based DCS.. This is a network of PLCThis is a network of PLC’’s used to perform the task ofs used to perform the task of conventional DCS and programmable functionality when required.conventional DCS and programmable functionality when required. Hybrid DCSHybrid DCS.. Performs both process and sequential control.Performs both process and sequential control. Open DCS SystemOpen DCS System.. This is FieldThis is Field--Bus Control. Advantages are lower wiring cost andBus Control. Advantages are lower wiring cost and less failure, smaller expansion costs and multi vendor interoperless failure, smaller expansion costs and multi vendor interoperabilityability DCS and PLC can be more closely and efficiently interconnected.DCS and PLC can be more closely and efficiently interconnected.
Honeywell TDC 3000 DCS ArchitectureHoneywell TDC 3000 DCS Architecture AMC AMC US#1 US#2 HM LCN A B HG A BData Hiway Field Field EC Link
Hiway Gateway (HG)Hiway Gateway (HG) •• LCN Module. Provides a two way communication link between the LoLCN Module. Provides a two way communication link between the Localcal Control Network and data hiway.Control Network and data hiway. •• 68020 based high performance intelligence module.68020 based high performance intelligence module. •• Converts data and protocol between Local Control Network and datConverts data and protocol between Local Control Network and data hiway.a hiway. •• Scans the hiway for alarm conditions.Scans the hiway for alarm conditions. •• Synchronize time keeping for hiwaySynchronize time keeping for hiway--based process connected boxes.based process connected boxes. •• One HG is required for each data hiway that is connected to theOne HG is required for each data hiway that is connected to the LCN. Up toLCN. Up to 20 data hiway pairs can be connected to an LCN.20 data hiway pairs can be connected to an LCN. •• Connects following hiway resident boxes to LCNConnects following hiway resident boxes to LCN 1.1. AMCsAMCs 2.2. CPC ( critical process controller ).CPC ( critical process controller ). 3.3. DHP.DHP. 4.4. Hiway traffic director etcHiway traffic director etc…… HG FunctionsHG Functions :: 1.1. Data access :Data access :-- gets box data requested from LCN modules.gets box data requested from LCN modules. 2.2. Event processing :Event processing :-- sends process and box alarm to LCN modulessends process and box alarm to LCN modules 3.3. Database configuration :Database configuration :-- 3000 points per hg can be configured.3000 points per hg can be configured.
Data HiwayData Hiway Data hiway provides communication link betweenData hiway provides communication link between hiwayhiway gateway,gateway, preferred access devices and process connecting box. Data hiwapreferred access devices and process connecting box. Data hiwayy operates atoperates at 250 kbps.250 kbps. It is redundant pair of 75 ohm coax cable conneIt is redundant pair of 75 ohm coax cable connected to box.cted to box. It may beIt may be 20,000 feet long.20,000 feet long. There are 3 kinds of devices on the data hiway,There are 3 kinds of devices on the data hiway, 1.1. Respond only devices Ex:Respond only devices Ex:-- AA--MC (Advanced MultifunctionMC (Advanced Multifunction controller)controller) 2.2. Polled devices Ex:Polled devices Ex:-- PIUPIU’’s (Process interface unit)s (Process interface unit) 3.3. Preferred access devicesPreferred access devices
History ModuleHistory Module •• LCN Module. Stores process and systemLCN Module. Stores process and system information that can be displayed.information that can be displayed. •• Based on microprocessors 68020.Based on microprocessors 68020. •• Winchester disk for data storage.Winchester disk for data storage. •• Communicates with all Modules on the LCN.Communicates with all Modules on the LCN. •• Stores history and general information.Stores history and general information.
Universal StationUniversal Station Universal station (US) communicates with all modulUniversal station (US) communicates with all modules on thees on the LCN, processLCN, process connected devices on the hiway via hiway gateway and UCN via neconnected devices on the hiway via hiway gateway and UCN via networktwork interface moduleinterface module (NIM).(NIM). The following are the features of US,The following are the features of US, •• Intelligent man/machine interface in the TDC 3000 system.Intelligent man/machine interface in the TDC 3000 system. •• Stands on the LCN. Communicates with all Modules on LCN, processStands on the LCN. Communicates with all Modules on LCN, process connected devices on the Hiway via Hiway Gateway.connected devices on the Hiway via Hiway Gateway. •• Provides comprehensive facilities to the process operator, proceProvides comprehensive facilities to the process operator, processss engineer and maintenance technician on the Universal Window.engineer and maintenance technician on the Universal Window. US provides comprehensive facilities to the followUS provides comprehensive facilities to the following people,ing people, •• Process engineerProcess engineer •• Process operatorProcess operator •• Maintenance technician.Maintenance technician.
AMCAMC •• TDC 3000 controllerTDC 3000 controller 1.1. Based on Motorola 68000 Microprocessor.Based on Motorola 68000 Microprocessor. 2.2. Faster execution and control with 500 ms processing rate.Faster execution and control with 500 ms processing rate. •• MultifunctionMultifunction –– Modulating, sequence, logic, I/O monitoringModulating, sequence, logic, I/O monitoring communication and diagnostic.communication and diagnostic. •• Faster peer to peer communication over EC link ( 500 kbits/sec )Faster peer to peer communication over EC link ( 500 kbits/sec ).. •• Proven control techniquesProven control techniques 1.1. Full function algorithms.Full function algorithms. 2.2. Process oriented programming.Process oriented programming. •• Configured as a box on TDC 3000 Data Hiway. Supported byConfigured as a box on TDC 3000 Data Hiway. Supported by 1.1. LCN devicesLCN devices –– US, AM, HM.US, AM, HM.
HONEYWELLHONEYWELL -- GUSGUS HM NIM HPM HPM HPM Local Control Network US#1 US#2 US#3 US#4 Printer PrinterDrive’s - - High Performance Manager History Module Network Interface Module Universal Station A B UniversalControlNetwork
Honeywell System DescriptionHoneywell System Description •• Global User StationGlobal User Station •• History ModulesHistory Modules •• Network Interface ModulesNetwork Interface Modules •• Communication SubsystemCommunication Subsystem -- Local Control Network & UniversalLocal Control Network & Universal Control NetworkControl Network •• High Performance Process ManagerHigh Performance Process Manager
Global User StationGlobal User Station OverviewOverview The TPS system provides an integrated interface between the procThe TPS system provides an integrated interface between the processess and the end user. This interface is named as the Global User Staand the end user. This interface is named as the Global User Station (GUS).tion (GUS). GUS is an important part in the Honeywell Total planGUS is an important part in the Honeywell Total plant Solutionst Solutions offerings. It provides access to plant wide process network, plaofferings. It provides access to plant wide process network, plant ornt or organization wide intranet or even Internet.organization wide intranet or even Internet. The following hardware is available to enhance the fThe following hardware is available to enhance the functionality of theunctionality of the GUS:GUS: •• Integrated Keyboard for Operators as well as Engineer.Integrated Keyboard for Operators as well as Engineer. •• Matrix printer supported by Windows NT.Matrix printer supported by Windows NT. •• 8 * CD8 * CD--ROMROM •• 100MB ZIP Drive100MB ZIP Drive •• 3.53.5”” Floppy DriveFloppy Drive GUS has following functionality's :GUS has following functionality's : •• TheThe ““HumanHuman ”” interface allows effective interaction of the Operator throughinterface allows effective interaction of the Operator through the use of operating displaysthe use of operating displays •• Engineering functions such as data point building, display buildEngineering functions such as data point building, display building and reporting and report building are available.building are available. •• Communication with other LCN modules is accomplished.Communication with other LCN modules is accomplished. •• Communication on Ethernet.Communication on Ethernet.
Honey well GUS Hardware:Honey well GUS Hardware: •• Processor : Pentium ProProcessor : Pentium Pro / 200MHZ/ 200MHZ •• Memory : 64MB RAM ECCMemory : 64MB RAM ECC •• Cache : 256KB ECCCache : 256KB ECC •• Storage : 2 GB hardStorage : 2 GB hard disk drive, CD ROM,disk drive, CD ROM, Cartridge DriveCartridge Drive •• Video : 21Video : 21”” high resolution screen 1280 * 1024high resolution screen 1280 * 1024 PixelsPixels •• Colours : 256 colorColours : 256 color palettepalette •• Keyboard : IntegratedKeyboard : Integrated keyboard with mousekeyboard with mouse •• PIN Connection : Built in EthernPIN Connection : Built in Ethernetet •• Cursor Control : QWERTY & MousCursor Control : QWERTY & Mouse/Touch Screene/Touch Screen Peripherals supportedPeripherals supported •• PrinterPrinter •• 8 * CD8 * CD--ROMROM •• 1/41/4”” Steamer TapeSteamer Tape •• 3.53.5”” Floppy DriveFloppy Drive •• 100 Mb ZIP Drive100 Mb ZIP Drive •• Annunciator relay on the consoleAnnunciator relay on the console--based keyboardbased keyboard
Honeywell GUS softwareHoneywell GUS software •• Operating System : Windows NT versiOperating System : Windows NT version 4.0on 4.0 •• Base System : Provides reaBase System : Provides real time datal time data exchangeexchange between the network and all GUSbetween the network and all GUS functions.functions.
History ModulesHistory Modules The History Modules is the bulk module that can be utilizeThe History Modules is the bulk module that can be utilized by all moduled by all module connectedconnected to the Local Control Network. It is as the name implies the masto the Local Control Network. It is as the name implies the mass memory of thes memory of the TPSTPS System. The memory components of this module are one 1.8 gigabySystem. The memory components of this module are one 1.8 gigabytete Winchester discs.Winchester discs. It is controlled by an M68040 microprocessor. This provides theIt is controlled by an M68040 microprocessor. This provides the module withmodule with significantsignificant computing power that this used to structure much of the incomincomputing power that this used to structure much of the incoming data andg data and format it intoformat it into a form for easy retrieval.a form for easy retrieval. The history in the model is provided by the History ModThe history in the model is provided by the History Module. Processule. Process variables arevariables are available for hourly, shift, daily and monthly average calculatavailable for hourly, shift, daily and monthly average calculation and recording.ion and recording. All system event history such as process alarms, systemAll system event history such as process alarms, system status changes,status changes, and errorand error messages are stored into the History Modules.messages are stored into the History Modules. Other modules have access to data in the History ModulesOther modules have access to data in the History Modules for theirfor their functions.functions. The History Module provides two functions, storage only and dataThe History Module provides two functions, storage only and data structuringstructuring
HM functions and Historization parameterHM functions and Historization parameter HM functionsHM functions :: It can automatically backup the control databasesIt can automatically backup the control databases in the HG, AM, CG.in the HG, AM, CG. HM can store,HM can store, •• Continuous process history.Continuous process history. •• Event journal (history).Event journal (history). •• Active system files.Active system files. •• Static system files.Static system files. •• On process analysis program (maintenance aid)On process analysis program (maintenance aid) HM Historization parametersHM Historization parameters :: There can be up to 10 HMThere can be up to 10 HM’’s on the LCN. There can be maximum of 150s on the LCN. There can be maximum of 150 groups pergroups per HM. Each group can have up to 20 points. All points in the groHM. Each group can have up to 20 points. All points in the group must be in theup must be in the samesame unit.unit.
Network Interface Module (NIM)Network Interface Module (NIM) The Network Interface Module (NIM) provides the link between tThe Network Interface Module (NIM) provides the link between the local Controlhe local Control Network and the Universal Control Network. As such it make theNetwork and the Universal Control Network. As such it make the transition fromtransition from thethe transmission technique and protocol or the Local Control Networtransmission technique and protocol or the Local Control Network to thek to the transmissiontransmission technique and the protocol of the Universal Control Network. Thtechnique and the protocol of the Universal Control Network. The NIM providese NIM provides accessaccess by LCN modules data from UCN resident devices. The NIM is availby LCN modules data from UCN resident devices. The NIM is available in theable in the redundantredundant configuration to provide continued operation in the event of thconfiguration to provide continued operation in the event of the primary failure. Ite primary failure. It cancan also do event processing.also do event processing. There can be up to 10 redundant NIM pairs per LCN. A NThere can be up to 10 redundant NIM pairs per LCN. A NIM can host uptoIM can host upto 8000 tag8000 tag names and supports a data transfer rate of 2400 parameters pernames and supports a data transfer rate of 2400 parameters per second.second.
Communication SubsystemCommunication Subsystem Local Control Network (LCN)Local Control Network (LCN) The backbone of every TPS system is a comThe backbone of every TPS system is a communication network,munication network, known asknown as Local Control Network. The LCN is a LAN through which TDC 3000Local Control Network. The LCN is a LAN through which TDC 3000 modulesmodules communicate with each other. The LCN is a broadcast type of LAN.communicate with each other. The LCN is a broadcast type of LAN. It is high speedIt is high speed redundant communication bus that connect all the control room eredundant communication bus that connect all the control room equipment. Allquipment. All informationinformation is transferred on the network at 5 million bits per sec.,serialis transferred on the network at 5 million bits per sec.,serially. It is based on thely. It is based on the IEEE 802.4IEEE 802.4 Token passing and Bus Standard.Token passing and Bus Standard. Each LCN device that is connected to the LEach LCN device that is connected to the Local Control Network isocal Control Network is called acalled a module. Up to 64 modules may be connected to the Local Contromodule. Up to 64 modules may be connected to the Local Control Network in al Network in a TPSTPS system. The Local Control Network is designated as the primarysystem. The Local Control Network is designated as the primary and the other asand the other as the backthe back
Universal Control Network (UCN)Universal Control Network (UCN) The Universal Control Network is a high sThe Universal Control Network is a high speed, high securitypeed, high security processprocess control network based on open system interconnection standards.control network based on open system interconnection standards. ItIt features a 5features a 5 megabit/second, carrier band, token bus network compatible withmegabit/second, carrier band, token bus network compatible with IEEE andIEEE and ISOISO standards. It is used as the real time redundant Communicationsstandards. It is used as the real time redundant Communications backbonebackbone forfor process connected devices such as the High Performance Processprocess connected devices such as the High Performance Process ManagerManager (HPM), Advanced Process Manager . The UCN supports peer(HPM), Advanced Process Manager . The UCN supports peer--toto--peerpeer communication for sharing data and allowing greater cocommunication for sharing data and allowing greater co--ordination ofordination of controlcontrol strategies among network devices. The UCN uses redundant costrategies among network devices. The UCN uses redundant co--axial cablesaxial cables and canand can support up to 32 redundant devicessupport up to 32 redundant devices UCN supports 2 types of devicesUCN supports 2 types of devices Communication SubsystemCommunication Subsystem
High Performance Process ManagerHigh Performance Process Manager (HPM)(HPM) The High Performance Process Manager is the latest in the ProgreThe High Performance Process Manager is the latest in the Progression ofssion of HighHigh Performance control products offered by Honeywell for the applicPerformance control products offered by Honeywell for the application toation to Improve controlling of existing and new industrial processes. HiImprove controlling of existing and new industrial processes. Highgh PerformancePerformance Process Manager is a fully integrated member of the TPS family.Process Manager is a fully integrated member of the TPS family. It isIt is capablecapable of :of : •• performing data acquisition and control functionsperforming data acquisition and control functions •• fully communicating with operators and engineers at the GUSs andfully communicating with operators and engineers at the GUSs and universal Work stations.universal Work stations. •• Supporting higherSupporting higher--level strategies available on the Local Controllevel strategies available on the Local Control Network through the Application Module and Host Computers.Network through the Application Module and Host Computers.
The High Performance Process Manager uses a powerful multiThe High Performance Process Manager uses a powerful multi--processorprocessor architecturearchitecture with separate microprocessors dedicated to perform specific taswith separate microprocessors dedicated to perform specific tasks. The HPMks. The HPM consistsconsists of two modules Communication and Control Module (CCM) and the Iof two modules Communication and Control Module (CCM) and the I/O/O subsystemsubsystem the I/O subsystem consist of up to 40 Smart I/O Modules (SIOM)the I/O subsystem consist of up to 40 Smart I/O Modules (SIOM). All control. All control operation are performed within the communication and control modoperation are performed within the communication and control module. Theule. The processprocess engineer has complete flexibility of choice within the maximum Hengineer has complete flexibility of choice within the maximum HPM designPM design limits.limits. These selections are implemented using the interactive tools prThese selections are implemented using the interactive tools provided byovided by both theboth the GUS and Universal Work Station. The I/O processors, for exampleGUS and Universal Work Station. The I/O processors, for example, provide, provide suchsuch functions as engineering unit conversion and alarm limit checkifunctions as engineering unit conversion and alarm limit checkingng independent of theindependent of the communication and control modules.communication and control modules. High Performance Process Manager Overview
YOKOGAWA CENTUM EXCEL ARCHITECTUREYOKOGAWA CENTUM EXCEL ARCHITECTURE EOPS /1 EOPS /2 ENGG. STATION EFGWEFMSEFCD Closed loop control signal Through I/O NEST HF BUS : High frequency Bus: no. of station on HF Bus are 32 EOPS : Extended Operator station: Hard disk capacity of EOPS is 80 MB EFCD : Extended field control station : 80 laps per controller EFMS : Extended field mauture station Max 255 inputs EFGN : Extended field gateway unit ENGS : Engineering station NIO : Nest I/O bus. Monitoring signals Through I/O NEST Third party system with PLC, Gas Analyser etc. thr RS 232C port At the rate of 9600 bps HF BUS (1 Mbps) A B I/O #1 ncst I/O #2 ncst I/O #3 I/O #4 I/O #5 ncst A B NIO Bus Micro-XL
HIS HIS PRTPRT HIS Windows NT Based Centum CS Configuration NIU NIU Ethernet Connectivity (optional) Inkjet Printer DM Printer FCS RIO BUS OPERATOR/ENGINEERING STATION OPERATOR STATION SUB-SYSTEM INTERPLANT NETWORK PC (OPTIONAL) DUAL “V NET” 10 Mbps HIS – Human Interface Station. FCS – Field Control Station. NIU – Node Interface Unit. RIO Bus – Remote I/O Bus.
Centum CS 3000 System OverviewCentum CS 3000 System Overview Centum CS 3000 is an integrated production control systemCentum CS 3000 is an integrated production control system for mediumfor medium and large controland large control applications. This system is a synthesis of the latest technoloapplications. This system is a synthesis of the latest technology withgy with YokogawaYokogawa’’s experiences experience and specialist knowand specialist know--how.how. Centum CS 3000 system featuresCentum CS 3000 system features :: •• Synthesis of DCS with Personal computers.Synthesis of DCS with Personal computers. •• Online Documentation.Online Documentation. •• Powerful Operation and Monitoring Functions.Powerful Operation and Monitoring Functions. •• Two Types of Control Station.Two Types of Control Station. •• Compact I/O Modules.Compact I/O Modules. •• Powerful Control and Communication Functions.Powerful Control and Communication Functions. •• Efficient Engineering.Efficient Engineering. •• Virtual Test functions donVirtual Test functions don’’t require Control Station hardware.t require Control Station hardware. •• FullFull--Featured Batch Package.Featured Batch Package. •• CENTUM CS microCENTUM CS micro--XL Integration ( to be released ).XL Integration ( to be released ).
