DCS_Overview[1].pp

7/30/2019 DCS_Overview[1].pp

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WEL - COME

TO

DISTRIBUTEDCONTROLSYSTEM

(DCS)


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What is DCS ?

DCS is abbreviation for Distributed Control System

As is apparent from the abbreviation, the word Distributed supports

following functionalitys

Physical Distribution - Nodes or Subsystems can be Distributed I.e

located physically apart

Functional Distribution - Specific Functionality is imparted for a

Node basing on the combination of hardware and software used. For

e.g Application work-processor with Historian, Application work-

processor with control configuration software Structural Distribution - Different Structural hardware platforms

(Application Workstation processor, Workstation processor, Control

processor etc.) are used to achieve the required functionality.


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WHY DCS ?

For Total Plant Automation

For Higher Productivity

For Optimal Process Control

For Regulatory Compliance

For Management Information System

In Tune With Global Requirement


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DCS MANUFACTURERS

ASEA BROWN BOWERI - ABB

TATA HONEYWEL

FOXBORO - INVENSYS

YOKOGOWA BLUE STAR - YBL

ALLEN BRADLEY

GE FANUC FISHER ROSEMOUNT


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DCS

SYSTEM FEAUTRES - ABB

The system compiles with the following features;

Masterless token passing Distribution Communication Network

Dual DCN rings share the communication Load

A fully integrated system and group of devices.

Distributed hardware and intelligence.

Expandable architecture to accommodate various system needs.


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DCS

SYSTEM FEAUTRES - ABB CONTD.

Integrated continuos and discontinuous control.

User oriented with commonality of interface for systemconfiguration, operator display and control.

Commonality of software to provide a more cohesive and

maintainable product.

Commonality of hardware providing similar

architecture,Operational philosophies, servicing philosophies,

Physical parts and mounting.


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SAMPLE COMMUNICATION NETWORK

TCP/IP N/W

IMS

OS

ES

DUAL DCN

RINGRING 0

RING 1

Advant

Controller 460

C Controller

SC Controller


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Distributed Communication Network

(DCN )

Total Nodes per Ring 29

Total Nodes/Network 255

Total Rings/Network 85

Maximum end-to-end length/Ring 14 miles/ring Maximum distance between two active nodes 5280 ft* wire

Fiber-optic 10,000 ft

*recommend 1 mile (5280 ft, 1600 M) between 3 nodes


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Typical Schematic Diagram For Information

Flow

JB TB B/R TRIO CSS

OS

JB TB B/R TRIO CSS

From TX

CONTROL ROOMFIELD

To I/P


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WORK STATION

COMMON HARDWAREDETAILS


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STATION OVERVIEW 515 M/C

Monitor

515 Machine

ABB

Keyboards

Track Ball


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ADVANT STATIONS


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FRONT VIEW OF 515 M/C

FRONT VIEW


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REAR VIEW OF 515 M/C

Internal Memory Hard Disk

HP-HIL bus

interface

RS-232 serial

interface

Centronics Parallel

Port

SCSI-2 bus

IEE802.3 Ethernet

LAN

Internla EISA Real

Time Accelerator

Board

Data Drives, CD-ROM

REAR VIEW


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STATION DETAILS

RTAB

EISAMEMORY SLOT

SPEAKER

AUDIBLE CBL

HARD DISK

CD ROM

SCSI CABLE

SMPS

POWER CBL

LED's

MOTHER BOARD

DCN 1

DCN 0


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HARDWARE PERIPHERAL DEVICES

HP Keyboard with MouseABB Keyboard

Page select Alarm PanelTape Drive (DAT)

Real Time Accelerator Board

Track Ball

Laser Printer


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System Mounted into the Console Cabinet

With Monitor


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ENGINEERING STATION(ES)


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SOFTWARE FOR ES

Operating system HP-UX 10.20 or later

Database Oracle RDMS

Developer 2000

Network TCP/IP (IEE 802.3)

DCN N/W (IEE 802.5)

Application Software AdvaBuild Basic Functions

Configurable Control Functions* Document Builder

Function Chart Builder

Structure Builder*

TCL Builder*

Template Builder*

TLL Builder


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How to Create a New Project


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STRUCTURE BUILDER


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CONTROL STRUCTURE DATABASE

HIERARCHY


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HIERARCHY CONTD.


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HIERARCHY CONTD.


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TYPICAL CONFIGURABLE CONTROLFUNCTIONS (CCF) LOOP

CCF is a block structured control language for both continuous and

discrete process control

CCF is configured using AdvaBuild Basic Functions software (Structure,

Template, and Function Chart Builders) which runs on the Advant

Station 500-Series Engineering Station.


