Cae Module 2_ System Design and Development With Plc, Hmi_scada, Dcs (Isa Cap Domain III & IV)

9/2/13 CAE MODULE 2: SYSTEM DESIGN AND DEVELOPMENT WITH PLC, HMI/SCADA, DCS (ISA CAP DOMAIN III & IV)

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CAE MODULE 2: SYSTEM DESIGN ANDDEVELOPMENT WITH PLC, HMI/SCADA, DCS(ISA CAP DOMAIN III & IV)MODULE 2: System Design and Development with PLC, HMI/SCADA,DCS (ISA CAP Domain III & IV)

Section 2.1- Working with Applicable Standards e.g. ISA S84, S5.1, IEC 61508, 21 CFR Part 11,NFPA, NEC,EPA, NEMA, UL, IEC 61131Section 2.2- Electrical & Instrumentation SystemsSection 2.3- PLC SystemsSection 2.4- HMI/SCADA SystemsSection 2.5- Distributed Control Systems (DCS)Section 2.6- Process Automation (DCS Production Plant Operation & Performance Management ofProcess Models)

Section 2.7- Industrial Communication System

SECTION 2.1

Working with Applicable Standards

ISA S84, S5.1, IEC 61508, 21 CFR Part 11, NFPA, NEC, EPA, NEMA, UL, IEC 61131

OVERVIEW

The aim of this section is to provide trainees with the knowledge to perform safety and hazard analysis, security analysis and

regulatory compliance assessments by highlighting key issues in order to conform to applicable standards, policies and regulations. It

also helps them to produce standards, templates and guidelines applicable to automation systems using the information gathered in

the definition stage and considering human factor effects in order to satisfy customer design criteria and preferences.

COURSE CONTENT

LESSON 1

Applicable standards (e.g., ISA S84, IEC 61508, 21 CFR Part 11, NFPA)

Environmental standards (EPA)

Electrical, electrical equipment, enclosure, and electrical classification standards (e.g., UL/FM, NEC, NEMA)

LESSON 2

Process Industry Practices (PIP) (Construction Industry Institute)

IEC 61131 programming languages

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Customer standards

Vendor standards

Template development methodology

Field devices

Control valves

Electrical standards (NEC)

Instrument selection and sizing tools

ISA standards (e.g., S88)

SECTION 2.2

Electrical & Instrumentation Systems

OVERVIEW

This module is designed for instrumentation specialists involved in the definition and specification of instrumentation and control

systems using the SmartPlant Instrumentation software and for IT specialists and support personnel who are responsible for

installation and system administration of SmartPlant Instrumentation. Students will learn how to define the instruments using

SmartPlant Instrumentation as per the specifications of project deliverables, software and hardware requirements, system, supporting

RDBMS installation, overview of database structure, database maintenance and overview of customization. The training program will

also focus on the concepts and characteristics associated with industrial processes, process variables and Basic process control.

Participant will have hand-on experience with a simple control system as well as process and controller simulators.

COURSE CONTENT

Variable Frequency Drives (VFDs)

i. vIntroduction to VFD/VSD Operations

ii. vVFD selection & Parameterization

iii. vLoad analysis

- Rated voltage

- Rated current

- Rated RPM

i. vCommissioning, No Load Test

i. vPLC-VFD Interface

ii. vPID Tuning

iii. vSpeed modulation

iv. vON/OFF Command

v. vTrip

vi. vInTools

Instrumentation Design

- System and Project Administration Overview

Instrument Index, Control loops, Specifications,

- User Report Interface ( Browser Module)

Process Data Definition

Loop Diagrams

Wiring

Hookups (Installation Details)

Specifications

Calculations

Instrumentation Operation & Maintenance

i. vClose loop control

ii. vUnderstanding operation of instruments/field device in general

iii. vIdentifying instruments vendor and specification

iv. vInstallation of field devices/instruments

v. vWorking with Instrument and Process variables

vi. vWorking with different instrument operation systems

vii. vPneumatic System operation

- On/Off Solenoids valves

- Piston displacement

- Control valves



- Actuators

i. vHydraulic System operation

ii. vWorking with actuators

iii. vPumps, valves, compressors, heaters, filters, boilers etc

iv. vInstrument calibration

v. vSelection of Measurement and Control Devices

vi. vRepair modes and records; Failure mode analysis;

vii. vMaintenance, calibration modes, and records; Calibration seals; Tools and equipment.

viii. vTroubleshooting and maintenance of instruments

- I/P Convertor

- Level Transmitters

- Flow Transmitters

- Proximity Sensors

- Pressure Transmitters

- Temperature Transmitters/RTDs

SECTION 2.3

Programmable Logic Controller, PLC Systems

OVERVIEW

Programmable Logic Controllers (PLCs) are the main engine behind most discrete control systems in many industries. This class aims

to introduce the principles of operations, maintenance techniques, basic troubleshooting techniques and thorough understanding of

overall machine design concepts using PLCs. Focus will also be on PLC based control system project development including

specification/parameter analysis, control system design, field devices selection, I/O configuration, PLC selection, project development

and implementation. Participants will have hands-on experience with different projects on live PLC including plant alarm systems,

sequential control systems feed forward systems, data logging & extraction and many more. The class training will be complemented

by class workshops, discussion on industry best practices and ISA videos on PLCs. Students will be issued a certificate at the end of

the training.

Trainees will be trained on the following PLC brands: Siemens, Allen Bradley, GE Fanuc, Mitsubishi, Omron, ABB etc.