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 ).
HIS HIS PRTPRT HIS CS3000 – System Configuration NIU NIU Ethernet Connectivity (optional) Inkjet Printer DM Printer FCS RIO BUS OPERATOR/ENGINEERING STATION OPERATOR STATION SUB-SYSTEM INTERPLANT NETWORK PC (OPTIONAL) V NET 10 Mbps HIS – Human Interface Station. FCS – Field Control Station. NIU – Node Interface Unit. RIO Bus – Remote I/O Bus. CGW – Communication gateway unit BCV – Bus Converter Remote Domain System CS, CS 1000 Centum – XL, -V, -MXL CGW BCV
CENTUM CS 3000 NETWORKCENTUM CS 3000 NETWORK FCS FCS FCS HIS HIS HIS V net
CENTUM CS3000 SYSTEM SPECIFICATIONCENTUM CS3000 SYSTEM SPECIFICATION •• NO. OF TAGS MONITOREDNO. OF TAGS MONITORED 1,00,0001,00,000 •• TOTAL NO. OF STATIONTOTAL NO. OF STATION 256256 •• NO. OF DOMAINSNO. OF DOMAINS 1616 •• NO. OF STATIONS IN A DOMAINNO. OF STATIONS IN A DOMAIN 6464 •• NO. OF HIS / DOMAINNO. OF HIS / DOMAIN 16 NOS16 NOS
CENTUM CS3000 SYSTEM SPECIFICATIONCENTUM CS3000 SYSTEM SPECIFICATION •• Max. no. of stations : 256 /Max. no. of stations : 256 / systemsystem •• Max. no. of DomainsMax. no. of Domains : 16 / system: 16 / system •• Numbering of DomainsNumbering of Domains :: 1 to 641 to 64 •• Domain No. CS3000 DomainDomain No. CS3000 Domain (V net Domain)(V net Domain) : 1 to 16: 1 to 16 •• Max. no. of stations/Domain : 64Max. no. of stations/Domain : 64 •• Domain No.Virtual DomainDomain No.Virtual Domain (Non V net Domain)(Non V net Domain) :: 17 to 6417 to 64 •• Station NO. HIS : 1 tStation NO. HIS : 1 to 64 in descendingo 64 in descending orderorder •• Station NO. FCSStation NO. FCS : 1 to 64 in ascending order: 1 to 64 in ascending order •• Max. No. of ICS / DomainMax. No. of ICS / Domain : 16: 16 •• Max. No. of NIU / FCS : 8Max. No. of NIU / FCS : 8 •• Max. No. of IOU / FCS : 40Max. No. of IOU / FCS : 40 ( Max. 5/ IOU)( Max. 5/ IOU) •• Max. length of VnetMax. length of Vnet : 20 Km: 20 Km •• Max. length of RIO bus : 20 KmMax. length of RIO bus : 20 Km (750m ~(750m ~ 20Km)20Km)
Centum CSCentum CS--3000 Communication3000 Communication V netV net V net is 10 mbps real time control bus which links stationV net is 10 mbps real time control bus which links station such as FCS , HIS , BCVsuch as FCS , HIS , BCV andand CGW. It can be dual redundant. It can be up to 500m using coaxiCGW. It can be dual redundant. It can be up to 500m using coaxial cable alone, oral cable alone, or up to 20up to 20 Km when repeater are used or optical fiber is used.Km when repeater are used or optical fiber is used. •• 10BASE2 cable10BASE2 cable used by HIS, maximum segment length = 185 mused by HIS, maximum segment length = 185 m •• 10BASE5 cable10BASE5 cable used by stations other than HIS(FCS,CGW etc.) maximum segused by stations other than HIS(FCS,CGW etc.) maximum segment length = 500ment length = 500 mm
V net CommunicationV net Communication FCS FCS HIS V net HIS Protocol : IEEE802.4 Access Control : Token Passing Trans. Speed : 10 Mbps Trans. Distance: 500m to 20Km Media : Coaxial/optical fiber
V net specificationV net specification Token passingToken passingProto typeProto type DualDual--redundantredundantRedundancyRedundancy 500M500M ––20Km Max20Km MaxTransmission DistanceTransmission Distance 10 Mbps10 MbpsCommunication rateCommunication rate Bus type or MultiBus type or Multi--drop typedrop typeTypeType Coaxial or fiber opticalCoaxial or fiber optical cablecable Transmission routeTransmission route SPECIFICATIONSPECIFICATIONITEMITEM
VV-- net Featuresnet Features •• Real time control bus. ( Dual redundant possible )Real time control bus. ( Dual redundant possible ) •• Cable : 50 ohm coax. cable with BNC connector ( 10Base2Cable : 50 ohm coax. cable with BNC connector ( 10Base2 comp. )comp. ) •• Communication speed : 10 Mbps.Communication speed : 10 Mbps. •• High reliable token passing communicationHigh reliable token passing communication ( performance guaranteed )( performance guaranteed ) •• Std. max. length : 185 m.Std. max. length : 185 m. •• Max. length : 20 Km ( with optical fiber )Max. length : 20 Km ( with optical fiber ) 1.6 Km ( with coax. Repeater )1.6 Km ( with coax. Repeater ) BNC Connector VL net I/F card ( PCI ) VL net cable
EthernetEthernet HIS and ENG, HIS and supervisory systems can beHIS and ENG, HIS and supervisory systems can be connected by anconnected by an Ethernet LAN; supervisory computers and personalEthernet LAN; supervisory computers and personal computers on the Ethernetcomputers on the Ethernet LAN can access messages and trend data in the CS 3000LAN can access messages and trend data in the CS 3000 system. The Ethernetsystem. The Ethernet can also be used for sending trend data files from the HIScan also be used for sending trend data files from the HIS to supervisoryto supervisory computers, or for equalizing the data in the two HIS stationcomputers, or for equalizing the data in the two HIS station ( rather than using( rather than using the V net control bus to do this ). A system with only onethe V net control bus to do this ). A system with only one HIS with engineeringHIS with engineering functions installed, does not need Ethernetfunctions installed, does not need Ethernet –– but in generalbut in general Ethernet ( andEthernet ( and corresponding network engineering ) is required.corresponding network engineering ) is required.
Ethernet SpecificationEthernet Specification CSMA/CD TypeCSMA/CD TypeProto typeProto type Not availableNot availableRedundancyRedundancy 500m500m –– 2.5 Km max.2.5 Km max.Transmission DistanceTransmission Distance 10 Mbps10 MbpsCommunication RateCommunication Rate Bus type or MultiBus type or Multi––drop typedrop typeTypeType Coaxial or Fiber optical cableCoaxial or Fiber optical cableTransmission RouteTransmission Route SPECIFICATIONSPECIFICATIONITEMITEM
TYPES OF HISTYPES OF HIS •• Console type HISConsole type HIS •• Desk top type HISDesk top type HIS •• PHIS Yokogawa brand OPSPHIS Yokogawa brand OPS
HIS HardwareHIS Hardware •• CPUCPU Pentium 166Pentium 166 •• Main memoryMain memory 96MB or larger(for op &96MB or larger(for op & monitoring only)monitoring only) •• Hard diskHard disk 1 GB or larger1 GB or larger •• DisplayDisplay 256Colors min. resolution 800*600256Colors min. resolution 800*600 1024*768 recommend(1280*1024 best)1024*768 recommend(1280*1024 best) •• Serial portSerial port RS232C*1 or more (for operationRS232C*1 or more (for operation keyboard)keyboard) •• Parallel portParallel port 1 port for printer or more1 port for printer or more •• OSOS Windows NT 4.0 WorkstationWindows NT 4.0 Workstation •• Operator stationsOperator stations Max. 8 stationsMax. 8 stations
Field Control Station ConfigurationField Control Station Configuration HIS Sub system Sub system I/O Unit I/O Unit HIS HIS V net Ethernet Node Interface Unit RIO Bus Node Compact FCS Standard FCS
Connection to Centum CS 3000 SystemConnection to Centum CS 3000 System FCS FCS Exapilot communication data Process data read/write V-net HIS ENG Exaopc Exapilot client (engineering, operation) Exapilot server (engineering, operation) Exapilot client (engineering, operation) Ethernet
Features ofFeatures of ExapilotExapilot •• Standardize and Automate Manual ProceduresStandardize and Automate Manual Procedures •• Improve Plant Operating EfficiencyImprove Plant Operating Efficiency •• Improve safety of Plant OperationImprove safety of Plant Operation Features of Event Analysis PackageFeatures of Event Analysis Package •• Analysis DCS Event History to Help You Enhance Efficiency.Analysis DCS Event History to Help You Enhance Efficiency. •• Enhance Process Stability: Balance Process Events and Operator AEnhance Process Stability: Balance Process Events and Operator Actions.ctions. •• When, Where, What (3W) Filters Help You Narrow Focus of AnalysisWhen, Where, What (3W) Filters Help You Narrow Focus of Analysis..
OPEN DCS SYSTEMOPEN DCS SYSTEM Safety Barrier Pressure TX. Control Valve Terminator H M I Ethernet Field Bus Power Supply Flow Trans.
Field busField bus It is a standardized digital communication protocol between a pIt is a standardized digital communication protocol between a processrocess Control field devicesControl field devices and the Control room. It is a simple pair of wires to power andand the Control room. It is a simple pair of wires to power and carry thecarry the communicationcommunication signal between the field devices and the Control room.signal between the field devices and the Control room. FEATURESFEATURES :: •• Drastic reduction in cable, conduits cable trays, marshallive raDrastic reduction in cable, conduits cable trays, marshallive racks, andcks, and connectors etc.connectors etc. •• Drastic reduction in installation cost.Drastic reduction in installation cost. •• Fewer non field devices.Fewer non field devices. •• More reliability due to the smaller number of devices.More reliability due to the smaller number of devices. •• More efficient operation due to better accuracy (no A/D and D/AMore efficient operation due to better accuracy (no A/D and D/A conversion).conversion). •• Easy integration into plant management system.Easy integration into plant management system. •• Flexibility for different suppliers are interoperable and intercFlexibility for different suppliers are interoperable and interchangeable.hangeable. •• Major reduction in maintenance cost.Major reduction in maintenance cost.
FieldField--bus Benefitsbus Benefits Wiring Screw Terms Wire (pair) I/O Cards IS Barriers Traditional Field bus 3500’ 168 2 2 640’ 64 1 1 Savings Savings % Savings $ 2860’ 104 1 1 82% 63% 50% 50% $ 3000 Material $ 2000 Labor $ 5000 Total Typically comments from a plant personal : •Easy to identify what’s out there. •Consistent calibration procedure. •Two days versus four days to commission system. •Familiar with twisted pair wiring – comfortable.
Function Block(s) Function Block(s) TransducerTransducer (Servo)(Servo) BlockBlock FOUNDATION™ fieldbus Basic Components Resource Block ResourceResource BlockBlock Valve FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary BlocksBlocks
Function Block(s) Function Block(s) TransducerTransducer BlockBlock Resource Block ResourceResource BlockBlock FOUNDATION™ fieldbus Temperature Transmitter FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary BlocksBlocks Basic Components
FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary H1 and H2H1 and H2 •• H1 SegmentH1 Segment –– Moderate speedModerate speed –– Use existing wiringUse existing wiring –– Bus poweredBus powered –– Can be intrinsicallyCan be intrinsically safesafe –– Low power 2 wireLow power 2 wire devicesdevices –– 4 wire devices4 wire devices –– Replace analog &Replace analog & proprietary digitalproprietary digital •• H2 SegmentH2 Segment –– High speedHigh speed –– Link multiple H1Link multiple H1 SegmentsSegments –– I/O subsystem busI/O subsystem bus –– ReplaceReplace proprietaryproprietary networksnetworks –– New wiringNew wiring
FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary New Approach for H2New Approach for H2 •• 100 Meg Ethernet technology with extensions100 Meg Ethernet technology with extensions –– Improve time to marketImprove time to market –– High speedHigh speed –– Mandatory redundancyMandatory redundancy –– Widely available technology and siliconWidely available technology and silicon –– Widely available toolsWidely available tools –– Limited incremental developmentLimited incremental development –– Many suppliersMany suppliers –– High volume for low costHigh volume for low cost –– Works with installed equipmentWorks with installed equipment –– Evergreen technologyEvergreen technology •• Better than ANY other solution!Better than ANY other solution!
H2 Segment 100 Meg Ethernet PLC H1/H2 Bridge Control Module H1/H2 Bridge Replaces Traditional I/O H1/H2 Bridge Replaces Traditional I/O Server H1 Segment H1 Segment H1 Segment FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary H1/H2 BridgesH1/H2 Bridges
FOUNDATIONFOUNDATION™™ fieldbus Standardsfieldbus Standards OrganizationsOrganizations •• IECIEC –– International ElectroInternational Electro--technical Commissiontechnical Commission •• ISAISA –– International Society for Measurement and ControlInternational Society for Measurement and Control (formerly: Instrument Society of America)(formerly: Instrument Society of America) •• SP50SP50 •• CENELECCENELEC –– European standards bodyEuropean standards body •• Parallel (competitive?) Working Groups to IECParallel (competitive?) Working Groups to IEC
FewerTerminationsFewerTerminations Fewer IS barriersFewer IS barriers Marshaling Junction Box IS (Ex i) Barriers H1 I/O Terminations H1 Fieldbus all-digital H1 Fieldbus all-digital H1 I/O Interface Controller Similar I/O CardsSimilar I/O Cards Cost savings: • wiring • I/O cards & cables • terminations • IS barriers • marshaling Cost savings: • wiring • I/O cards & cables • terminations • IS barriers • marshaling Fewer TerminationsFewer Terminations Reduced WiringReduced Wiring FOUNDATIONFOUNDATION™™ fieldbus Topographyfieldbus Topography H1 Fieldbus InstallationsH1 Fieldbus Installations
Barriers FOUNDATIONFOUNDATION™™ fieldbus Topographyfieldbus Topography Intrinsic SafetyIntrinsic Safety
DeltaV System ArchitectureDeltaV System Architecture PrinterPrinter 8 port Hub primary 8 port Hub Redundant Serial P S D I D O D I A O A I A I Contr. Contr. P S Blank Blank H I Blank Blank Blank D O Blank PLC For 8 DI & 8 DO H1 Connector 1 Operator stationEngineering station 8 wide carrier for I/O subsystem 2 wide carrier for Power/Controller Power supply Controller Fieldbus Transmitter 3244MVF1NAB4 Pressure Transmitter 3051TG2A2B21AB4M5FF Smart valve positioner FSDVC0400-201 I/O extension cable RS232 Modbus Fieldbus Power
DCS communication system HierarchyDCS communication system Hierarchy MIS SCHED. SUP. DDC SUP. DDC DDC DDC S A A A A AS S S S S S PLANT Level 5 Management Low data rates Superior responsibility Level 1 Sensors (S) & Actuators (A) High data rates Low responsibility Level 2 Direct digital Control (DDC) Level 3 Supervisory control Level 4 Scheduling High Low
History of Process Control SignalHistory of Process Control Signal Around 50 years ago, most plant used 3Around 50 years ago, most plant used 3--15psi pneumatic signal to control their15psi pneumatic signal to control their process.process. The last change change in signal standard was the open protocolThe last change change in signal standard was the open protocol HART digitalHART digital communicationscommunications format. The HART protocol provides simultaneous digital communiformat. The HART protocol provides simultaneous digital communications with the 4cations with the 4--2020 mAmA output.output. The next protocol change will be fieldbus. FieldThe next protocol change will be fieldbus. Fieldbus is entirely digitalbus is entirely digital--there isthere is no analogno analog Signal. Fieldbus also allows migration of control functions to fSignal. Fieldbus also allows migration of control functions to field devices.ield devices. Process control TimelineProcess control Timeline –– The Evolution of Signal StandardThe Evolution of Signal Standard Signal standards have evolved over the years, starting with theSignal standards have evolved over the years, starting with the 33--15 psi15 psi standard.standard. There are also other communication methods, but they have not gThere are also other communication methods, but they have not gained widespreadained widespread acceptance.acceptance. With many standard there is typically a slow transition period aWith many standard there is typically a slow transition period as plants plant engineers andengineers and managers test period does gain widespread acceptance. However,managers test period does gain widespread acceptance. However, once the benefits ofonce the benefits of thethe Fieldbus become tested and proven, more plant will install FielFieldbus become tested and proven, more plant will install Fieldbus because of itsdbus because of its Digital plus Analog: HART with 4-20mA Digital: Fieldbus Analog: 4-20mA Pneumatic: 3-15 psi 1940 1950 1960 1970 1980 1990 2000 2010
I/O Bus Network ProtocolI/O Bus Network Protocol I/O Bus Network Discrete Byte-wide Data Bit-wide data Several Hundred Data Bytes Analog Device bus network Process bus network
Protocol StandardProtocol Standard Device bus network Process bus network Field Bus Foundation (Field Bus std.) Profibus Trade Organization (Profibus std.) Byte-Wide Data Bit-Wide Data CAN Bus Inter Bus-S Device net SDS Seriplex Inter Bus Loop ASI
Fieldbus ArchitectureFieldbus Architecture Fieldbus is more than just a new signal communications protocol,Fieldbus is more than just a new signal communications protocol, but a whole new waybut a whole new way toto control the process. With the release of the low fieldbus (H1),control the process. With the release of the low fieldbus (H1), the entire fieldbus willthe entire fieldbus will bebe defined. Most of the recent published literature has focused ondefined. Most of the recent published literature has focused on the intricate details ofthe intricate details of thethe fieldbus architecture, especially those layers that have not befieldbus architecture, especially those layers that have not been released. However,en released. However, exceptexcept physical layer and the user layer, these layer are transparentphysical layer and the user layer, these layer are transparent to the engineers and theto the engineers and the manager.manager. Physical Layer Data Layer Application Layer User Layer Systemmanagement NetworkManagement Maintenance information system Workstation stack PumpLevel Transmitter ValveMultivariable Transmitter
Open System Interconnected ReferenceOpen System Interconnected Reference ModelModel Application Presentation Session Transport Network Data link Physical MBAP, SMB, FTP, SMTP, FMS, IEC 61158, ANSI/ISA S50.2,IEEE 1451 TCP, SPX, UDP IP, IPX, NetBeui HDLC, ETHERNET, ANSI/ISA S50.02 EIA-485, ETHERNET,ANSI/ISA S50.02 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. 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.