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TEMPLATE BUILDER


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FUNCTION CHART BUILDER


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Compiler

The compiler builds database files from the source files in the AdvaBuild

database, and it creates a report file.

Installer

The installer makes the selected database active (ready for downloading to

Random Access Memory on the Advant OCS Subsystems).

Downloader

Downloading is the process by which the installed database is loaded into

the memories of the Advant OCS subsystems.

DATABASE UTILITY


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Decompiler

Decompiling is the process by which tuning changes are entered into the

database source files so that the source files match the installed database.

Load and Loop_load

You can compile, install, and download individual loops or all loops

under a selected Control block via one command: LOAD (for ControlBlock level) and LOOP_LOAD (for individual loops).

DATABASE UTILITY


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TAYLOR CONTROL LANGUAGE (TCL)

TCL is modeled after Pascal and has some functional elements that are

similar to those found in Pascal such as compound statements,

IFTHENELSE statements, and so on.

There are also many functional elements unique to TCL. These unique

elements are designed to facilitate software development for process

control in the Advant OCS environment.

It also provides an introduction to data base configuration requirements,development support and runtime support for TCL.


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EXAMPLE 1

HOUR:= TIME(3)

IF (HOUR = 12) THENEVENT RESTART

SE TEVENT ($CV101.STAT = #OPEN OR

$CV201.STAT =#OPEN);

ACTION (ABORT, SEQUENCEA, UNIT1);

ACTION (ACTIVE (4), SEQUENCEB, UNIT1);

ENDEVENT;


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EXAMPLE 2

OPER CHARGE;DBVAR MEASURE: REAL;

BEGIN

STEPDB REF

$CV101.MEASURE:= 100.00;

ENDSTEP

END.



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OPERATOR STATION(OS)


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SOFTWARE FOR OS

Operating system

HP-UX 10.20 or later

Database

Oracle RDMS

Developer 2000 Network

TCP/IP (IEE 802.3)

DCN N/W (IEE 802.5)

Application Software

AdvaCommand Basic Functions Display Builder

Environment Builder


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OPERATOR STATION MAIN WINDOW


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Caps Lock Indicator


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Product Overview

The AdvaCommand software package provides the

operator interface for monitoring and controlling

plant processes through the Advant OCS.

The system operator interact with the plant

processes through a hierarchy of standard and

custom (user-specific) displays


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Display Menu


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Last Page Menu

The previous displays are listed in

reverse chronological order. Up to 50

displays are listed in the Last Page

Menu.

The Last Page Menu only shows one

instance of a display name. When a

display is added to the Last Page

Menu, any previous occurrences of

that display in the menu list will be

removed and the display will be added

to the top of the list.


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Personal Menu

A personal display menu, can be

configured for each user. The personal

menu is a scrollable list of the most

frequently requested, or most critical

displays for a user.

The maximum number of displays for

each user is 50. Items with a + in front

of them indicate overlap displays.


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Tag View Menu


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Dynamic Function Keys

The runtime displays have function keys on the bottom of their

screens to allow an easy means to navigate between them.

There are default function key definitions for most displays in

the environments.


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Dynamic Function Keys

The function key definitions can be customized for each environment.The displays supporting custom function key definitions are:

Area displays

Group displays

Loop displays

Overview displays

TCL displays

Unit displays

Sequence displays

Batch displays

Ladder Logic displays


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Dialogs

When you execute a function that requires operator

interaction, the appropriate dialog box is displayed

over the dynamic function keys.

For example when you take control of a loop,


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Display Request Key

Any display can be accessed by entering the display name and the

required parameters in the Display Request dialog,

The below dialog is opened by pressing the Display Request. key on the

keyboard.

It has three push button options:

Loop Detail Enters LOOPDETAIL, in the Command field.

LoopFCM Enters LOOPFCM, in the Command field

Default Entry Clears the Command field.


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The Universal Keyboard


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The Universal Keyboard details


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The Universal Keyboard details contd.


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The XCONFIG Screen

The XCONFIG screen allows

you to change mouse/trackball

and screen saver parameters.

Cursor shape and color can alsobe changed from this display.

Changes become effective

immediately.


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Page Selector Alarm Panel

The Page Selector Alarm Panel (PSAP), is

made up of 48 identical stations

Each of which provides a push-button

Four LEDs, and a text area.

The PSAP is the panel equivalent of the

Overview Display.

You can have one PSAP per Operator

Station.