COURSE CONTENT

Introduction to Automation & Control System Engineering

PLC System Architecture

Working with PLC Hardware / Installation

PLC Wiring

Relay Logic Controls

PLC Operation Cycle

PLC Configuration/Set ups

PLC Communication/Interfacing/Networking/Remote IO Configuration

Digital & Analog I/O Addressing Techniques

PLC Programming

i. vLadder & Function Block Programming

- Bit, Byte & Word Instructions

-Timers & Counters

-PID Mode Programming

-Comparison / Mathematical Instructions

-Analog Signal Processing (ASP)

-Subroutines Programming

-Interrupts Programming

-Forcing inputs & outputs

-Program Debugging



-Downloading/uploading

PLC Status Troubleshooting

HMI Interface

SECTION 2.4

Human Machine Interface/Supervisory Control & Data Acquisition,

HMI/SCADA Systems

OVERVIEW

The aim of this module is to build a good understanding about the basics of supervisory control and data acquisition (SCADA) andhuman machine interface (HMI). A special emphasis on real life implementations, case studies and international standards wouldensure participants to co-relate the theory with their day-to-day practice. The class training will be complemented by class workshops,discussion on industry best practices. Students will be issued a certificate at the end of the training.

Trainees will be trained on the following software: Wonderware Intouch, Simantic WinCC, Intellution Ifix etc.

COURSE CONTENT

Introduction to HMI/SCADA

Communication Protocols

Database & DDE Connection (Server, I/O Drivers)

Interface with PLC and field devices

Data acquisition from field devices

Operator Screen Interface Design (Statics)

Object Functionality Definition

Tag Creation, Addressing & Configuration

Animation of Objects (Dynamics Properties Movement, Filling, Visibility, Display Type, Blinking etc)

Alarms/Events Configuration

Real-time & Historical Trends

Interface with PLC and field devices

SCADA/HMI Systems Administration

User account set up

Security profile/access right set up

Engineering & Operator station configurations

SECTION 2.5

Distributed Control Systems, DCS

OVERVIEW

The training provides an understanding of the fundamentals of Distributed Control Systems (DCS). The evolution of computer control

systems is discussed and the architecture of contemporary DCS is described in detail. The lesson covers hardware, configuration, data

communications, user interface and I/O devices.

COURSE CONTENT

Introduction to DCS operation

DCS System Architecture

- DCS CPU-Processor

- Hardware Configuration

- I/O Modules

- Communication Modules

- I/O Wiring Techniques

Distribution node A-Configuration

- Profibus Master / Slave

Distribution node B-Configuration

- Optical Module Bus



DCS CPU Programming

- Instruction set programming

- CPU Settings

- CPU Addressing

- Nodes Addressing

- Downloading/uploading

- Functional System Monitoring

- System Diagnosis

Operator Interface

- Working with Navigations

- SCADA portal

- Detailed designing

- Face/points

- Alarm/Trends/Events

- OPC/ODBC

- Controller Interface

HMI System Design & Programming

- Screen Designing

- Controller Interface

- Upload/Download

Communication Protocols

- Ethernet

- Modbus

- Profibus

- Optical Module bus

- Fieldbus

PAC

- Hardware configuration

- I/O Modules

- I/O Wiring

- Troubleshooting

- Simple & Complex Programming

- CPU Addressing

- I/O Addressing

- Upload & download

- Monitoring/fault finding

- Positioning functions

- High speed counter

- PID Control

Real time interface

- Process control

- 2-Axis motion control

- Servo drive/motor

- Encoder

SECTION 2.6

Process Automation (DCS Production Plant Operation & Performance Management of ProcessModels)

OVERVIEW

Day by day monitoring of plant performance is very important in a process control system. Because of inherent risk common onproduction and manufacturing plants, more especially when the process variables and values are tampered with, operators find itdifficult to be trained on live plant. Process simulation software is therefore a substitute.

This course provides an understanding of the fundamentals of Process Control Systems, Process Variables & Values, Instrumentation,and Distributed Control Systems (DCS) i.e. Process monitoring and Control with Yokogawa CS3000 operator station. Processes likethe following, amongst others stated in the contents bellow will be covered; Distillation Column, Gas & Steam Plant monitoring,Centrifugal compressor, Crystallizer, Fixed Bed Reactor, etc.



COURSE CONTENT

Introduction to Process Control Systems and Instrumentation.

Introduction to Process Variables and Process Values.

Architecture of DCS.

Field control stations

Safety control stations

Advantage of DCS over PLC

Scope of DCS in the field of Automation.

Human interface stations & engineering stations

Basic Process Models

oCentrifugal compressor

oCrystallizer

oCyclone separator

oDistillation column

oEvaporator

oFlash drum

oGas turbine

oHeat exchanger

oHeater

oPlug flow reactor

oCentrifugal pump

oCSTR

oFixed bed reactor

oSuperheated steam generator

oCo-generation boiler

Control ModelsOn off level controllerOn off temperature controllerP & PI controller on flow

Pressure controllerLevel transmitter and controllerDirect and cascade controlSplit range pressure controlRatio control

Feed backward and forward controlThree element boiler controlControl valve characteristicsCharacteristics coefficient of control valve

Study of rangeability of control valveInteracting and non-interacting level systembasic instrumentation troubleshooting system

SECTION 2.7

Industrial Communication System

OVERVIEW

This course will show the ideas and basis that support the communications between Industrial Digital Devices, mainly between themand field devices or supervisory systems.

COURSE CONTENT

Concept of Data CommunicationSerial Communication- Technologies and Applications

LAN TechnologiesProcess Control Network and Data SecurityWorking with communication protocols: RS232/485, MODBUS, OPC, PROFIBUS, ETHERNET, CONTROLNET, DEVICENET, etcProprietary PLC/DCS Networks

Documents

Cae Module 2_ System Design and Development With Plc, Hmi_scada, Dcs (Isa Cap Domain III & IV)