Field BusField Bus Field Bus is a biField Bus is a bi--directional digital communication that interconnects smart fielddirectional digital communication that interconnects smart field devices todevices to control system or to instrument located in the control room.control system or to instrument located in the control room. Field Bus is based on the OSI (Open System Interconnect), whichField Bus is based on the OSI (Open System Interconnect), which was developed bywas developed by the ISOthe ISO (International Standard Organization) to represent the various f(International Standard Organization) to represent the various functions required inunctions required in anyany Communication network.Communication network. Connects theConnects the equipmentequipment PhysicalPhysical11 Establishes the dataEstablishes the data link connectionlink connection LinkLink22 Establishes networkEstablishes network connectionsconnections NetworkNetwork33 Secures the transportSecures the transport connectionconnection TransportTransport44 Handles the dialogueHandles the dialogueSessionSession55 Converts dataConverts dataPresentationPresentation66 Provides formattedProvides formatted datadata ApplicationApplication77 FunctionFunctionLayerLayer
Field BusField Bus The OSI model consists of seven layers. However for real time aThe OSI model consists of seven layers. However for real time applicationpplication layers 3 to 6 arelayers 3 to 6 are not considered since they deal with transference of data amongnot considered since they deal with transference of data among networks.networks. For suchFor such application following layers are used:application following layers are used: •• LAYER 1LAYER 1 -- PHYSICAL LAYERPHYSICAL LAYER Defines the type of signal, transmitting medium, data tranDefines the type of signal, transmitting medium, data transmissionsmission speed, etc.speed, etc. •• LAYER 2LAYER 2 –– DATALINK LAYERDATALINK LAYER Define the interface between the physical layer and the applicatDefine the interface between the physical layer and the application layer.ion layer. It establishesIt establishes how the messages shall be structured and normalizes the ushow the messages shall be structured and normalizes the use ofe of multiple masters.multiple masters. •• LAYER 3LAYER 3 –– APPLICATION LAYERAPPLICATION LAYER Defines how data is specified, its addresses and its representatDefines how data is specified, its addresses and its representation.ion.The Fieldbus was invented by an Indian engineer Mr. Ram Ramchandran ( M.S in Comp. Tech , Texas)
PHYSICAL LAYERPHYSICAL LAYER The Physical layer defines the medium that transport the messageThe Physical layer defines the medium that transport the messages frames, the signals frames, the signal shape andshape and amplitude limits, data transfer rate, and power distribution.amplitude limits, data transfer rate, and power distribution. Technical Characteristics:Technical Characteristics: Physical MediumPhysical Medium Three types are defined: wires, optic fiber, and radio signals.Three types are defined: wires, optic fiber, and radio signals. TheThe specification forspecification for wire has been already approved.wire has been already approved. Bit rate for wire mediaBit rate for wire media 31.25 Kbps (H1)31.25 Kbps (H1) 1 megabits and 2.5 megabits (H2).1 megabits and 2.5 megabits (H2). H1 and H2 are classification of the two hanks of Field Bus targeH1 and H2 are classification of the two hanks of Field Bus target applications.t applications. H1 hasH1 has low speed and utilizes existing wires. H2 has high speed and maylow speed and utilizes existing wires. H2 has high speed and may requirerequire independentindependent wires to power up field devices.wires to power up field devices. Number of devices per link (31.25Kbps)Number of devices per link (31.25Kbps) 2 to 32 devices, without power and no IS (intrinsic safety).2 to 32 devices, without power and no IS (intrinsic safety). 2 to 6 with power and IS.2 to 6 with power and IS. Maximum distanceMaximum distance Up to 1900 meters for 31.25Kbps, without repeaters. Up to 750 meUp to 1900 meters for 31.25Kbps, without repeaters. Up to 750 meters for 1ters for 1 megabits. Up to 500 meter for 2.5 megabits.
PHYSICAL LAYERPHYSICAL LAYER Signal ModulationSignal Modulation Manchester bi phase L synchronous.Manchester bi phase L synchronous. Physical layer preamblePhysical layer preamble on transmissions, the physical layer will add to the data sent bon transmissions, the physical layer will add to the data sent by the layery the layer above aabove a preamble and one start delimiter in the beginning of the frame apreamble and one start delimiter in the beginning of the frame and one endnd one end delimiterdelimiter at the end delimiter at the end of the of the frame.at the end delimiter at the end of the of the frame.
DATA LINK LAYERDATA LINK LAYER The Data Link Layer will assure the integrity of the message byThe Data Link Layer will assure the integrity of the message by using the frame checkusing the frame check sequence:sequence: Two bytes added to the frames and a polynomial calculation of alTwo bytes added to the frames and a polynomial calculation of all frame data.l frame data. The Data Link Layer also checks to see that the data reaches theThe Data Link Layer also checks to see that the data reaches the devices correctly.devices correctly. Technical characteristicsTechnical characteristics Medium Access:Medium Access: There are three forms to access the network:There are three forms to access the network: •• Token passing:Token passing: Token is the right to initiate a transaction on the bus. A devicToken is the right to initiate a transaction on the bus. A device must have thee must have the token totoken to initiate a conversation. As soon it finishes it will return theinitiate a conversation. As soon it finishes it will return the token to the LAStoken to the LAS (Link(Link Active Scheduler). The LAS send the token to the unit that requeActive Scheduler). The LAS send the token to the unit that requested in eithersted in either in ain a prepre--configured way or via scheduling.configured way or via scheduling. •• Immediate response:Immediate response: A master station will give an opportunity to the station to replA master station will give an opportunity to the station to reply with one frame.y with one frame. •• Requested token:Requested token: a device request a token by using a code in any of the responsea device request a token by using a code in any of the response sent to thesent to the bus. Thebus. The
APPLICATION LAYER AND MANAGEMENTAPPLICATION LAYER AND MANAGEMENT The Application Layer provides a simple interface to the end useThe Application Layer provides a simple interface to the end userr’’s application.s application. Basically , itBasically , it defines how to read, write , interpret and execute a message odefines how to read, write , interpret and execute a message or command. Ar command. A big part of this jobbig part of this job is to define the message syntax. The contents include the requeis to define the message syntax. The contents include the requested message,sted message, action taken, andaction taken, and the response message.the response message. The management defines how to initialize the network : tag assiThe management defines how to initialize the network : tag assignment,gnment, address assignment,address assignment, clock assignment, clock synchronization, distributed applicatioclock assignment, clock synchronization, distributed application schedulingn scheduling across the networkacross the network or association of the input and output parameters of the functior association of the input and output parameters of the function blocks. Iton blocks. It also controls thealso controls the operation of the network with statistic of faults and detectionoperation of the network with statistic of faults and detection of the addition ofof the addition of the new elementthe new element or the absence of a station. The system always look for the newor the absence of a station. The system always look for the new stations onstations on the bus by pollingthe bus by polling the possible station addresses.the possible station addresses.
Digital Communication ProtocolDigital Communication Protocol ISOISO -- International Standard Organization. Responsible for developingInternational Standard Organization. Responsible for developing thethe model that the communication specimodel that the communication specification are based upon asfication are based upon as well aswell as standards for each layer of communstandards for each layer of communication specification.ication specification. IEEEIEEE -- Institute of Electrical and Electronics Engineers. Formed the IInstitute of Electrical and Electronics Engineers. Formed the IEEEEEE 802802 project for defining standards forproject for defining standards for network media and accessnetwork media and access methods.methods. SP72SP72 -- Institute Society of America, Standards and Practice committeeInstitute Society of America, Standards and Practice committee Number 72Number 72 Developing EIA1393 companion standDeveloping EIA1393 companion standard for process controlard for process control messaging.messaging. SP50SP50 -- Institute Society of America, Standards and Practice committeeInstitute Society of America, Standards and Practice committee Number 50Number 50 Developing standards for digital cDeveloping standards for digital communication between fieldommunication between field devices.devices. F.I.PF.I.P -- Factory Information Protocol, approved French National StandardFactory Information Protocol, approved French National Standard.. ProfibusProfibus -- Process Fieldbus, approved German National Standard.Process Fieldbus, approved German National Standard.
HART COMMUNICATION PROTOCOLHART COMMUNICATION PROTOCOL Why HART protocolWhy HART protocol ?? 44--20 ma is tried, tested and widely used standard but only limited20 ma is tried, tested and widely used standard but only limited amount ofamount of informationinformation is sent by a 4is sent by a 4--20 ma signal.20 ma signal. HART (Hiway Addressable Remote Transducer) protocol enhances tHART (Hiway Addressable Remote Transducer) protocol enhances thesehese operations byoperations by transmitting digital data along with the 4transmitting digital data along with the 4--20 ma signal20 ma signal –– without interfering withwithout interfering with it !it ! HART permits twoHART permits two--way communications. It also has all digital mode that allowsway communications. It also has all digital mode that allows instrument to be connected to a single cable, cutting installinstrument to be connected to a single cable, cutting installation costsation costs dramatically.dramatically. Features :Features : 1.1. Field proven concept that is easy to understand and use.Field proven concept that is easy to understand and use. 2.2. Compatible with existing 4Compatible with existing 4--20 ma systems.20 ma systems. 3.3. Simultaneous pointSimultaneous point--toto--point 4point 4--20 ma and digital communication.20 ma and digital communication. 4.4. Alternative multiAlternative multi--drop mode.drop mode. 5.5. Measured variables, tag no. , range and span settings, deviceMeasured variables, tag no. , range and span settings, device information, diagnostics and simple messages transmitted.information, diagnostics and simple messages transmitted. 6.6. Digital response time of 500 msec; burst mode response of 300 msDigital response time of 500 msec; burst mode response of 300 msec.ec. 7.7. Open architecture; freely available to any vendor and every userOpen architecture; freely available to any vendor and every user..
Method of Operation :Method of Operation : The Hart protocol operates using the FSK principal. The digitaThe Hart protocol operates using the FSK principal. The digital data isl data is made up from twomade up from two frequenciesfrequencies ––1200 Hz and 2200 Hz representing bits 1 and 01200 Hz and 2200 Hz representing bits 1 and 0 respectively. Sinusoidalrespectively. Sinusoidal waves of these frequencies are superimposed on the DC analogwaves of these frequencies are superimposed on the DC analog signalsignal cables to givecables to give simultaneous analog and digital communicationssimultaneous analog and digital communications HART Protocol Structure :HART Protocol Structure : HART follows the basic Open Systems Interconnection (OSI) refeHART follows the basic Open Systems Interconnection (OSI) referencerence model, developedmodel, developed by the International Organization for Standard (ISO). The HARby the International Organization for Standard (ISO). The HART protocolT protocol uses a reduceduses a reduced OSI model, implementing only layers 1,2 and 7OSI model, implementing only layers 1,2 and 7 HART COMMUNICATION PROTOCOL
OSI reference modelOSI reference model Open Systems InterconnectionsOpen Systems Interconnections HART COMMUNICATION PROTOCOL Bell 202Bell 202Connects theConnects thePhysicalPhysical11 HART protocolHART protocol regulationsregulations Establishes theEstablishes the data linkdata link connectionconnection LinkLink22 EstablishesEstablishes networknetwork connectionsconnections NetworkNetwork33 Secures theSecures the transporttransport connectionconnection TransportTransport44 Handles theHandles the dialoguedialogue SessionSession55 Converts dataConverts dataPresentationPresentation66 HART instructionsHART instructionsProvides formattedProvides formatted datadata ApplicationApplication77 HARTHARTFUNCTIONSFUNCTIONSLAYERLAYER
Layer 1, the physical layer, operates on the FSK principleLayer 1, the physical layer, operates on the FSK principle Data transfer rate: 1200 bit/sData transfer rate: 1200 bit/s LogicLogic ““00”” frequency: 2200 Hzfrequency: 2200 Hz LogicLogic ““11”” frequency: 1200 Hzfrequency: 1200 Hz the vast majority of existing wiring is used for this type ofthe vast majority of existing wiring is used for this type of digital communication.digital communication. Layer 2, the link layer establishes the format for a hart messaLayer 2, the link layer establishes the format for a hart message. HART is age. HART is a master/slavemaster/slave protocol.protocol. the structure of these messages is given below:the structure of these messages is given below: SDSD –– start character. ADstart character. AD –– display terminal and fielddisplay terminal and field addresses.addresses. CDCD –– HART instruction. BCHART instruction. BC –– Byte count.Byte count. StatusStatus –– Field device and communication status (only from field device tField device and communication status (only from field device too master)master) The individual characters are : 1 start bit, 8 data bits, 1The individual characters are : 1 start bit, 8 data bits, 1 bit for odd parity and 1bit for odd parity and 1 HART PROTOCOL LAYERS ParityParityDatDat aa StatuStatu ss BCBCCDCDADADSDSDPreamblPreambl ee
Layer 7, the application layer, brings the HART instruction inLayer 7, the application layer, brings the HART instruction into play. The masterto play. The master sendssends messages with requests for specified values, actual values anmessages with requests for specified values, actual values and any other data ord any other data or parametersparameters available from the device. The field device interprets theseavailable from the device. The field device interprets these instruction as definedinstruction as defined in thein the HART protocol. The response message provides the master with tHART protocol. The response message provides the master with the statushe status informationinformation and data from the slave.and data from the slave. For slave devices, logical uniform communication is provided bFor slave devices, logical uniform communication is provided by the followingy the following commandcommand sets:sets: Universal commandsUniversal commands –– understood by all field devices.understood by all field devices. Common practice commandsCommon practice commands –– provide functions which can be carried out byprovide functions which can be carried out by many,many, though not all, field devices.though not all, field devices. DriveDrive--specific commandsspecific commands –– provide functions which are restricted to anprovide functions which are restricted to an individualindividual HART PROTOCOL LAYERS
DATA TRANSMISSIONDATA TRANSMISSION Types of data transmission : Frequency shiftTypes of data transmission : Frequency shift keying (FSK)keying (FSK) Transfer rate : 1200 bTransfer rate : 1200 bit/s.it/s. ‘‘00’’ bit information frequency : 2200 Hzbit information frequency : 2200 Hz ‘‘11’’ bit information frequency : 1200 Hzbit information frequency : 1200 Hz Signal structure : 1 startSignal structure : 1 start bit, 8 data bits, 1 bit forbit, 8 data bits, 1 bit for odd parity, 1 stop bit.odd parity, 1 stop bit. Transfer rate for simple variables : Approximately 2/sTransfer rate for simple variables : Approximately 2/s (poll/response)(poll/response) DATA INTEGRITYDATA INTEGRITY Physical layer : Error rate destination circuit : 1Physical layer : Error rate destination circuit : 1/(10^5)/(10^5) Link layer : Recognizes : all groups up to 3 cLink layer : Recognizes : all groups up to 3 corrupt bits andorrupt bits and practically all longerpractically all longer and multiple groups.and multiple groups. Application layer : Communication status terminated in aApplication layer : Communication status terminated in a responseresponse message.message. HART PROTOCOL – TECHNICAL DATA
MODBUSMODBUS The MODBUS protocol describes an industrial commuThe MODBUS protocol describes an industrial communication andnication and distributeddistributed control system developed bycontrol system developed by GouldGould--ModiconModicon. MODBUS is a Master/Slave. MODBUS is a Master/Slave communications protocol, whereby one device (Master), controlcommunications protocol, whereby one device (Master), controls all serials all serial activities byactivities by selectively polling one or more slave devices. The protocol pselectively polling one or more slave devices. The protocol provides for one masterrovides for one master devicedevice and up to 247 slave devices on a common line. Each device isand up to 247 slave devices on a common line. Each device is assigned anassigned an address toaddress to distinguish it from all other connected device.distinguish it from all other connected device. Only a master initiates a transaction. TransactioOnly a master initiates a transaction. Transactions are either ans are either a query/response type,query/response type, or a broadcast/noor a broadcast/no--response type. A transaction comprises a single query andresponse type. A transaction comprises a single query and singlesingle response frame or a single broadcast frame.response frame or a single broadcast frame. Certain characteristic of a MODBUS protocol are fCertain characteristic of a MODBUS protocol are fixed such as frameixed such as frame format, frameformat, frame sequences, handling of communication errors and exception consequences, handling of communication errors and exception conditions, and theditions, and the functionsfunctions performed.performed.
RSRS--232 Communication232 Communication RSRS--232 is an asynchronous communication network. Normally, a binary232 is an asynchronous communication network. Normally, a binary system issystem is used to transmit data in ASCII (American Standard Code for Infoused to transmit data in ASCII (American Standard Code for Informationrmation Interchange)Interchange) format. This code translates human readable code (letter/numberformat. This code translates human readable code (letter/numbers) intos) into ““computercomputer readablereadable”” code(1code(1’’s and 0s and 0’’s).s). There are 2 types of RSThere are 2 types of RS--232 devices. The first is called a DTE (Data Terminal232 devices. The first is called a DTE (Data Terminal Equipment) device and a common example is a computer. The otherEquipment) device and a common example is a computer. The other type of device istype of device is calledcalled DCE (Data Communication Equipment) device and a common exampleDCE (Data Communication Equipment) device and a common example is a modem.is a modem. In RSIn RS--232 the first thing a terminal send is start bit. This start bit232 the first thing a terminal send is start bit. This start bit is ais a synchronizingsynchronizing bit added just before each character being send. The last thingbit added just before each character being send. The last thing send is a stop bit.send is a stop bit. This stop bitThis stop bit informs to the receiving terminal that the last character has jinforms to the receiving terminal that the last character has just being send.ust being send.
RSRS--232 communication is done through Serial port which usually has232 communication is done through Serial port which usually has a 9a 9--pinpin configuration. The pin and their purposes are shown below.configuration. The pin and their purposes are shown below. RS-232 Communication Ring indicator (RI) *only for modems*Ring indicator (RI) *only for modems*99 Clear to Send (CTS)Clear to Send (CTS)88 Request to send (RTS)Request to send (RTS)77 Data set ready (DSR)Data set ready (DSR)66 Signal ground (GND)Signal ground (GND)55 Data terminal ready (DTR)Data terminal ready (DTR)44 Transmit data (TD)Transmit data (TD)33 Receive data (RD)Receive data (RD)22 Frame groundFrame ground11 PURPOSEPURPOSE99--PINPIN
PC-to-PC Communication through Serial Port CD 10 RXD 20 TXD 30 DTR 40 GND 50 DSR 60 RTS 70 CTS 80 RI 90 01 CD 02 RXD 03 TXD 04 DTR 05 GND 06 DSR 07 RTS 08 CTS 09 RI 9-Pin D Connector
PC-to-PC Communication through LPT1 Port 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
FlavoursFlavours of Internet Telephonyof Internet Telephony The Internet The Internet The Internet PC PC PC Phone PhonePhone Local ISP Local ISP Local ISP Local ISP Voice Gateway Local ISP Voice Gateway Local ISP Voice Gateway PC-to-PC PC-to-Phone Phone-to-Phone Dial-up or Leased Line Access Code
APACSAPACS -- Operation PlatformOperation Platform Database OwnershipDatabase Ownership Operator Console Engineer Console Operator Console Controller Module Transmitter Interlock I/P Valve I/O Modules I/O Level •TAGS •Range •Engineering Unit •Diagnostics Console Level Controller Level
TODAYS INDUSTRIAL SYSTEMSTODAYS INDUSTRIAL SYSTEMS H M I Planning H M I 1 2 3 4 5 6 Application Drivers Devices PLC I/O DCS -----------------------
PC Based Industrial SystemsPC Based Industrial Systems H M I Planning H M I 1 2 3 Devices PLC I/O DCS OPC Client Application OPC Server ----------------------------------
Enterprise Automation SchemesEnterprise Automation Schemes Windows NT Windows NT Embedded Real System Control network Corporate IT Network Server
Windows NT (Windows NT (““New technologyNew technology””)) FEATURESFEATURES:: •• A true 32 bit processing.A true 32 bit processing. •• A very reliable operating system.A very reliable operating system. •• Real operating system.Real operating system. TECHNICAL ASPECTTECHNICAL ASPECT:: •• Multiprocessing, Multithreading and partitioned memory space.Multiprocessing, Multithreading and partitioned memory space. •• SecuritySecurity -- C2 compliance.C2 compliance. •• InIn--built networking.built networking. •• Internationalization .Internationalization . •• Human interface as Windows 95.Human interface as Windows 95. •• ObjectObject -- based : DCOM/OLEbased : DCOM/OLE -- ActiveX.ActiveX. •• for special need of the process industries. DCOM and OLE are notfor special need of the process industries. DCOM and OLE are not robust,robust, deterministic and secure.deterministic and secure. •• ClientClient -- Server architecture.Server architecture.