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STANDARD DISPLAYS

OVERVIEW DISPLAYS

Any Number of Overviews Displays Allowed

48 Screen Targets - Configured as Required

AREA DISPLAYS

Area Graphics

Area Status

Area Trend Area Alarm

Any Number of Areas are allowed

Each Area Has a Maximum of Three Groups


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STANDARD DISPLAYS

GROUP DISPLAYS

Group Graphics

Group Status

Group Trend Group Alarm

Each Group has a Maximum of 12 Controller loops or 36

Indication Loops or Mixture of the two types


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Overview Display


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Overview Display contd.

The Overview Display, is the software equivalent of the PageSelector Alarm Panel.

It allows you to monitor alarms for a number of areas and groups

from one display, and it provides one-step access to critical displays.

The Overview Display contains 48 target blocks that represent either

a specific area, group, TCL sequence, or external display.

Each block can be configured to execute one of the following

functions when selected:

Call up a standard display or a custom graphic display Initiate a TCL program sequence state or status transition

Invoke an RDP (Remote Display Protocol) Display

Call up an external applications


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Area Alarm Display

The Area Alarm Display,

chronologically lists alarm

messages for all tags in the

selected area that are currently in

alarm.

Alarm messages are listed in last-

in-first-out order by time of alarm

detection, with the most recent

alarm at the top of the screen.

If more alarms exist than can fit

on one screen, you can use the

scroll bar to view additional

alarm messages.


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GRAPHICS


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Area Status Display

The Area Status Display,

shows the current status

of all tags in the area (up

to three groups).


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Group Alarm Display

The Group Alarm Display,provides a chronological list

of alarm messages for tag

attributes in the selected

group that is currently in

alarm.


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Group Status Display

The Group StatusDisplay, shows the

current status of all

tags within the group.

Trend data is alsoshown for PID and

A/M control loops

which have trending

configured in the

database.


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Group Trend Display

The Group Trend Display,provides trend records for

up to 12 loops.

Trend records for each

loop are collected by the

node where the loop

resides and are sent to the

Operator Station.


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Group Trend Display

Trend Time Base

The trend time base is the period of time in which a trend shows 50

data points (one divisions worth of data).

The X-axis is labeled with the appropriate times under each

division. Trend time base is determined by the trend

rate which is configured individually for each tag during control

database configuration,


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Loop Detail Display

The Loop Detail Display providesthe means to manipulate tunable

parameters.

Generally (and by default), users

with Operator authority have read-only access to the Loop Detail

Display.

Control/tuning functions are

restricted to users with Supervisor,Engineer, or Environment authority.


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Loop FCM Display

The Loop FCM Display,

shows the relationships

between the functional

class modules (FCMs)

that make up the loop.

Each FCM in the loop is

represented by a block on

the display.


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Unit Detail Display

The Unit Detail Display, lists thesequences that reside on and can

be run on a unit.

This display is accessed by

selecting UNITDETAIL from theTCL/Batch Display Menu, then

selecting a specific unit name

from the Unit menu.


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Loading a Sequence Onto a Unit

ACTIVE Starts executing steps. RESUME Starts a paused sequence.

PAUSE Stops a sequence between steps, making it

inactive.

ABORT Ends a sequence in the middle of a step,

making it inactive.


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Sequence Debug Display

The Sequence Debug Display,

supports runtime troubleshooting and

debugging of sequences.

The display is accessed by selecting

SEQUENCEDEBUG from the

TCL/Batch Display menu, then

selecting a specific sequence from the

Sequence menu.


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Taylor Ladder Logic (TLL)

Segment Display


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Environment Alarm Display


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Logger Control

The logging printer is

controlled either by the Logger

Control Display, or internally

by the Logger software.


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System Status Display

The System Status Display,

shows the current status of all

subsystems (nodes)

recognized on the DCN.


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System Status Display for AC460 system


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DISPLAY BUILDER

Click on the Display Menu button in the MainWindow. This calls up a list of available

submenus and displays.

Click on the submenu name EXTERNALAPPLICATIONS.

This displays the External Applications Displaymenu.

Click on Display Builder. The initial start-updisplay for the Display Builder,

Templates Dialog Box


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DISPLAY BUILDER cont....

$tag-type.parameter


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Display Converter To prepare the display that

you have recently configured

for dynamic interaction within

a particular runtime process

database, you must first

convert it to a status that isfunctionally compatible with a

runtime process environment.

This is done via the Display

Converter window,

Installer Once the display is converted to runtime status, you

must install it to interact dynamically within a

specific runtime process control environment.


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The Distributor Window

The DisplayDistributor is

accessed from the

External Applications

submenu of theDisplay Menu, which

is located on the

upper left of the

Operator Stations

Main Window.