Transparent interTransparent inter--connectivity to typical business systems in plants:connectivity to typical business systems in plants: 1) ODBC : It provides access to most SQL databases1) ODBC : It provides access to most SQL databases.. 2) ActiveX/OLE : Supports data access between appl2) ActiveX/OLE : Supports data access between application andication and embedding ofembedding of one applications funone applications function within another.ction within another. 3) DDE : Dynamic Data Exchange supports simple data exch3) DDE : Dynamic Data Exchange supports simple data exchangeange betweenbetween applications such as plant data poapplications such as plant data populating an Excel spreadpulating an Excel spread sheets.sheets. Windows NT Interconnectivity
Windows NT featuresWindows NT features Windows NT is gaining ground in open control because of the foWindows NT is gaining ground in open control because of the following advantages :llowing advantages : •• User acceptance.User acceptance. •• Corporate interoperabilityCorporate interoperability •• Ease of use.Ease of use. •• Connectivity.Connectivity. •• Scalability for small and large application.Scalability for small and large application. However, Windows NT has the following disadvantages :However, Windows NT has the following disadvantages : •• Needs a lot memory and processing power.Needs a lot memory and processing power. •• Optimized for office, not control, requirements.Optimized for office, not control, requirements. •• Requires a disk drive which may fail.Requires a disk drive which may fail. •• Depends on single vendor.Depends on single vendor. •• Reboots at unexpected timesReboots at unexpected times •• Unstable operating system.Unstable operating system.
Embedded control Operating SystemEmbedded control Operating System -- QNXQNX QNX realQNX real--time operating system, has evolved from the firsttime operating system, has evolved from the first--ever microever micro--kernelkernel operatingoperating system for PCs into one of the best selling and most trusted opesystem for PCs into one of the best selling and most trusted operating systems forrating systems for missionmission critical application. Today, QNX is the real time operating systcritical application. Today, QNX is the real time operating system in industrialem in industrial automation,automation, hand held devices, controllers and soft PLCshand held devices, controllers and soft PLCs QNX is recognized as :QNX is recognized as : •• The fastest and most dependable real time operating system.The fastest and most dependable real time operating system. •• The most proven high speed, deterministic real time kernel.The most proven high speed, deterministic real time kernel. •• Having a hard real time engine that gives PLCHaving a hard real time engine that gives PLC--style control.style control. •• Enabling data acquisition with milliseconds resolution.Enabling data acquisition with milliseconds resolution. •• Providing a faultProviding a fault--tolerant architecture on which you can run control, events,tolerant architecture on which you can run control, events, alarms in a virtually crashalarms in a virtually crash--proof environment.proof environment.
Windows NTWindows NT -- for Process controlfor Process control Windows NT features :Windows NT features : •• A true 32 bit processing.A true 32 bit processing. •• A very reliable operating system.A very reliable operating system. •• Real operating system.Real operating system. •• Multiprocessing, Multithreading and partitioned memory space.Multiprocessing, Multithreading and partitioned memory space. •• SecuritySecurity -- C2 compliance.C2 compliance. •• InIn--built networking.built networking. •• Internationalization.Internationalization. •• Human interface.Human interface. •• ObjectObject--based DCOM/OLE :based DCOM/OLE : The sending object is shown as client and receiving objThe sending object is shown as client and receiving object is known asect is known as server. Theserver. The MS technology allows any developer to produce small, seMS technology allows any developer to produce small, self contain objectslf contain objects that havethat have ““packagedpackaged”” visual component and specific action. These components arevisual component and specific action. These components are calledcalled ““ActiveXActiveX”” objects. NTobjects. NT’’s OLE technology is part of Microsofts OLE technology is part of Microsoft’’s Distributeds Distributed Component Object Model (DCOM) operating across networksComponent Object Model (DCOM) operating across networks. Anyone can. Anyone can developdevelop ActiveX Object using VC++ or even VB on a PC. For speciaActiveX Object using VC++ or even VB on a PC. For special needs of thel needs of the processprocess control industries DCOM and OLE are not secure, determinicontrol industries DCOM and OLE are not secure, deterministic and robuststic and robust enough.enough.
EthernetEthernet Ethernet was originally designed by Digital, Intel andEthernet was originally designed by Digital, Intel and Xerox (DIX) in the earlyXerox (DIX) in the early 19701970’’ss and has been designed as a broadcast system. The original formaand has been designed as a broadcast system. The original format for Ethernet wast for Ethernet was developeddeveloped in Xerox Palo Alto Research center (PARC), California in 1972.in Xerox Palo Alto Research center (PARC), California in 1972. The two inventorsThe two inventors werewere Robert Metcalf and David Boggs.Robert Metcalf and David Boggs. Ethernet version 1.0 and 2.0 followed until the IEEE 8Ethernet version 1.0 and 2.0 followed until the IEEE 802.3 committee re02.3 committee re-- jigged thejigged the Ethernet II packet to form the Ethernet 802.3 packet. NowadaysEthernet II packet to form the Ethernet 802.3 packet. Nowadays you will see eitheryou will see either Ethernet II (DIX) format or Ethernet 802.3 format being used.Ethernet II (DIX) format or Ethernet 802.3 format being used. TheThe ‘‘EtherEther’’ part of Ethernet denotes that the system is not meant to bepart of Ethernet denotes that the system is not meant to be restricted only torestricted only to one medium type, copper cables, fiber cables and even radio wavone medium type, copper cables, fiber cables and even radio waves can be used.es can be used. Briefly, stated Ethernet what is referred to as the PhBriefly, stated Ethernet what is referred to as the Physical layer and the Dataysical layer and the Data-- link layerslink layers protocols. The physical layer defines the cable types, connectoprotocols. The physical layer defines the cable types, connectors and electricalrs and electrical characteristics.characteristics. The Data link layer defines the format an Ethernet frames, theThe Data link layer defines the format an Ethernet frames, the error checkingerror checking method and themethod and the
10Base510Base5 Traditionally, Ethernet is used overTraditionally, Ethernet is used over ‘‘thickthick’’ coaxial cable called 10Base5 (coaxial cable called 10Base5 ( the 10the 10 denotes 10 Mbps, base means that the signal is baseband i.e, tadenotes 10 Mbps, base means that the signal is baseband i.e, takes the wholekes the whole bandwidthbandwidth of the cable, 5 denotes 500m maximum length ). The minimum lengof the cable, 5 denotes 500m maximum length ). The minimum lengthth between stationsbetween stations is 2.5m.is 2.5m. The cable is run in one long length forming aThe cable is run in one long length forming a ‘‘Bus TopologyBus Topology’’. The. The segments aresegments are terminated by 50 ohm resistor and the shield should be groundedterminated by 50 ohm resistor and the shield should be grounded at one endat one end only.only. 10Base210Base2 Thin Ethernet (Thinnet) uses RGThin Ethernet (Thinnet) uses RG--58 cable and is called 10Base2 (the 258 cable and is called 10Base2 (the 2 denotesdenotes 200 mtr maximum length cable). Each station connects to the Thin200 mtr maximum length cable). Each station connects to the Thinnet by waynet by way of EthernetEthernet
10BaseT10BaseT Nowadays, it is becoming increasingly important to useNowadays, it is becoming increasingly important to use Ethernet acrossEthernet across UnshieldedUnshielded Twisted Pair (UTP) or Shielded Twisted Pair (STP), this being cTwisted Pair (UTP) or Shielded Twisted Pair (STP), this being called 10BaseT (the Talled 10BaseT (the T denotes twisted pair). UTP is installed in star wire format anddenotes twisted pair). UTP is installed in star wire format and Ethernet Hubs withEthernet Hubs with UTP portsUTP ports (RJ45) centrally located. Also there should be no more than a 1(RJ45) centrally located. Also there should be no more than a 11.5db signal loss and1.5db signal loss and thethe minimum distance between devices is 2.5 meters.minimum distance between devices is 2.5 meters. The advantages of the UTP/STP technology are gained froThe advantages of the UTP/STP technology are gained from the flexibility ofm the flexibility of thethe system, with respect to moves, changes, fault finding, reliabilsystem, with respect to moves, changes, fault finding, reliability and security.ity and security. 10BaseF10BaseF 10BaseF standard developed by IEEE 802.3 committee defi10BaseF standard developed by IEEE 802.3 committee defines the use of Fibernes the use of Fiber forfor Ethernet. 10BaseFB allows up to 2 Km per segment and is defineEthernet. 10BaseFB allows up to 2 Km per segment and is defined for Backboned for Backbone EthernetEthernet
The following table shows the RJ45 pin outs for 10BaseT :The following table shows the RJ45 pin outs for 10BaseT : Brown/WhiteBrown/White88 White/BrownWhite/Brown77 Green/WhiteGreen/WhiteReceiveReceive66 White/BlueWhite/Blue55 Blue/WhiteBlue/White44 White/GreenWhite/GreenReceiveReceive33 Orange/WhiteOrange/WhiteTransmitTransmit22 White/OrangeWhite/OrangeTransmitTransmit11 ColourColourFunctionFunctionRJ45 PinRJ45 Pin EthernetEthernet
PCPC--toto--PC Communication throughPC Communication through EthernetEthernet RJ45 RJ45 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8
Controller Controller Controller Controller Workstation Workstation Workstation Workstation Switched Hub Segmented (star) topology Bus topology Ethernet TopologyEthernet Topology
Wireless LANWireless LAN Wireless LAN is based on standard IEEE 802.11b which throughputWireless LAN is based on standard IEEE 802.11b which throughput of up to 11Mbps inof up to 11Mbps in thethe 2.42.4 GhzGhz band. Similar Wireless Personal Area Network (WPAN) are Bluetooband. Similar Wireless Personal Area Network (WPAN) are Bluetooth andth and Infrared.Infrared. Ethernet works on the CSMA/CD technology but wireless LAN haEthernet works on the CSMA/CD technology but wireless LAN has difficulty ofs difficulty of detectingdetecting collision in Radio frequency. Therefore they are using CSMA/CA (collision in Radio frequency. Therefore they are using CSMA/CA (Collision Sense MultipleCollision Sense Multiple Access / Collision Avoidance) technology to transmit data. PhysiAccess / Collision Avoidance) technology to transmit data. Physical Layer is eithercal Layer is either Photonic orPhotonic or Radio frequency.Radio frequency.
Process control Software characteristicsProcess control Software characteristics The most important feature of process control system is that itThe most important feature of process control system is that it needs to beneeds to be reliable.reliable. TheThe process control system used has to be completely crashprocess control system used has to be completely crash--proof and any changes inproof and any changes in thethe system need to be made onsystem need to be made on--line.line. The process control needs to be madeThe process control needs to be made real time,real time, which means that it canwhich means that it can update the I/Oupdate the I/O data table and process the control program in the time requireddata table and process the control program in the time required by the process.by the process. A process control system that isA process control system that is deterministicdeterministic refers to whether the operatingrefers to whether the operating systemsystem allows the highest priority task to work without interruption fallows the highest priority task to work without interruption from task with lowerrom task with lower priority.priority. Software offerings in the automation and the process control fSoftware offerings in the automation and the process control fields must beields must be versatileversatile andand openopen enough to address the needs of different applications.enough to address the needs of different applications. Finally the chosen solution must deliver tangible, quantifiablFinally the chosen solution must deliver tangible, quantifiable values such as :e values such as : 1.1. Reducing project implementation time and cost.Reducing project implementation time and cost. 2.2. Improving timeImproving time--toto--market.market. 3.3. Achieving higher production and quality.Achieving higher production and quality. 4.4. Cutting maintenance and training cost.Cutting maintenance and training cost.
PCPC--based control system featuresbased control system features Unlike the other systems, PCs provide a more open architectureUnlike the other systems, PCs provide a more open architecture making them idealmaking them ideal forfor improving, optimizing and integrating the overall automation primproving, optimizing and integrating the overall automation process, as well asocess, as well as conductingconducting control task.control task. In addition PCs offer the following features :In addition PCs offer the following features : •• Lower cost.Lower cost. •• Ease of use.Ease of use. •• Graphical user interface.Graphical user interface. •• Easy integration of logic, motion and process control.Easy integration of logic, motion and process control. •• Simplified application development.Simplified application development. •• Software portabilitySoftware portability •• Independence from proprietary control system.Independence from proprietary control system. Using PCs enable the following functions,Using PCs enable the following functions, •• Millisecond time stamping which is essential to utilities.Millisecond time stamping which is essential to utilities. •• Real time control.Real time control. •• Sequence of events.Sequence of events. •• Alarming.Alarming. •• Data collection.Data collection.
PLC conceptual overviewPLC conceptual overview Process Graphics History & Trend Alarm & Events SCADA configuration editor Other Aspect system ABB Siemens Allen Bradley GE Fanuc …. opc Modbus comli Protocol xx Protocol yy SCADA server OPC server OP Client SCADA Control Aspect Real-time database
PLC Programming StandardsPLC Programming Standards The open, manufacturerThe open, manufacturer--independent programming standard forindependent programming standard for automation isautomation is IEC 61131IEC 61131--3. You can thus choose what configuration interface you wish to3. You can thus choose what configuration interface you wish to useuse whenwhen writing your application :writing your application : •• Ladder DiagramLadder Diagram •• Instruction ListInstruction List •• Function Block DiagramFunction Block Diagram •• Sequential Function ChartSequential Function Chart •• Structured TextStructured Text All users, be they plant electrician or coAll users, be they plant electrician or computer scientists, thus havemputer scientists, thus have a configuration interface in which they can feel at home.a configuration interface in which they can feel at home.
Industrial IT TrendsIndustrial IT Trends The availability of information is becoming increasingly crucialThe availability of information is becoming increasingly crucial in the view of growingin the view of growing globalglobal competition. In future, a decisive competitive edge can only becompetition. In future, a decisive competitive edge can only be achieved by providingachieved by providing thethe right information at the right time, in the right place and inright information at the right time, in the right place and in the right form for the rightthe right form for the right person.person. these leadingthese leading-- edge application are continuously optimized and repositioned.edge application are continuously optimized and repositioned. Industrial IT consists of five components:Industrial IT consists of five components: 1.1. Engineering ITEngineering IT 2.2. Operation ITOperation IT 3.3. Production ITProduction IT 4.4. Optimization ITOptimization IT 5.5. Evolution / InformationEvolution / Information
ASSET OPTIMIZATION Industrial IT TrendIndustrial IT Trend Sales & Marketing Planning & Scheduling Plant & Process Eng. Operation & Maintenance Distribution Real-time Automation & Information e-PRODUCTIVITY Business Systems Plant
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DISTRIBUTED CONTROL SYSTEMS BASICS.

  • 2. DCS EVOLUTIONDCS EVOLUTION--CENTRALISED CONTROLCENTRALISED CONTROL
  • 3. DCS EVOLUTIONDCS EVOLUTION--DISTRIBUTED CONTROLDISTRIBUTED CONTROL
  • 4. DCS EVOLUTIONDCS EVOLUTION--FIELDBUS CONTROLFIELDBUS CONTROL
  • 5. DCS EVOLUTIONDCS EVOLUTION-- WEB CONTROLWEB CONTROL
  • 6. DCS EVOLUTIONDCS EVOLUTION--WEB CONTROL APPLICATIONWEB CONTROL APPLICATION
  • 7. ABB DCS ARCITECTUREABB DCS ARCITECTURE
  • 8. ABB DCS HARDWAREABB DCS HARDWARE
  • 9. CONTROL SYSTEMS TRENDCONTROL SYSTEMS TREND 1) PLC1) PLC 2) DCS2) DCS 3) PC3) PC -- Based ControlBased Control.. •• PLCPLC :: Introduced in the late 1960 to replace Relays and HardIntroduced in the late 1960 to replace Relays and Hard--wiredwired Programming.Programming.
  • 10. DCSDCS :: Introduced in the MidIntroduced in the Mid--1970 to1970 to replace pneumatic controls by usingreplace pneumatic controls by using computers.computers. •• PCPC--Based ControlBased Control :: Introduced by the early 1980s to avoid theIntroduced by the early 1980s to avoid the proprietary PLC & DCS systems.proprietary PLC & DCS systems.
  • 11. DCS EVOLUTIONDCS EVOLUTION •• LOCAL CONTROLLOCAL CONTROL :: Initially control was performed local to the equipmentInitially control was performed local to the equipment control. Thecontrol. The ADVANTAGEADVANTAGE was low wiring costs .was low wiring costs .DISADVANTAGESDISADVANTAGES werewere -- not much control, monitoring, alarming & history.not much control, monitoring, alarming & history. •• CENTRALISED CONTROLCENTRALISED CONTROL:: With the advent of minicomputer, sensors andWith the advent of minicomputer, sensors and actuators were into the Central Control (Computer).actuators were into the Central Control (Computer). •• DISTRIBUTED CONTROLDISTRIBUTED CONTROL:: With the advent of microcomputer, DistributedWith the advent of microcomputer, Distributed control systems were installed in the plants near to the controlcontrol systems were installed in the plants near to the control room viaroom via proprietary digital communications lines called as Data Hiway. Fproprietary digital communications lines called as Data Hiway. First DCS wasirst DCS was developed by Honeywell,U.S in 1975.developed by Honeywell,U.S in 1975. TheThe ADVANTAGESADVANTAGES were greatly reduced wiring costs, much more limitedwere greatly reduced wiring costs, much more limited failure and less cost to add more points.failure and less cost to add more points. TheThe DISADVANTAGESDISADVANTAGES were that wiring costs were that wiring costswere that wiring costs were that wiring costs were still significant and there was lack of interoperability amwere still significant and there was lack of interoperability among controllers ofong controllers of various manufacturers due to the proprietary protocols. Hence thvarious manufacturers due to the proprietary protocols. Hence the user wase user was locked into a single vendor.locked into a single vendor.
  • 12. DCS System Installations in RCFDCS System Installations in RCF 1. Yokogawa1. Yokogawa -- CS 3000 : Ammonia IICS 3000 : Ammonia II 2. Yokogawa2. Yokogawa -- CS 3000 : A N PCS 3000 : A N P 3. Yokogawa3. Yokogawa -- CS 3000 : N N A PCS 3000 : N N A P 4. Moore4. Moore -- APACSAPACS : Methyl amine: Methyl amine 5. Fisher5. Fisher -- RosemantRosemant -- Delta V field Bus : S T PDelta V field Bus : S T P 6. Honeywell6. Honeywell -- GUS : Ammonia I SynthesisGUS : Ammonia I Synthesis 7. Yokogawa7. Yokogawa -- Centum Excel : Steam Generation PlantCentum Excel : Steam Generation Plant 8. Moore8. Moore -- APACS : SuphalaAPACS : Suphala 9. Yokogawa9. Yokogawa -- Micro Excel : MethanolMicro Excel : Methanol 10. Yokogawa10. Yokogawa -- Micro Excel : S A P/C N AMicro Excel : S A P/C N A 11. ABB11. ABB -- Freelance 2000 : A B CFreelance 2000 : A B C 12. Honeywell12. Honeywell -- TDC 3000 : Ammonia ITDC 3000 : Ammonia I 13. Honeywell13. Honeywell -- GUS : Ammonia/UreaGUS : Ammonia/Urea -- ThalThal 14. Fox14. Fox boroboro -- I/A series : D M A CI/A series : D M A C -- ThalThal 15. Fisher15. Fisher -- Rosemant RS3 : P G RRosemant RS3 : P G R 16. Fisher16. Fisher -- Rosemant RS3 : Steam GenerationRosemant RS3 : Steam Generation -- ThalThal 17. Moore17. Moore -- APACS : Water Treatment PAPACS : Water Treatment Plantlant -- ThalThal
  • 13. DCSDCS •• The importance of DCS systems to increase as global competitiveThe importance of DCS systems to increase as global competitive dynamics in food and beverage, specialty metals, pulp and paper,dynamics in food and beverage, specialty metals, pulp and paper, pharmaceutical and fire chemical processing.pharmaceutical and fire chemical processing. •• The DCS has networking capabilities which are useful for businesThe DCS has networking capabilities which are useful for businesss management.management. •• The DCS has capacity for processing large number of I/O points.The DCS has capacity for processing large number of I/O points. TYPES OF DCSTYPES OF DCS :: 1) Conventional DCS .1) Conventional DCS . 2) PLC based DCS.2) PLC based DCS. 3) Hybrid DCS.3) Hybrid DCS. 4) Open DCS System4) Open DCS System
  • 14. CONVENTIONAL DCSCONVENTIONAL DCS This is a pureThis is a pure ““Process onlyProcess only”” control system. Usually purchased fromcontrol system. Usually purchased from one vendor. This DCS arranged into three categories:one vendor. This DCS arranged into three categories: •• SmallSmall -- Less than $ 100,000.Less than $ 100,000. •• MediumMedium -- Greater than $100,000 & Less than $500,000.Greater than $100,000 & Less than $500,000. •• LargeLarge -- Greater than $500,000.Greater than $500,000. PLC Based DCSPLC Based DCS.. This is a network of PLCThis is a network of PLC’’s used to perform the task ofs used to perform the task of conventional DCS and programmable functionality when required.conventional DCS and programmable functionality when required. Hybrid DCSHybrid DCS.. Performs both process and sequential control.Performs both process and sequential control. Open DCS SystemOpen DCS System.. This is FieldThis is Field--Bus Control. Advantages are lower wiring cost andBus Control. Advantages are lower wiring cost and less failure, smaller expansion costs and multi vendor interoperless failure, smaller expansion costs and multi vendor interoperabilityability DCS and PLC can be more closely and efficiently interconnected.DCS and PLC can be more closely and efficiently interconnected.
  • 15. Honeywell TDC 3000 DCS ArchitectureHoneywell TDC 3000 DCS Architecture AMC AMC US#1 US#2 HM LCN A B HG A BData Hiway Field Field EC Link
  • 16. Hiway Gateway (HG)Hiway Gateway (HG) •• LCN Module. Provides a two way communication link between the LoLCN Module. Provides a two way communication link between the Localcal Control Network and data hiway.Control Network and data hiway. •• 68020 based high performance intelligence module.68020 based high performance intelligence module. •• Converts data and protocol between Local Control Network and datConverts data and protocol between Local Control Network and data hiway.a hiway. •• Scans the hiway for alarm conditions.Scans the hiway for alarm conditions. •• Synchronize time keeping for hiwaySynchronize time keeping for hiway--based process connected boxes.based process connected boxes. •• One HG is required for each data hiway that is connected to theOne HG is required for each data hiway that is connected to the LCN. Up toLCN. Up to 20 data hiway pairs can be connected to an LCN.20 data hiway pairs can be connected to an LCN. •• Connects following hiway resident boxes to LCNConnects following hiway resident boxes to LCN 1.1. AMCsAMCs 2.2. CPC ( critical process controller ).CPC ( critical process controller ). 3.3. DHP.DHP. 4.4. Hiway traffic director etcHiway traffic director etc…… HG FunctionsHG Functions :: 1.1. Data access :Data access :-- gets box data requested from LCN modules.gets box data requested from LCN modules. 2.2. Event processing :Event processing :-- sends process and box alarm to LCN modulessends process and box alarm to LCN modules 3.3. Database configuration :Database configuration :-- 3000 points per hg can be configured.3000 points per hg can be configured.
  • 17. Data HiwayData Hiway Data hiway provides communication link betweenData hiway provides communication link between hiwayhiway gateway,gateway, preferred access devices and process connecting box. Data hiwapreferred access devices and process connecting box. Data hiwayy operates atoperates at 250 kbps.250 kbps. It is redundant pair of 75 ohm coax cable conneIt is redundant pair of 75 ohm coax cable connected to box.cted to box. It may beIt may be 20,000 feet long.20,000 feet long. There are 3 kinds of devices on the data hiway,There are 3 kinds of devices on the data hiway, 1.1. Respond only devices Ex:Respond only devices Ex:-- AA--MC (Advanced MultifunctionMC (Advanced Multifunction controller)controller) 2.2. Polled devices Ex:Polled devices Ex:-- PIUPIU’’s (Process interface unit)s (Process interface unit) 3.3. Preferred access devicesPreferred access devices
  • 18. History ModuleHistory Module •• LCN Module. Stores process and systemLCN Module. Stores process and system information that can be displayed.information that can be displayed. •• Based on microprocessors 68020.Based on microprocessors 68020. •• Winchester disk for data storage.Winchester disk for data storage. •• Communicates with all Modules on the LCN.Communicates with all Modules on the LCN. •• Stores history and general information.Stores history and general information.
  • 19. Universal StationUniversal Station Universal station (US) communicates with all modulUniversal station (US) communicates with all modules on thees on the LCN, processLCN, process connected devices on the hiway via hiway gateway and UCN via neconnected devices on the hiway via hiway gateway and UCN via networktwork interface moduleinterface module (NIM).(NIM). The following are the features of US,The following are the features of US, •• Intelligent man/machine interface in the TDC 3000 system.Intelligent man/machine interface in the TDC 3000 system. •• Stands on the LCN. Communicates with all Modules on LCN, processStands on the LCN. Communicates with all Modules on LCN, process connected devices on the Hiway via Hiway Gateway.connected devices on the Hiway via Hiway Gateway. •• Provides comprehensive facilities to the process operator, proceProvides comprehensive facilities to the process operator, processss engineer and maintenance technician on the Universal Window.engineer and maintenance technician on the Universal Window. US provides comprehensive facilities to the followUS provides comprehensive facilities to the following people,ing people, •• Process engineerProcess engineer •• Process operatorProcess operator •• Maintenance technician.Maintenance technician.
  • 20. AMCAMC •• TDC 3000 controllerTDC 3000 controller 1.1. Based on Motorola 68000 Microprocessor.Based on Motorola 68000 Microprocessor. 2.2. Faster execution and control with 500 ms processing rate.Faster execution and control with 500 ms processing rate. •• MultifunctionMultifunction –– Modulating, sequence, logic, I/O monitoringModulating, sequence, logic, I/O monitoring communication and diagnostic.communication and diagnostic. •• Faster peer to peer communication over EC link ( 500 kbits/sec )Faster peer to peer communication over EC link ( 500 kbits/sec ).. •• Proven control techniquesProven control techniques 1.1. Full function algorithms.Full function algorithms. 2.2. Process oriented programming.Process oriented programming. •• Configured as a box on TDC 3000 Data Hiway. Supported byConfigured as a box on TDC 3000 Data Hiway. Supported by 1.1. LCN devicesLCN devices –– US, AM, HM.US, AM, HM.
  • 21. HONEYWELLHONEYWELL -- GUSGUS HM NIM HPM HPM HPM Local Control Network US#1 US#2 US#3 US#4 Printer PrinterDrive’s - - High Performance Manager History Module Network Interface Module Universal Station A B UniversalControlNetwork
  • 22. Honeywell System DescriptionHoneywell System Description •• Global User StationGlobal User Station •• History ModulesHistory Modules •• Network Interface ModulesNetwork Interface Modules •• Communication SubsystemCommunication Subsystem -- Local Control Network & UniversalLocal Control Network & Universal Control NetworkControl Network •• High Performance Process ManagerHigh Performance Process Manager
  • 23. Global User StationGlobal User Station OverviewOverview The TPS system provides an integrated interface between the procThe TPS system provides an integrated interface between the processess and the end user. This interface is named as the Global User Staand the end user. This interface is named as the Global User Station (GUS).tion (GUS). GUS is an important part in the Honeywell Total planGUS is an important part in the Honeywell Total plant Solutionst Solutions offerings. It provides access to plant wide process network, plaofferings. It provides access to plant wide process network, plant ornt or organization wide intranet or even Internet.organization wide intranet or even Internet. The following hardware is available to enhance the fThe following hardware is available to enhance the functionality of theunctionality of the GUS:GUS: •• Integrated Keyboard for Operators as well as Engineer.Integrated Keyboard for Operators as well as Engineer. •• Matrix printer supported by Windows NT.Matrix printer supported by Windows NT. •• 8 * CD8 * CD--ROMROM •• 100MB ZIP Drive100MB ZIP Drive •• 3.53.5”” Floppy DriveFloppy Drive GUS has following functionality's :GUS has following functionality's : •• TheThe ““HumanHuman ”” interface allows effective interaction of the Operator throughinterface allows effective interaction of the Operator through the use of operating displaysthe use of operating displays •• Engineering functions such as data point building, display buildEngineering functions such as data point building, display building and reporting and report building are available.building are available. •• Communication with other LCN modules is accomplished.Communication with other LCN modules is accomplished. •• Communication on Ethernet.Communication on Ethernet.
  • 24. Honey well GUS Hardware:Honey well GUS Hardware: •• Processor : Pentium ProProcessor : Pentium Pro / 200MHZ/ 200MHZ •• Memory : 64MB RAM ECCMemory : 64MB RAM ECC •• Cache : 256KB ECCCache : 256KB ECC •• Storage : 2 GB hardStorage : 2 GB hard disk drive, CD ROM,disk drive, CD ROM, Cartridge DriveCartridge Drive •• Video : 21Video : 21”” high resolution screen 1280 * 1024high resolution screen 1280 * 1024 PixelsPixels •• Colours : 256 colorColours : 256 color palettepalette •• Keyboard : IntegratedKeyboard : Integrated keyboard with mousekeyboard with mouse •• PIN Connection : Built in EthernPIN Connection : Built in Ethernetet •• Cursor Control : QWERTY & MousCursor Control : QWERTY & Mouse/Touch Screene/Touch Screen Peripherals supportedPeripherals supported •• PrinterPrinter •• 8 * CD8 * CD--ROMROM •• 1/41/4”” Steamer TapeSteamer Tape •• 3.53.5”” Floppy DriveFloppy Drive •• 100 Mb ZIP Drive100 Mb ZIP Drive •• Annunciator relay on the consoleAnnunciator relay on the console--based keyboardbased keyboard
  • 25. Honeywell GUS softwareHoneywell GUS software •• Operating System : Windows NT versiOperating System : Windows NT version 4.0on 4.0 •• Base System : Provides reaBase System : Provides real time datal time data exchangeexchange between the network and all GUSbetween the network and all GUS functions.functions.
  • 26. History ModulesHistory Modules The History Modules is the bulk module that can be utilizeThe History Modules is the bulk module that can be utilized by all moduled by all module connectedconnected to the Local Control Network. It is as the name implies the masto the Local Control Network. It is as the name implies the mass memory of thes memory of the TPSTPS System. The memory components of this module are one 1.8 gigabySystem. The memory components of this module are one 1.8 gigabytete Winchester discs.Winchester discs. It is controlled by an M68040 microprocessor. This provides theIt is controlled by an M68040 microprocessor. This provides the module withmodule with significantsignificant computing power that this used to structure much of the incomincomputing power that this used to structure much of the incoming data andg data and format it intoformat it into a form for easy retrieval.a form for easy retrieval. The history in the model is provided by the History ModThe history in the model is provided by the History Module. Processule. Process variables arevariables are available for hourly, shift, daily and monthly average calculatavailable for hourly, shift, daily and monthly average calculation and recording.ion and recording. All system event history such as process alarms, systemAll system event history such as process alarms, system status changes,status changes, and errorand error messages are stored into the History Modules.messages are stored into the History Modules. Other modules have access to data in the History ModulesOther modules have access to data in the History Modules for theirfor their functions.functions. The History Module provides two functions, storage only and dataThe History Module provides two functions, storage only and data structuringstructuring
  • 27. HM functions and Historization parameterHM functions and Historization parameter HM functionsHM functions :: It can automatically backup the control databasesIt can automatically backup the control databases in the HG, AM, CG.in the HG, AM, CG. HM can store,HM can store, •• Continuous process history.Continuous process history. •• Event journal (history).Event journal (history). •• Active system files.Active system files. •• Static system files.Static system files. •• On process analysis program (maintenance aid)On process analysis program (maintenance aid) HM Historization parametersHM Historization parameters :: There can be up to 10 HMThere can be up to 10 HM’’s on the LCN. There can be maximum of 150s on the LCN. There can be maximum of 150 groups pergroups per HM. Each group can have up to 20 points. All points in the groHM. Each group can have up to 20 points. All points in the group must be in theup must be in the samesame unit.unit.
  • 28. Network Interface Module (NIM)Network Interface Module (NIM) The Network Interface Module (NIM) provides the link between tThe Network Interface Module (NIM) provides the link between the local Controlhe local Control Network and the Universal Control Network. As such it make theNetwork and the Universal Control Network. As such it make the transition fromtransition from thethe transmission technique and protocol or the Local Control Networtransmission technique and protocol or the Local Control Network to thek to the transmissiontransmission technique and the protocol of the Universal Control Network. Thtechnique and the protocol of the Universal Control Network. The NIM providese NIM provides accessaccess by LCN modules data from UCN resident devices. The NIM is availby LCN modules data from UCN resident devices. The NIM is available in theable in the redundantredundant configuration to provide continued operation in the event of thconfiguration to provide continued operation in the event of the primary failure. Ite primary failure. It cancan also do event processing.also do event processing. There can be up to 10 redundant NIM pairs per LCN. A NThere can be up to 10 redundant NIM pairs per LCN. A NIM can host uptoIM can host upto 8000 tag8000 tag names and supports a data transfer rate of 2400 parameters pernames and supports a data transfer rate of 2400 parameters per second.second.
  • 29. Communication SubsystemCommunication Subsystem Local Control Network (LCN)Local Control Network (LCN) The backbone of every TPS system is a comThe backbone of every TPS system is a communication network,munication network, known asknown as Local Control Network. The LCN is a LAN through which TDC 3000Local Control Network. The LCN is a LAN through which TDC 3000 modulesmodules communicate with each other. The LCN is a broadcast type of LAN.communicate with each other. The LCN is a broadcast type of LAN. It is high speedIt is high speed redundant communication bus that connect all the control room eredundant communication bus that connect all the control room equipment. Allquipment. All informationinformation is transferred on the network at 5 million bits per sec.,serialis transferred on the network at 5 million bits per sec.,serially. It is based on thely. It is based on the IEEE 802.4IEEE 802.4 Token passing and Bus Standard.Token passing and Bus Standard. Each LCN device that is connected to the LEach LCN device that is connected to the Local Control Network isocal Control Network is called acalled a module. Up to 64 modules may be connected to the Local Contromodule. Up to 64 modules may be connected to the Local Control Network in al Network in a TPSTPS system. The Local Control Network is designated as the primarysystem. The Local Control Network is designated as the primary and the other asand the other as the backthe back
  • 30. Universal Control Network (UCN)Universal Control Network (UCN) The Universal Control Network is a high sThe Universal Control Network is a high speed, high securitypeed, high security processprocess control network based on open system interconnection standards.control network based on open system interconnection standards. ItIt features a 5features a 5 megabit/second, carrier band, token bus network compatible withmegabit/second, carrier band, token bus network compatible with IEEE andIEEE and ISOISO standards. It is used as the real time redundant Communicationsstandards. It is used as the real time redundant Communications backbonebackbone forfor process connected devices such as the High Performance Processprocess connected devices such as the High Performance Process ManagerManager (HPM), Advanced Process Manager . The UCN supports peer(HPM), Advanced Process Manager . The UCN supports peer--toto--peerpeer communication for sharing data and allowing greater cocommunication for sharing data and allowing greater co--ordination ofordination of controlcontrol strategies among network devices. The UCN uses redundant costrategies among network devices. The UCN uses redundant co--axial cablesaxial cables and canand can support up to 32 redundant devicessupport up to 32 redundant devices UCN supports 2 types of devicesUCN supports 2 types of devices Communication SubsystemCommunication Subsystem
  • 31. High Performance Process ManagerHigh Performance Process Manager (HPM)(HPM) The High Performance Process Manager is the latest in the ProgreThe High Performance Process Manager is the latest in the Progression ofssion of HighHigh Performance control products offered by Honeywell for the applicPerformance control products offered by Honeywell for the application toation to Improve controlling of existing and new industrial processes. HiImprove controlling of existing and new industrial processes. Highgh PerformancePerformance Process Manager is a fully integrated member of the TPS family.Process Manager is a fully integrated member of the TPS family. It isIt is capablecapable of :of : •• performing data acquisition and control functionsperforming data acquisition and control functions •• fully communicating with operators and engineers at the GUSs andfully communicating with operators and engineers at the GUSs and universal Work stations.universal Work stations. •• Supporting higherSupporting higher--level strategies available on the Local Controllevel strategies available on the Local Control Network through the Application Module and Host Computers.Network through the Application Module and Host Computers.
  • 32. The High Performance Process Manager uses a powerful multiThe High Performance Process Manager uses a powerful multi--processorprocessor architecturearchitecture with separate microprocessors dedicated to perform specific taswith separate microprocessors dedicated to perform specific tasks. The HPMks. The HPM consistsconsists of two modules Communication and Control Module (CCM) and the Iof two modules Communication and Control Module (CCM) and the I/O/O subsystemsubsystem the I/O subsystem consist of up to 40 Smart I/O Modules (SIOM)the I/O subsystem consist of up to 40 Smart I/O Modules (SIOM). All control. All control operation are performed within the communication and control modoperation are performed within the communication and control module. Theule. The processprocess engineer has complete flexibility of choice within the maximum Hengineer has complete flexibility of choice within the maximum HPM designPM design limits.limits. These selections are implemented using the interactive tools prThese selections are implemented using the interactive tools provided byovided by both theboth the GUS and Universal Work Station. The I/O processors, for exampleGUS and Universal Work Station. The I/O processors, for example, provide, provide suchsuch functions as engineering unit conversion and alarm limit checkifunctions as engineering unit conversion and alarm limit checkingng independent of theindependent of the communication and control modules.communication and control modules. High Performance Process Manager Overview
  • 33. YOKOGAWA CENTUM EXCEL ARCHITECTUREYOKOGAWA CENTUM EXCEL ARCHITECTURE EOPS /1 EOPS /2 ENGG. STATION EFGWEFMSEFCD Closed loop control signal Through I/O NEST HF BUS : High frequency Bus: no. of station on HF Bus are 32 EOPS : Extended Operator station: Hard disk capacity of EOPS is 80 MB EFCD : Extended field control station : 80 laps per controller EFMS : Extended field mauture station Max 255 inputs EFGN : Extended field gateway unit ENGS : Engineering station NIO : Nest I/O bus. Monitoring signals Through I/O NEST Third party system with PLC, Gas Analyser etc. thr RS 232C port At the rate of 9600 bps HF BUS (1 Mbps) A B I/O #1 ncst I/O #2 ncst I/O #3 I/O #4 I/O #5 ncst A B NIO Bus Micro-XL
  • 34. HIS HIS PRTPRT HIS Windows NT Based Centum CS Configuration NIU NIU Ethernet Connectivity (optional) Inkjet Printer DM Printer FCS RIO BUS OPERATOR/ENGINEERING STATION OPERATOR STATION SUB-SYSTEM INTERPLANT NETWORK PC (OPTIONAL) DUAL “V NET” 10 Mbps HIS – Human Interface Station. FCS – Field Control Station. NIU – Node Interface Unit. RIO Bus – Remote I/O Bus.
  • 35. Centum CS 3000 System OverviewCentum CS 3000 System Overview Centum CS 3000 is an integrated production control systemCentum CS 3000 is an integrated production control system for mediumfor medium and large controland large control applications. This system is a synthesis of the latest technoloapplications. This system is a synthesis of the latest technology withgy with YokogawaYokogawa’’s experiences experience and specialist knowand specialist know--how.how. Centum CS 3000 system featuresCentum CS 3000 system features :: •• Synthesis of DCS with Personal computers.Synthesis of DCS with Personal computers. •• Online Documentation.Online Documentation. •• Powerful Operation and Monitoring Functions.Powerful Operation and Monitoring Functions. •• Two Types of Control Station.Two Types of Control Station. •• Compact I/O Modules.Compact I/O Modules. •• Powerful Control and Communication Functions.Powerful Control and Communication Functions. •• Efficient Engineering.Efficient Engineering. •• Virtual Test functions donVirtual Test functions don’’t require Control Station hardware.t require Control Station hardware. •• FullFull--Featured Batch Package.Featured Batch Package. •• CENTUM CS microCENTUM CS micro--XL Integration ( to be released ).XL Integration ( to be released ).
  • 36. 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 ).
  • 37. HIS HIS PRTPRT HIS CS3000 – System Configuration NIU NIU Ethernet Connectivity (optional) Inkjet Printer DM Printer FCS RIO BUS OPERATOR/ENGINEERING STATION OPERATOR STATION SUB-SYSTEM INTERPLANT NETWORK PC (OPTIONAL) V NET 10 Mbps HIS – Human Interface Station. FCS – Field Control Station. NIU – Node Interface Unit. RIO Bus – Remote I/O Bus. CGW – Communication gateway unit BCV – Bus Converter Remote Domain System CS, CS 1000 Centum – XL, -V, -MXL CGW BCV
  • 38. CENTUM CS 3000 NETWORKCENTUM CS 3000 NETWORK FCS FCS FCS HIS HIS HIS V net
  • 39. CENTUM CS3000 SYSTEM SPECIFICATIONCENTUM CS3000 SYSTEM SPECIFICATION •• NO. OF TAGS MONITOREDNO. OF TAGS MONITORED 1,00,0001,00,000 •• TOTAL NO. OF STATIONTOTAL NO. OF STATION 256256 •• NO. OF DOMAINSNO. OF DOMAINS 1616 •• NO. OF STATIONS IN A DOMAINNO. OF STATIONS IN A DOMAIN 6464 •• NO. OF HIS / DOMAINNO. OF HIS / DOMAIN 16 NOS16 NOS
  • 40. CENTUM CS3000 SYSTEM SPECIFICATIONCENTUM CS3000 SYSTEM SPECIFICATION •• Max. no. of stations : 256 /Max. no. of stations : 256 / systemsystem •• Max. no. of DomainsMax. no. of Domains : 16 / system: 16 / system •• Numbering of DomainsNumbering of Domains :: 1 to 641 to 64 •• Domain No. CS3000 DomainDomain No. CS3000 Domain (V net Domain)(V net Domain) : 1 to 16: 1 to 16 •• Max. no. of stations/Domain : 64Max. no. of stations/Domain : 64 •• Domain No.Virtual DomainDomain No.Virtual Domain (Non V net Domain)(Non V net Domain) :: 17 to 6417 to 64 •• Station NO. HIS : 1 tStation NO. HIS : 1 to 64 in descendingo 64 in descending orderorder •• Station NO. FCSStation NO. FCS : 1 to 64 in ascending order: 1 to 64 in ascending order •• Max. No. of ICS / DomainMax. No. of ICS / Domain : 16: 16 •• Max. No. of NIU / FCS : 8Max. No. of NIU / FCS : 8 •• Max. No. of IOU / FCS : 40Max. No. of IOU / FCS : 40 ( Max. 5/ IOU)( Max. 5/ IOU) •• Max. length of VnetMax. length of Vnet : 20 Km: 20 Km •• Max. length of RIO bus : 20 KmMax. length of RIO bus : 20 Km (750m ~(750m ~ 20Km)20Km)
  • 41. Centum CSCentum CS--3000 Communication3000 Communication V netV net V net is 10 mbps real time control bus which links stationV net is 10 mbps real time control bus which links station such as FCS , HIS , BCVsuch as FCS , HIS , BCV andand CGW. It can be dual redundant. It can be up to 500m using coaxiCGW. It can be dual redundant. It can be up to 500m using coaxial cable alone, oral cable alone, or up to 20up to 20 Km when repeater are used or optical fiber is used.Km when repeater are used or optical fiber is used. •• 10BASE2 cable10BASE2 cable used by HIS, maximum segment length = 185 mused by HIS, maximum segment length = 185 m •• 10BASE5 cable10BASE5 cable used by stations other than HIS(FCS,CGW etc.) maximum segused by stations other than HIS(FCS,CGW etc.) maximum segment length = 500ment length = 500 mm
  • 42. V net CommunicationV net Communication FCS FCS HIS V net HIS Protocol : IEEE802.4 Access Control : Token Passing Trans. Speed : 10 Mbps Trans. Distance: 500m to 20Km Media : Coaxial/optical fiber
  • 43. V net specificationV net specification Token passingToken passingProto typeProto type DualDual--redundantredundantRedundancyRedundancy 500M500M ––20Km Max20Km MaxTransmission DistanceTransmission Distance 10 Mbps10 MbpsCommunication rateCommunication rate Bus type or MultiBus type or Multi--drop typedrop typeTypeType Coaxial or fiber opticalCoaxial or fiber optical cablecable Transmission routeTransmission route SPECIFICATIONSPECIFICATIONITEMITEM
  • 44. VV-- net Featuresnet Features •• Real time control bus. ( Dual redundant possible )Real time control bus. ( Dual redundant possible ) •• Cable : 50 ohm coax. cable with BNC connector ( 10Base2Cable : 50 ohm coax. cable with BNC connector ( 10Base2 comp. )comp. ) •• Communication speed : 10 Mbps.Communication speed : 10 Mbps. •• High reliable token passing communicationHigh reliable token passing communication ( performance guaranteed )( performance guaranteed ) •• Std. max. length : 185 m.Std. max. length : 185 m. •• Max. length : 20 Km ( with optical fiber )Max. length : 20 Km ( with optical fiber ) 1.6 Km ( with coax. Repeater )1.6 Km ( with coax. Repeater ) BNC Connector VL net I/F card ( PCI ) VL net cable
  • 45. EthernetEthernet HIS and ENG, HIS and supervisory systems can beHIS and ENG, HIS and supervisory systems can be connected by anconnected by an Ethernet LAN; supervisory computers and personalEthernet LAN; supervisory computers and personal computers on the Ethernetcomputers on the Ethernet LAN can access messages and trend data in the CS 3000LAN can access messages and trend data in the CS 3000 system. The Ethernetsystem. The Ethernet can also be used for sending trend data files from the HIScan also be used for sending trend data files from the HIS to supervisoryto supervisory computers, or for equalizing the data in the two HIS stationcomputers, or for equalizing the data in the two HIS station ( rather than using( rather than using the V net control bus to do this ). A system with only onethe V net control bus to do this ). A system with only one HIS with engineeringHIS with engineering functions installed, does not need Ethernetfunctions installed, does not need Ethernet –– but in generalbut in general Ethernet ( andEthernet ( and corresponding network engineering ) is required.corresponding network engineering ) is required.
  • 46. Ethernet SpecificationEthernet Specification CSMA/CD TypeCSMA/CD TypeProto typeProto type Not availableNot availableRedundancyRedundancy 500m500m –– 2.5 Km max.2.5 Km max.Transmission DistanceTransmission Distance 10 Mbps10 MbpsCommunication RateCommunication Rate Bus type or MultiBus type or Multi––drop typedrop typeTypeType Coaxial or Fiber optical cableCoaxial or Fiber optical cableTransmission RouteTransmission Route SPECIFICATIONSPECIFICATIONITEMITEM
  • 47. TYPES OF HISTYPES OF HIS •• Console type HISConsole type HIS •• Desk top type HISDesk top type HIS •• PHIS Yokogawa brand OPSPHIS Yokogawa brand OPS
  • 48. HIS HardwareHIS Hardware •• CPUCPU Pentium 166Pentium 166 •• Main memoryMain memory 96MB or larger(for op &96MB or larger(for op & monitoring only)monitoring only) •• Hard diskHard disk 1 GB or larger1 GB or larger •• DisplayDisplay 256Colors min. resolution 800*600256Colors min. resolution 800*600 1024*768 recommend(1280*1024 best)1024*768 recommend(1280*1024 best) •• Serial portSerial port RS232C*1 or more (for operationRS232C*1 or more (for operation keyboard)keyboard) •• Parallel portParallel port 1 port for printer or more1 port for printer or more •• OSOS Windows NT 4.0 WorkstationWindows NT 4.0 Workstation •• Operator stationsOperator stations Max. 8 stationsMax. 8 stations
  • 49. Field Control Station ConfigurationField Control Station Configuration HIS Sub system Sub system I/O Unit I/O Unit HIS HIS V net Ethernet Node Interface Unit RIO Bus Node Compact FCS Standard FCS
  • 50. Connection to Centum CS 3000 SystemConnection to Centum CS 3000 System FCS FCS Exapilot communication data Process data read/write V-net HIS ENG Exaopc Exapilot client (engineering, operation) Exapilot server (engineering, operation) Exapilot client (engineering, operation) Ethernet
  • 51. Features ofFeatures of ExapilotExapilot •• Standardize and Automate Manual ProceduresStandardize and Automate Manual Procedures •• Improve Plant Operating EfficiencyImprove Plant Operating Efficiency •• Improve safety of Plant OperationImprove safety of Plant Operation Features of Event Analysis PackageFeatures of Event Analysis Package •• Analysis DCS Event History to Help You Enhance Efficiency.Analysis DCS Event History to Help You Enhance Efficiency. •• Enhance Process Stability: Balance Process Events and Operator AEnhance Process Stability: Balance Process Events and Operator Actions.ctions. •• When, Where, What (3W) Filters Help You Narrow Focus of AnalysisWhen, Where, What (3W) Filters Help You Narrow Focus of Analysis..
  • 52. OPEN DCS SYSTEMOPEN DCS SYSTEM Safety Barrier Pressure TX. Control Valve Terminator H M I Ethernet Field Bus Power Supply Flow Trans.
  • 53. Field busField bus It is a standardized digital communication protocol between a pIt is a standardized digital communication protocol between a processrocess Control field devicesControl field devices and the Control room. It is a simple pair of wires to power andand the Control room. It is a simple pair of wires to power and carry thecarry the communicationcommunication signal between the field devices and the Control room.signal between the field devices and the Control room. FEATURESFEATURES :: •• Drastic reduction in cable, conduits cable trays, marshallive raDrastic reduction in cable, conduits cable trays, marshallive racks, andcks, and connectors etc.connectors etc. •• Drastic reduction in installation cost.Drastic reduction in installation cost. •• Fewer non field devices.Fewer non field devices. •• More reliability due to the smaller number of devices.More reliability due to the smaller number of devices. •• More efficient operation due to better accuracy (no A/D and D/AMore efficient operation due to better accuracy (no A/D and D/A conversion).conversion). •• Easy integration into plant management system.Easy integration into plant management system. •• Flexibility for different suppliers are interoperable and intercFlexibility for different suppliers are interoperable and interchangeable.hangeable. •• Major reduction in maintenance cost.Major reduction in maintenance cost.
  • 54. FieldField--bus Benefitsbus Benefits Wiring Screw Terms Wire (pair) I/O Cards IS Barriers Traditional Field bus 3500’ 168 2 2 640’ 64 1 1 Savings Savings % Savings $ 2860’ 104 1 1 82% 63% 50% 50% $ 3000 Material $ 2000 Labor $ 5000 Total Typically comments from a plant personal : •Easy to identify what’s out there. •Consistent calibration procedure. •Two days versus four days to commission system. •Familiar with twisted pair wiring – comfortable.
  • 57. FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary H1 and H2H1 and H2 •• H1 SegmentH1 Segment –– Moderate speedModerate speed –– Use existing wiringUse existing wiring –– Bus poweredBus powered –– Can be intrinsicallyCan be intrinsically safesafe –– Low power 2 wireLow power 2 wire devicesdevices –– 4 wire devices4 wire devices –– Replace analog &Replace analog & proprietary digitalproprietary digital •• H2 SegmentH2 Segment –– High speedHigh speed –– Link multiple H1Link multiple H1 SegmentsSegments –– I/O subsystem busI/O subsystem bus –– ReplaceReplace proprietaryproprietary networksnetworks –– New wiringNew wiring
  • 58. FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary New Approach for H2New Approach for H2 •• 100 Meg Ethernet technology with extensions100 Meg Ethernet technology with extensions –– Improve time to marketImprove time to market –– High speedHigh speed –– Mandatory redundancyMandatory redundancy –– Widely available technology and siliconWidely available technology and silicon –– Widely available toolsWidely available tools –– Limited incremental developmentLimited incremental development –– Many suppliersMany suppliers –– High volume for low costHigh volume for low cost –– Works with installed equipmentWorks with installed equipment –– Evergreen technologyEvergreen technology •• Better than ANY other solution!Better than ANY other solution!
  • 59. H2 Segment 100 Meg Ethernet PLC H1/H2 Bridge Control Module H1/H2 Bridge Replaces Traditional I/O H1/H2 Bridge Replaces Traditional I/O Server H1 Segment H1 Segment H1 Segment FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary H1/H2 BridgesH1/H2 Bridges
  • 60. FOUNDATIONFOUNDATION™™ fieldbus Standardsfieldbus Standards OrganizationsOrganizations •• IECIEC –– International ElectroInternational Electro--technical Commissiontechnical Commission •• ISAISA –– International Society for Measurement and ControlInternational Society for Measurement and Control (formerly: Instrument Society of America)(formerly: Instrument Society of America) •• SP50SP50 •• CENELECCENELEC –– European standards bodyEuropean standards body •• Parallel (competitive?) Working Groups to IECParallel (competitive?) Working Groups to IEC
  • 61. FewerTerminationsFewerTerminations Fewer IS barriersFewer IS barriers Marshaling Junction Box IS (Ex i) Barriers H1 I/O Terminations H1 Fieldbus all-digital H1 Fieldbus all-digital H1 I/O Interface Controller Similar I/O CardsSimilar I/O Cards Cost savings: • wiring • I/O cards & cables • terminations • IS barriers • marshaling Cost savings: • wiring • I/O cards & cables • terminations • IS barriers • marshaling Fewer TerminationsFewer Terminations Reduced WiringReduced Wiring FOUNDATIONFOUNDATION™™ fieldbus Topographyfieldbus Topography H1 Fieldbus InstallationsH1 Fieldbus Installations
  • 62. Barriers FOUNDATIONFOUNDATION™™ fieldbus Topographyfieldbus Topography Intrinsic SafetyIntrinsic Safety
  • 63. DeltaV System ArchitectureDeltaV System Architecture PrinterPrinter 8 port Hub primary 8 port Hub Redundant Serial P S D I D O D I A O A I A I Contr. Contr. P S Blank Blank H I Blank Blank Blank D O Blank PLC For 8 DI & 8 DO H1 Connector 1 Operator stationEngineering station 8 wide carrier for I/O subsystem 2 wide carrier for Power/Controller Power supply Controller Fieldbus Transmitter 3244MVF1NAB4 Pressure Transmitter 3051TG2A2B21AB4M5FF Smart valve positioner FSDVC0400-201 I/O extension cable RS232 Modbus Fieldbus Power
  • 64. DCS communication system HierarchyDCS communication system Hierarchy MIS SCHED. SUP. DDC SUP. DDC DDC DDC S A A A A AS S S S S S PLANT Level 5 Management Low data rates Superior responsibility Level 1 Sensors (S) & Actuators (A) High data rates Low responsibility Level 2 Direct digital Control (DDC) Level 3 Supervisory control Level 4 Scheduling High Low
  • 65. History of Process Control SignalHistory of Process Control Signal Around 50 years ago, most plant used 3Around 50 years ago, most plant used 3--15psi pneumatic signal to control their15psi pneumatic signal to control their process.process. The last change change in signal standard was the open protocolThe last change change in signal standard was the open protocol HART digitalHART digital communicationscommunications format. The HART protocol provides simultaneous digital communiformat. The HART protocol provides simultaneous digital communications with the 4cations with the 4--2020 mAmA output.output. The next protocol change will be fieldbus. FieldThe next protocol change will be fieldbus. Fieldbus is entirely digitalbus is entirely digital--there isthere is no analogno analog Signal. Fieldbus also allows migration of control functions to fSignal. Fieldbus also allows migration of control functions to field devices.ield devices. Process control TimelineProcess control Timeline –– The Evolution of Signal StandardThe Evolution of Signal Standard Signal standards have evolved over the years, starting with theSignal standards have evolved over the years, starting with the 33--15 psi15 psi standard.standard. There are also other communication methods, but they have not gThere are also other communication methods, but they have not gained widespreadained widespread acceptance.acceptance. With many standard there is typically a slow transition period aWith many standard there is typically a slow transition period as plants plant engineers andengineers and managers test period does gain widespread acceptance. However,managers test period does gain widespread acceptance. However, once the benefits ofonce the benefits of thethe Fieldbus become tested and proven, more plant will install FielFieldbus become tested and proven, more plant will install Fieldbus because of itsdbus because of its Digital plus Analog: HART with 4-20mA Digital: Fieldbus Analog: 4-20mA Pneumatic: 3-15 psi 1940 1950 1960 1970 1980 1990 2000 2010
  • 66. I/O Bus Network ProtocolI/O Bus Network Protocol I/O Bus Network Discrete Byte-wide Data Bit-wide data Several Hundred Data Bytes Analog Device bus network Process bus network
  • 67. Protocol StandardProtocol Standard Device bus network Process bus network Field Bus Foundation (Field Bus std.) Profibus Trade Organization (Profibus std.) Byte-Wide Data Bit-Wide Data CAN Bus Inter Bus-S Device net SDS Seriplex Inter Bus Loop ASI
  • 68. Fieldbus ArchitectureFieldbus Architecture Fieldbus is more than just a new signal communications protocol,Fieldbus is more than just a new signal communications protocol, but a whole new waybut a whole new way toto control the process. With the release of the low fieldbus (H1),control the process. With the release of the low fieldbus (H1), the entire fieldbus willthe entire fieldbus will bebe defined. Most of the recent published literature has focused ondefined. Most of the recent published literature has focused on the intricate details ofthe intricate details of thethe fieldbus architecture, especially those layers that have not befieldbus architecture, especially those layers that have not been released. However,en released. However, exceptexcept physical layer and the user layer, these layer are transparentphysical layer and the user layer, these layer are transparent to the engineers and theto the engineers and the manager.manager. Physical Layer Data Layer Application Layer User Layer Systemmanagement NetworkManagement Maintenance information system Workstation stack PumpLevel Transmitter ValveMultivariable Transmitter
  • 69. Open System Interconnected ReferenceOpen System Interconnected Reference ModelModel Application Presentation Session Transport Network Data link Physical MBAP, SMB, FTP, SMTP, FMS, IEC 61158, ANSI/ISA S50.2,IEEE 1451 TCP, SPX, UDP IP, IPX, NetBeui HDLC, ETHERNET, ANSI/ISA S50.02 EIA-485, ETHERNET,ANSI/ISA S50.02 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. 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.
  • 70. Field BusField Bus Field Bus is a biField Bus is a bi--directional digital communication that interconnects smart fielddirectional digital communication that interconnects smart field devices todevices to control system or to instrument located in the control room.control system or to instrument located in the control room. Field Bus is based on the OSI (Open System Interconnect), whichField Bus is based on the OSI (Open System Interconnect), which was developed bywas developed by the ISOthe ISO (International Standard Organization) to represent the various f(International Standard Organization) to represent the various functions required inunctions required in anyany Communication network.Communication network. Connects theConnects the equipmentequipment PhysicalPhysical11 Establishes the dataEstablishes the data link connectionlink connection LinkLink22 Establishes networkEstablishes network connectionsconnections NetworkNetwork33 Secures the transportSecures the transport connectionconnection TransportTransport44 Handles the dialogueHandles the dialogueSessionSession55 Converts dataConverts dataPresentationPresentation66 Provides formattedProvides formatted datadata ApplicationApplication77 FunctionFunctionLayerLayer
  • 71. Field BusField Bus The OSI model consists of seven layers. However for real time aThe OSI model consists of seven layers. However for real time applicationpplication layers 3 to 6 arelayers 3 to 6 are not considered since they deal with transference of data amongnot considered since they deal with transference of data among networks.networks. For suchFor such application following layers are used:application following layers are used: •• LAYER 1LAYER 1 -- PHYSICAL LAYERPHYSICAL LAYER Defines the type of signal, transmitting medium, data tranDefines the type of signal, transmitting medium, data transmissionsmission speed, etc.speed, etc. •• LAYER 2LAYER 2 –– DATALINK LAYERDATALINK LAYER Define the interface between the physical layer and the applicatDefine the interface between the physical layer and the application layer.ion layer. It establishesIt establishes how the messages shall be structured and normalizes the ushow the messages shall be structured and normalizes the use ofe of multiple masters.multiple masters. •• LAYER 3LAYER 3 –– APPLICATION LAYERAPPLICATION LAYER Defines how data is specified, its addresses and its representatDefines how data is specified, its addresses and its representation.ion.The Fieldbus was invented by an Indian engineer Mr. Ram Ramchandran ( M.S in Comp. Tech , Texas)
  • 72. PHYSICAL LAYERPHYSICAL LAYER The Physical layer defines the medium that transport the messageThe Physical layer defines the medium that transport the messages frames, the signals frames, the signal shape andshape and amplitude limits, data transfer rate, and power distribution.amplitude limits, data transfer rate, and power distribution. Technical Characteristics:Technical Characteristics: Physical MediumPhysical Medium Three types are defined: wires, optic fiber, and radio signals.Three types are defined: wires, optic fiber, and radio signals. TheThe specification forspecification for wire has been already approved.wire has been already approved. Bit rate for wire mediaBit rate for wire media 31.25 Kbps (H1)31.25 Kbps (H1) 1 megabits and 2.5 megabits (H2).1 megabits and 2.5 megabits (H2). H1 and H2 are classification of the two hanks of Field Bus targeH1 and H2 are classification of the two hanks of Field Bus target applications.t applications. H1 hasH1 has low speed and utilizes existing wires. H2 has high speed and maylow speed and utilizes existing wires. H2 has high speed and may requirerequire independentindependent wires to power up field devices.wires to power up field devices. Number of devices per link (31.25Kbps)Number of devices per link (31.25Kbps) 2 to 32 devices, without power and no IS (intrinsic safety).2 to 32 devices, without power and no IS (intrinsic safety). 2 to 6 with power and IS.2 to 6 with power and IS. Maximum distanceMaximum distance Up to 1900 meters for 31.25Kbps, without repeaters. Up to 750 meUp to 1900 meters for 31.25Kbps, without repeaters. Up to 750 meters for 1ters for 1 megabits. Up to 500 meter for 2.5 megabits.
  • 73. PHYSICAL LAYERPHYSICAL LAYER Signal ModulationSignal Modulation Manchester bi phase L synchronous.Manchester bi phase L synchronous. Physical layer preamblePhysical layer preamble on transmissions, the physical layer will add to the data sent bon transmissions, the physical layer will add to the data sent by the layery the layer above aabove a preamble and one start delimiter in the beginning of the frame apreamble and one start delimiter in the beginning of the frame and one endnd one end delimiterdelimiter at the end delimiter at the end of the of the frame.at the end delimiter at the end of the of the frame.
  • 74. DATA LINK LAYERDATA LINK LAYER The Data Link Layer will assure the integrity of the message byThe Data Link Layer will assure the integrity of the message by using the frame checkusing the frame check sequence:sequence: Two bytes added to the frames and a polynomial calculation of alTwo bytes added to the frames and a polynomial calculation of all frame data.l frame data. The Data Link Layer also checks to see that the data reaches theThe Data Link Layer also checks to see that the data reaches the devices correctly.devices correctly. Technical characteristicsTechnical characteristics Medium Access:Medium Access: There are three forms to access the network:There are three forms to access the network: •• Token passing:Token passing: Token is the right to initiate a transaction on the bus. A devicToken is the right to initiate a transaction on the bus. A device must have thee must have the token totoken to initiate a conversation. As soon it finishes it will return theinitiate a conversation. As soon it finishes it will return the token to the LAStoken to the LAS (Link(Link Active Scheduler). The LAS send the token to the unit that requeActive Scheduler). The LAS send the token to the unit that requested in eithersted in either in ain a prepre--configured way or via scheduling.configured way or via scheduling. •• Immediate response:Immediate response: A master station will give an opportunity to the station to replA master station will give an opportunity to the station to reply with one frame.y with one frame. •• Requested token:Requested token: a device request a token by using a code in any of the responsea device request a token by using a code in any of the response sent to thesent to the bus. Thebus. The
  • 75. APPLICATION LAYER AND MANAGEMENTAPPLICATION LAYER AND MANAGEMENT The Application Layer provides a simple interface to the end useThe Application Layer provides a simple interface to the end userr’’s application.s application. Basically , itBasically , it defines how to read, write , interpret and execute a message odefines how to read, write , interpret and execute a message or command. Ar command. A big part of this jobbig part of this job is to define the message syntax. The contents include the requeis to define the message syntax. The contents include the requested message,sted message, action taken, andaction taken, and the response message.the response message. The management defines how to initialize the network : tag assiThe management defines how to initialize the network : tag assignment,gnment, address assignment,address assignment, clock assignment, clock synchronization, distributed applicatioclock assignment, clock synchronization, distributed application schedulingn scheduling across the networkacross the network or association of the input and output parameters of the functior association of the input and output parameters of the function blocks. Iton blocks. It also controls thealso controls the operation of the network with statistic of faults and detectionoperation of the network with statistic of faults and detection of the addition ofof the addition of the new elementthe new element or the absence of a station. The system always look for the newor the absence of a station. The system always look for the new stations onstations on the bus by pollingthe bus by polling the possible station addresses.the possible station addresses.
  • 76. Digital Communication ProtocolDigital Communication Protocol ISOISO -- International Standard Organization. Responsible for developingInternational Standard Organization. Responsible for developing thethe model that the communication specimodel that the communication specification are based upon asfication are based upon as well aswell as standards for each layer of communstandards for each layer of communication specification.ication specification. IEEEIEEE -- Institute of Electrical and Electronics Engineers. Formed the IInstitute of Electrical and Electronics Engineers. Formed the IEEEEEE 802802 project for defining standards forproject for defining standards for network media and accessnetwork media and access methods.methods. SP72SP72 -- Institute Society of America, Standards and Practice committeeInstitute Society of America, Standards and Practice committee Number 72Number 72 Developing EIA1393 companion standDeveloping EIA1393 companion standard for process controlard for process control messaging.messaging. SP50SP50 -- Institute Society of America, Standards and Practice committeeInstitute Society of America, Standards and Practice committee Number 50Number 50 Developing standards for digital cDeveloping standards for digital communication between fieldommunication between field devices.devices. F.I.PF.I.P -- Factory Information Protocol, approved French National StandardFactory Information Protocol, approved French National Standard.. ProfibusProfibus -- Process Fieldbus, approved German National Standard.Process Fieldbus, approved German National Standard.
  • 77. HART COMMUNICATION PROTOCOLHART COMMUNICATION PROTOCOL Why HART protocolWhy HART protocol ?? 44--20 ma is tried, tested and widely used standard but only limited20 ma is tried, tested and widely used standard but only limited amount ofamount of informationinformation is sent by a 4is sent by a 4--20 ma signal.20 ma signal. HART (Hiway Addressable Remote Transducer) protocol enhances tHART (Hiway Addressable Remote Transducer) protocol enhances thesehese operations byoperations by transmitting digital data along with the 4transmitting digital data along with the 4--20 ma signal20 ma signal –– without interfering withwithout interfering with it !it ! HART permits twoHART permits two--way communications. It also has all digital mode that allowsway communications. It also has all digital mode that allows instrument to be connected to a single cable, cutting installinstrument to be connected to a single cable, cutting installation costsation costs dramatically.dramatically. Features :Features : 1.1. Field proven concept that is easy to understand and use.Field proven concept that is easy to understand and use. 2.2. Compatible with existing 4Compatible with existing 4--20 ma systems.20 ma systems. 3.3. Simultaneous pointSimultaneous point--toto--point 4point 4--20 ma and digital communication.20 ma and digital communication. 4.4. Alternative multiAlternative multi--drop mode.drop mode. 5.5. Measured variables, tag no. , range and span settings, deviceMeasured variables, tag no. , range and span settings, device information, diagnostics and simple messages transmitted.information, diagnostics and simple messages transmitted. 6.6. Digital response time of 500 msec; burst mode response of 300 msDigital response time of 500 msec; burst mode response of 300 msec.ec. 7.7. Open architecture; freely available to any vendor and every userOpen architecture; freely available to any vendor and every user..
  • 78. Method of Operation :Method of Operation : The Hart protocol operates using the FSK principal. The digitaThe Hart protocol operates using the FSK principal. The digital data isl data is made up from twomade up from two frequenciesfrequencies ––1200 Hz and 2200 Hz representing bits 1 and 01200 Hz and 2200 Hz representing bits 1 and 0 respectively. Sinusoidalrespectively. Sinusoidal waves of these frequencies are superimposed on the DC analogwaves of these frequencies are superimposed on the DC analog signalsignal cables to givecables to give simultaneous analog and digital communicationssimultaneous analog and digital communications HART Protocol Structure :HART Protocol Structure : HART follows the basic Open Systems Interconnection (OSI) refeHART follows the basic Open Systems Interconnection (OSI) referencerence model, developedmodel, developed by the International Organization for Standard (ISO). The HARby the International Organization for Standard (ISO). The HART protocolT protocol uses a reduceduses a reduced OSI model, implementing only layers 1,2 and 7OSI model, implementing only layers 1,2 and 7 HART COMMUNICATION PROTOCOL
  • 79. OSI reference modelOSI reference model Open Systems InterconnectionsOpen Systems Interconnections HART COMMUNICATION PROTOCOL Bell 202Bell 202Connects theConnects thePhysicalPhysical11 HART protocolHART protocol regulationsregulations Establishes theEstablishes the data linkdata link connectionconnection LinkLink22 EstablishesEstablishes networknetwork connectionsconnections NetworkNetwork33 Secures theSecures the transporttransport connectionconnection TransportTransport44 Handles theHandles the dialoguedialogue SessionSession55 Converts dataConverts dataPresentationPresentation66 HART instructionsHART instructionsProvides formattedProvides formatted datadata ApplicationApplication77 HARTHARTFUNCTIONSFUNCTIONSLAYERLAYER
  • 80. Layer 1, the physical layer, operates on the FSK principleLayer 1, the physical layer, operates on the FSK principle Data transfer rate: 1200 bit/sData transfer rate: 1200 bit/s LogicLogic ““00”” frequency: 2200 Hzfrequency: 2200 Hz LogicLogic ““11”” frequency: 1200 Hzfrequency: 1200 Hz the vast majority of existing wiring is used for this type ofthe vast majority of existing wiring is used for this type of digital communication.digital communication. Layer 2, the link layer establishes the format for a hart messaLayer 2, the link layer establishes the format for a hart message. HART is age. HART is a master/slavemaster/slave protocol.protocol. the structure of these messages is given below:the structure of these messages is given below: SDSD –– start character. ADstart character. AD –– display terminal and fielddisplay terminal and field addresses.addresses. CDCD –– HART instruction. BCHART instruction. BC –– Byte count.Byte count. StatusStatus –– Field device and communication status (only from field device tField device and communication status (only from field device too master)master) The individual characters are : 1 start bit, 8 data bits, 1The individual characters are : 1 start bit, 8 data bits, 1 bit for odd parity and 1bit for odd parity and 1 HART PROTOCOL LAYERS ParityParityDatDat aa StatuStatu ss BCBCCDCDADADSDSDPreamblPreambl ee
  • 81. Layer 7, the application layer, brings the HART instruction inLayer 7, the application layer, brings the HART instruction into play. The masterto play. The master sendssends messages with requests for specified values, actual values anmessages with requests for specified values, actual values and any other data ord any other data or parametersparameters available from the device. The field device interprets theseavailable from the device. The field device interprets these instruction as definedinstruction as defined in thein the HART protocol. The response message provides the master with tHART protocol. The response message provides the master with the statushe status informationinformation and data from the slave.and data from the slave. For slave devices, logical uniform communication is provided bFor slave devices, logical uniform communication is provided by the followingy the following commandcommand sets:sets: Universal commandsUniversal commands –– understood by all field devices.understood by all field devices. Common practice commandsCommon practice commands –– provide functions which can be carried out byprovide functions which can be carried out by many,many, though not all, field devices.though not all, field devices. DriveDrive--specific commandsspecific commands –– provide functions which are restricted to anprovide functions which are restricted to an individualindividual HART PROTOCOL LAYERS
  • 82. DATA TRANSMISSIONDATA TRANSMISSION Types of data transmission : Frequency shiftTypes of data transmission : Frequency shift keying (FSK)keying (FSK) Transfer rate : 1200 bTransfer rate : 1200 bit/s.it/s. ‘‘00’’ bit information frequency : 2200 Hzbit information frequency : 2200 Hz ‘‘11’’ bit information frequency : 1200 Hzbit information frequency : 1200 Hz Signal structure : 1 startSignal structure : 1 start bit, 8 data bits, 1 bit forbit, 8 data bits, 1 bit for odd parity, 1 stop bit.odd parity, 1 stop bit. Transfer rate for simple variables : Approximately 2/sTransfer rate for simple variables : Approximately 2/s (poll/response)(poll/response) DATA INTEGRITYDATA INTEGRITY Physical layer : Error rate destination circuit : 1Physical layer : Error rate destination circuit : 1/(10^5)/(10^5) Link layer : Recognizes : all groups up to 3 cLink layer : Recognizes : all groups up to 3 corrupt bits andorrupt bits and practically all longerpractically all longer and multiple groups.and multiple groups. Application layer : Communication status terminated in aApplication layer : Communication status terminated in a responseresponse message.message. HART PROTOCOL – TECHNICAL DATA
  • 83. MODBUSMODBUS The MODBUS protocol describes an industrial commuThe MODBUS protocol describes an industrial communication andnication and distributeddistributed control system developed bycontrol system developed by GouldGould--ModiconModicon. MODBUS is a Master/Slave. MODBUS is a Master/Slave communications protocol, whereby one device (Master), controlcommunications protocol, whereby one device (Master), controls all serials all serial activities byactivities by selectively polling one or more slave devices. The protocol pselectively polling one or more slave devices. The protocol provides for one masterrovides for one master devicedevice and up to 247 slave devices on a common line. Each device isand up to 247 slave devices on a common line. Each device is assigned anassigned an address toaddress to distinguish it from all other connected device.distinguish it from all other connected device. Only a master initiates a transaction. TransactioOnly a master initiates a transaction. Transactions are either ans are either a query/response type,query/response type, or a broadcast/noor a broadcast/no--response type. A transaction comprises a single query andresponse type. A transaction comprises a single query and singlesingle response frame or a single broadcast frame.response frame or a single broadcast frame. Certain characteristic of a MODBUS protocol are fCertain characteristic of a MODBUS protocol are fixed such as frameixed such as frame format, frameformat, frame sequences, handling of communication errors and exception consequences, handling of communication errors and exception conditions, and theditions, and the functionsfunctions performed.performed.
  • 84. RSRS--232 Communication232 Communication RSRS--232 is an asynchronous communication network. Normally, a binary232 is an asynchronous communication network. Normally, a binary system issystem is used to transmit data in ASCII (American Standard Code for Infoused to transmit data in ASCII (American Standard Code for Informationrmation Interchange)Interchange) format. This code translates human readable code (letter/numberformat. This code translates human readable code (letter/numbers) intos) into ““computercomputer readablereadable”” code(1code(1’’s and 0s and 0’’s).s). There are 2 types of RSThere are 2 types of RS--232 devices. The first is called a DTE (Data Terminal232 devices. The first is called a DTE (Data Terminal Equipment) device and a common example is a computer. The otherEquipment) device and a common example is a computer. The other type of device istype of device is calledcalled DCE (Data Communication Equipment) device and a common exampleDCE (Data Communication Equipment) device and a common example is a modem.is a modem. In RSIn RS--232 the first thing a terminal send is start bit. This start bit232 the first thing a terminal send is start bit. This start bit is ais a synchronizingsynchronizing bit added just before each character being send. The last thingbit added just before each character being send. The last thing send is a stop bit.send is a stop bit. This stop bitThis stop bit informs to the receiving terminal that the last character has jinforms to the receiving terminal that the last character has just being send.ust being send.
  • 85. RSRS--232 communication is done through Serial port which usually has232 communication is done through Serial port which usually has a 9a 9--pinpin configuration. The pin and their purposes are shown below.configuration. The pin and their purposes are shown below. RS-232 Communication Ring indicator (RI) *only for modems*Ring indicator (RI) *only for modems*99 Clear to Send (CTS)Clear to Send (CTS)88 Request to send (RTS)Request to send (RTS)77 Data set ready (DSR)Data set ready (DSR)66 Signal ground (GND)Signal ground (GND)55 Data terminal ready (DTR)Data terminal ready (DTR)44 Transmit data (TD)Transmit data (TD)33 Receive data (RD)Receive data (RD)22 Frame groundFrame ground11 PURPOSEPURPOSE99--PINPIN
  • 86. PC-to-PC Communication through Serial Port CD 10 RXD 20 TXD 30 DTR 40 GND 50 DSR 60 RTS 70 CTS 80 RI 90 01 CD 02 RXD 03 TXD 04 DTR 05 GND 06 DSR 07 RTS 08 CTS 09 RI 9-Pin D Connector
  • 87. PC-to-PC Communication through LPT1 Port 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
  • 88. FlavoursFlavours of Internet Telephonyof Internet Telephony The Internet The Internet The Internet PC PC PC Phone PhonePhone Local ISP Local ISP Local ISP Local ISP Voice Gateway Local ISP Voice Gateway Local ISP Voice Gateway PC-to-PC PC-to-Phone Phone-to-Phone Dial-up or Leased Line Access Code
  • 89. APACSAPACS -- Operation PlatformOperation Platform Database OwnershipDatabase Ownership Operator Console Engineer Console Operator Console Controller Module Transmitter Interlock I/P Valve I/O Modules I/O Level •TAGS •Range •Engineering Unit •Diagnostics Console Level Controller Level
  • 90. TODAYS INDUSTRIAL SYSTEMSTODAYS INDUSTRIAL SYSTEMS H M I Planning H M I 1 2 3 4 5 6 Application Drivers Devices PLC I/O DCS -----------------------
  • 91. PC Based Industrial SystemsPC Based Industrial Systems H M I Planning H M I 1 2 3 Devices PLC I/O DCS OPC Client Application OPC Server ----------------------------------
  • 92. Enterprise Automation SchemesEnterprise Automation Schemes Windows NT Windows NT Embedded Real System Control network Corporate IT Network Server
  • 93. Windows NT (Windows NT (““New technologyNew technology””)) FEATURESFEATURES:: •• A true 32 bit processing.A true 32 bit processing. •• A very reliable operating system.A very reliable operating system. •• Real operating system.Real operating system. TECHNICAL ASPECTTECHNICAL ASPECT:: •• Multiprocessing, Multithreading and partitioned memory space.Multiprocessing, Multithreading and partitioned memory space. •• SecuritySecurity -- C2 compliance.C2 compliance. •• InIn--built networking.built networking. •• Internationalization .Internationalization . •• Human interface as Windows 95.Human interface as Windows 95. •• ObjectObject -- based : DCOM/OLEbased : DCOM/OLE -- ActiveX.ActiveX. •• for special need of the process industries. DCOM and OLE are notfor special need of the process industries. DCOM and OLE are not robust,robust, deterministic and secure.deterministic and secure. •• ClientClient -- Server architecture.Server architecture.
  • 94. Transparent interTransparent inter--connectivity to typical business systems in plants:connectivity to typical business systems in plants: 1) ODBC : It provides access to most SQL databases1) ODBC : It provides access to most SQL databases.. 2) ActiveX/OLE : Supports data access between appl2) ActiveX/OLE : Supports data access between application andication and embedding ofembedding of one applications funone applications function within another.ction within another. 3) DDE : Dynamic Data Exchange supports simple data exch3) DDE : Dynamic Data Exchange supports simple data exchangeange betweenbetween applications such as plant data poapplications such as plant data populating an Excel spreadpulating an Excel spread sheets.sheets. Windows NT Interconnectivity
  • 95. Windows NT featuresWindows NT features Windows NT is gaining ground in open control because of the foWindows NT is gaining ground in open control because of the following advantages :llowing advantages : •• User acceptance.User acceptance. •• Corporate interoperabilityCorporate interoperability •• Ease of use.Ease of use. •• Connectivity.Connectivity. •• Scalability for small and large application.Scalability for small and large application. However, Windows NT has the following disadvantages :However, Windows NT has the following disadvantages : •• Needs a lot memory and processing power.Needs a lot memory and processing power. •• Optimized for office, not control, requirements.Optimized for office, not control, requirements. •• Requires a disk drive which may fail.Requires a disk drive which may fail. •• Depends on single vendor.Depends on single vendor. •• Reboots at unexpected timesReboots at unexpected times •• Unstable operating system.Unstable operating system.
  • 96. Embedded control Operating SystemEmbedded control Operating System -- QNXQNX QNX realQNX real--time operating system, has evolved from the firsttime operating system, has evolved from the first--ever microever micro--kernelkernel operatingoperating system for PCs into one of the best selling and most trusted opesystem for PCs into one of the best selling and most trusted operating systems forrating systems for missionmission critical application. Today, QNX is the real time operating systcritical application. Today, QNX is the real time operating system in industrialem in industrial automation,automation, hand held devices, controllers and soft PLCshand held devices, controllers and soft PLCs QNX is recognized as :QNX is recognized as : •• The fastest and most dependable real time operating system.The fastest and most dependable real time operating system. •• The most proven high speed, deterministic real time kernel.The most proven high speed, deterministic real time kernel. •• Having a hard real time engine that gives PLCHaving a hard real time engine that gives PLC--style control.style control. •• Enabling data acquisition with milliseconds resolution.Enabling data acquisition with milliseconds resolution. •• Providing a faultProviding a fault--tolerant architecture on which you can run control, events,tolerant architecture on which you can run control, events, alarms in a virtually crashalarms in a virtually crash--proof environment.proof environment.
  • 97. Windows NTWindows NT -- for Process controlfor Process control Windows NT features :Windows NT features : •• A true 32 bit processing.A true 32 bit processing. •• A very reliable operating system.A very reliable operating system. •• Real operating system.Real operating system. •• Multiprocessing, Multithreading and partitioned memory space.Multiprocessing, Multithreading and partitioned memory space. •• SecuritySecurity -- C2 compliance.C2 compliance. •• InIn--built networking.built networking. •• Internationalization.Internationalization. •• Human interface.Human interface. •• ObjectObject--based DCOM/OLE :based DCOM/OLE : The sending object is shown as client and receiving objThe sending object is shown as client and receiving object is known asect is known as server. Theserver. The MS technology allows any developer to produce small, seMS technology allows any developer to produce small, self contain objectslf contain objects that havethat have ““packagedpackaged”” visual component and specific action. These components arevisual component and specific action. These components are calledcalled ““ActiveXActiveX”” objects. NTobjects. NT’’s OLE technology is part of Microsofts OLE technology is part of Microsoft’’s Distributeds Distributed Component Object Model (DCOM) operating across networksComponent Object Model (DCOM) operating across networks. Anyone can. Anyone can developdevelop ActiveX Object using VC++ or even VB on a PC. For speciaActiveX Object using VC++ or even VB on a PC. For special needs of thel needs of the processprocess control industries DCOM and OLE are not secure, determinicontrol industries DCOM and OLE are not secure, deterministic and robuststic and robust enough.enough.
  • 98. EthernetEthernet Ethernet was originally designed by Digital, Intel andEthernet was originally designed by Digital, Intel and Xerox (DIX) in the earlyXerox (DIX) in the early 19701970’’ss and has been designed as a broadcast system. The original formaand has been designed as a broadcast system. The original format for Ethernet wast for Ethernet was developeddeveloped in Xerox Palo Alto Research center (PARC), California in 1972.in Xerox Palo Alto Research center (PARC), California in 1972. The two inventorsThe two inventors werewere Robert Metcalf and David Boggs.Robert Metcalf and David Boggs. Ethernet version 1.0 and 2.0 followed until the IEEE 8Ethernet version 1.0 and 2.0 followed until the IEEE 802.3 committee re02.3 committee re-- jigged thejigged the Ethernet II packet to form the Ethernet 802.3 packet. NowadaysEthernet II packet to form the Ethernet 802.3 packet. Nowadays you will see eitheryou will see either Ethernet II (DIX) format or Ethernet 802.3 format being used.Ethernet II (DIX) format or Ethernet 802.3 format being used. TheThe ‘‘EtherEther’’ part of Ethernet denotes that the system is not meant to bepart of Ethernet denotes that the system is not meant to be restricted only torestricted only to one medium type, copper cables, fiber cables and even radio wavone medium type, copper cables, fiber cables and even radio waves can be used.es can be used. Briefly, stated Ethernet what is referred to as the PhBriefly, stated Ethernet what is referred to as the Physical layer and the Dataysical layer and the Data-- link layerslink layers protocols. The physical layer defines the cable types, connectoprotocols. The physical layer defines the cable types, connectors and electricalrs and electrical characteristics.characteristics. The Data link layer defines the format an Ethernet frames, theThe Data link layer defines the format an Ethernet frames, the error checkingerror checking method and themethod and the
  • 99. 10Base510Base5 Traditionally, Ethernet is used overTraditionally, Ethernet is used over ‘‘thickthick’’ coaxial cable called 10Base5 (coaxial cable called 10Base5 ( the 10the 10 denotes 10 Mbps, base means that the signal is baseband i.e, tadenotes 10 Mbps, base means that the signal is baseband i.e, takes the wholekes the whole bandwidthbandwidth of the cable, 5 denotes 500m maximum length ). The minimum lengof the cable, 5 denotes 500m maximum length ). The minimum lengthth between stationsbetween stations is 2.5m.is 2.5m. The cable is run in one long length forming aThe cable is run in one long length forming a ‘‘Bus TopologyBus Topology’’. The. The segments aresegments are terminated by 50 ohm resistor and the shield should be groundedterminated by 50 ohm resistor and the shield should be grounded at one endat one end only.only. 10Base210Base2 Thin Ethernet (Thinnet) uses RGThin Ethernet (Thinnet) uses RG--58 cable and is called 10Base2 (the 258 cable and is called 10Base2 (the 2 denotesdenotes 200 mtr maximum length cable). Each station connects to the Thin200 mtr maximum length cable). Each station connects to the Thinnet by waynet by way of EthernetEthernet
  • 100. 10BaseT10BaseT Nowadays, it is becoming increasingly important to useNowadays, it is becoming increasingly important to use Ethernet acrossEthernet across UnshieldedUnshielded Twisted Pair (UTP) or Shielded Twisted Pair (STP), this being cTwisted Pair (UTP) or Shielded Twisted Pair (STP), this being called 10BaseT (the Talled 10BaseT (the T denotes twisted pair). UTP is installed in star wire format anddenotes twisted pair). UTP is installed in star wire format and Ethernet Hubs withEthernet Hubs with UTP portsUTP ports (RJ45) centrally located. Also there should be no more than a 1(RJ45) centrally located. Also there should be no more than a 11.5db signal loss and1.5db signal loss and thethe minimum distance between devices is 2.5 meters.minimum distance between devices is 2.5 meters. The advantages of the UTP/STP technology are gained froThe advantages of the UTP/STP technology are gained from the flexibility ofm the flexibility of thethe system, with respect to moves, changes, fault finding, reliabilsystem, with respect to moves, changes, fault finding, reliability and security.ity and security. 10BaseF10BaseF 10BaseF standard developed by IEEE 802.3 committee defi10BaseF standard developed by IEEE 802.3 committee defines the use of Fibernes the use of Fiber forfor Ethernet. 10BaseFB allows up to 2 Km per segment and is defineEthernet. 10BaseFB allows up to 2 Km per segment and is defined for Backboned for Backbone EthernetEthernet
  • 101. The following table shows the RJ45 pin outs for 10BaseT :The following table shows the RJ45 pin outs for 10BaseT : Brown/WhiteBrown/White88 White/BrownWhite/Brown77 Green/WhiteGreen/WhiteReceiveReceive66 White/BlueWhite/Blue55 Blue/WhiteBlue/White44 White/GreenWhite/GreenReceiveReceive33 Orange/WhiteOrange/WhiteTransmitTransmit22 White/OrangeWhite/OrangeTransmitTransmit11 ColourColourFunctionFunctionRJ45 PinRJ45 Pin EthernetEthernet
  • 102. PCPC--toto--PC Communication throughPC Communication through EthernetEthernet RJ45 RJ45 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8
  • 103. Controller Controller Controller Controller Workstation Workstation Workstation Workstation Switched Hub Segmented (star) topology Bus topology Ethernet TopologyEthernet Topology
  • 104. Wireless LANWireless LAN Wireless LAN is based on standard IEEE 802.11b which throughputWireless LAN is based on standard IEEE 802.11b which throughput of up to 11Mbps inof up to 11Mbps in thethe 2.42.4 GhzGhz band. Similar Wireless Personal Area Network (WPAN) are Bluetooband. Similar Wireless Personal Area Network (WPAN) are Bluetooth andth and Infrared.Infrared. Ethernet works on the CSMA/CD technology but wireless LAN haEthernet works on the CSMA/CD technology but wireless LAN has difficulty ofs difficulty of detectingdetecting collision in Radio frequency. Therefore they are using CSMA/CA (collision in Radio frequency. Therefore they are using CSMA/CA (Collision Sense MultipleCollision Sense Multiple Access / Collision Avoidance) technology to transmit data. PhysiAccess / Collision Avoidance) technology to transmit data. Physical Layer is eithercal Layer is either Photonic orPhotonic or Radio frequency.Radio frequency.
  • 105. Process control Software characteristicsProcess control Software characteristics The most important feature of process control system is that itThe most important feature of process control system is that it needs to beneeds to be reliable.reliable. TheThe process control system used has to be completely crashprocess control system used has to be completely crash--proof and any changes inproof and any changes in thethe system need to be made onsystem need to be made on--line.line. The process control needs to be madeThe process control needs to be made real time,real time, which means that it canwhich means that it can update the I/Oupdate the I/O data table and process the control program in the time requireddata table and process the control program in the time required by the process.by the process. A process control system that isA process control system that is deterministicdeterministic refers to whether the operatingrefers to whether the operating systemsystem allows the highest priority task to work without interruption fallows the highest priority task to work without interruption from task with lowerrom task with lower priority.priority. Software offerings in the automation and the process control fSoftware offerings in the automation and the process control fields must beields must be versatileversatile andand openopen enough to address the needs of different applications.enough to address the needs of different applications. Finally the chosen solution must deliver tangible, quantifiablFinally the chosen solution must deliver tangible, quantifiable values such as :e values such as : 1.1. Reducing project implementation time and cost.Reducing project implementation time and cost. 2.2. Improving timeImproving time--toto--market.market. 3.3. Achieving higher production and quality.Achieving higher production and quality. 4.4. Cutting maintenance and training cost.Cutting maintenance and training cost.
  • 106. PCPC--based control system featuresbased control system features Unlike the other systems, PCs provide a more open architectureUnlike the other systems, PCs provide a more open architecture making them idealmaking them ideal forfor improving, optimizing and integrating the overall automation primproving, optimizing and integrating the overall automation process, as well asocess, as well as conductingconducting control task.control task. In addition PCs offer the following features :In addition PCs offer the following features : •• Lower cost.Lower cost. •• Ease of use.Ease of use. •• Graphical user interface.Graphical user interface. •• Easy integration of logic, motion and process control.Easy integration of logic, motion and process control. •• Simplified application development.Simplified application development. •• Software portabilitySoftware portability •• Independence from proprietary control system.Independence from proprietary control system. Using PCs enable the following functions,Using PCs enable the following functions, •• Millisecond time stamping which is essential to utilities.Millisecond time stamping which is essential to utilities. •• Real time control.Real time control. •• Sequence of events.Sequence of events. •• Alarming.Alarming. •• Data collection.Data collection.
  • 107. PLC conceptual overviewPLC conceptual overview Process Graphics History & Trend Alarm & Events SCADA configuration editor Other Aspect system ABB Siemens Allen Bradley GE Fanuc …. opc Modbus comli Protocol xx Protocol yy SCADA server OPC server OP Client SCADA Control Aspect Real-time database
  • 108. PLC Programming StandardsPLC Programming Standards The open, manufacturerThe open, manufacturer--independent programming standard forindependent programming standard for automation isautomation is IEC 61131IEC 61131--3. You can thus choose what configuration interface you wish to3. You can thus choose what configuration interface you wish to useuse whenwhen writing your application :writing your application : •• Ladder DiagramLadder Diagram •• Instruction ListInstruction List •• Function Block DiagramFunction Block Diagram •• Sequential Function ChartSequential Function Chart •• Structured TextStructured Text All users, be they plant electrician or coAll users, be they plant electrician or computer scientists, thus havemputer scientists, thus have a configuration interface in which they can feel at home.a configuration interface in which they can feel at home.
  • 109. Industrial IT TrendsIndustrial IT Trends The availability of information is becoming increasingly crucialThe availability of information is becoming increasingly crucial in the view of growingin the view of growing globalglobal competition. In future, a decisive competitive edge can only becompetition. In future, a decisive competitive edge can only be achieved by providingachieved by providing thethe right information at the right time, in the right place and inright information at the right time, in the right place and in the right form for the rightthe right form for the right person.person. these leadingthese leading-- edge application are continuously optimized and repositioned.edge application are continuously optimized and repositioned. Industrial IT consists of five components:Industrial IT consists of five components: 1.1. Engineering ITEngineering IT 2.2. Operation ITOperation IT 3.3. Production ITProduction IT 4.4. Optimization ITOptimization IT 5.5. Evolution / InformationEvolution / Information
  • 110. ASSET OPTIMIZATION Industrial IT TrendIndustrial IT Trend Sales & Marketing Planning & Scheduling Plant & Process Eng. Operation & Maintenance Distribution Real-time Automation & Information e-PRODUCTIVITY Business Systems Plant