Selecting the

Display Distributor

calls up the


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BUILDING AN ENVIRONMENT

Click on the DisplayMenu button in theMain Window. This

calls up a list of available

submenus and displays. Click on the submenu

name EXTERNALAPPLICATIONS.This displays the External

Applications Display

menu.

Click on EnvironmentBuilder. The initial start-up display for the Display

Builder,


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BUILDING AN ENVIRONMENT


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MOD 300 ERROR MESSAGE FORMAT

FIX=0000 AP=131D WModule SEMSGENT Task SEMSGLID (Operator)

FIX = NO_FIXED_ERR, AP = SE+SE_HRD_RESET

AP1 unused, AP2 unused

TEXT: *OPERATOR REQUEST TO HARD-RESET CONTROLLER

CAUSE: Operator sent a request to reset controller.

EFFECT: Controller is reset.

ACTION: None. where

FIX identifies the function which was called by the module that reported it

AP Error Code is the four digit hexadecimal code. The first two digits identify the application(AP) which reported the error.

Severity Information (I), Warning (W), Error (E), Fatal (F), Success (S)

Module the module within the AP that detected the error

Task the logical task ID

AP1 & AP2 parameters to further identify the error

TEXT the message that appears when ALL_MESSAGES_TEXT is in effect

CAUSE reason for error

EFFECT result of error

ACTION next appropriate step for you to take


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NEVER DOS

Turn off the workstation without a proper shutdown

If in doubt Call Plant Instrumentation or CES - DCS

Never physically turn off printer. If you need to halt the operation of

the printer select pause from the LOGGER CONTROLLER PANEL

Powering of the Printer WILL Cause Memory Problems


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INFORMATION MANAGEMENT

SYSTEM (IMS)


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SOFTWARE FOR IMS Operating system

HP-UX 10.20 or later

Database Oracle RDMS

Developer 2000

SQLPLUS

Network

TCP/IP (IEE 802.3)

DCN N/W (IEE 802.5)

SQL*Net

Application Software

AdvaInform Basic Functions

History Builder

Report Builder

Display Builder

User API


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Overview

Some of the functions supported by the AdvaInform BasicFunctions are:

Data storage and analysis by standard AdvaInform software packages.

Transfer of data between the IMS and external nodes (computers) on the PlantNetwork.

Support for interaction between application programs and objects in an Advant OCS.

Providing a SQL*Plus Interface for communication with the Advant OCS database anddatabases on host computers.

Development and integration of applications (your own as well as vendor applications)into the Advant OCS.


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IMS Menu

Access to AdvaInform Basic Functions and optional AdvaInformand AdvaBuild functions is provided via the IMS menu, There

are three IMS user levels(categories) associated with the IMS

menu:

Operator

Engineer

System.


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IMS Interface Menu Items


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IMS Interface Menu Items contd.


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MAJOR COMPONENTS OF HISTORY

DATA

SOURCE

DATA

COLLECTION

DATA STORAGE

(HISTORY LOGS)

DATA

PRESENTATION

APPLICATIONS

ARCHIVING


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AdvaInform History

AdvaInform History stores data on disk. Values of Advant OCS objects

from any node in the system can be sampled and stored

Historical storage can be long term on disk or values can be archived to

tape for permanent storage. Tape can be stored off site for an extra level

of security.


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DATA COLLECTION

The Data Collection components samples the data and applies the

stamps to the samples.

Synchronous Collections - the log collects data periodically.

Asynchronous Collections - the Application sends the data to the log

when the data is available.

Data can be manipulated before storage:

Compaction algorithm can be used to save disk space. This is optional

and cannot be used in all cases

Multiple values can be sampled and a mathematical, algorithm

performed on the samples with the result of the calculation being thestored value.


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DATA STORAGE IN HISTORICAL

LOGS

DATA

SOURCE

DATA

COLLECTION

Logs are the basic historical storage item.

Log Capacity

Data Entries

Logs reside on disk.

A log contains data for one specific item such as open loop attribute. A log holds multiple data values with each value being called an entry.

When the Log is full, new entries overwrite the oldest entries.

Each Entry consist of time stamp, a value, and a status


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A log is entirely in one node

A log is a software object.

Logs can be read by SQL Queries employing the AdvainformSQL*Connect software. This allows historical data to be put into

reports or used by other applications.

Logs can be accessed by Advainform User API programs. Programs

can be used to read Values for the logs or they can activate or

deactivate data collections by the log.

DATA STORAGE IN HISTORICAL

LOGS


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NUMERIC LOG

Continuous variables, one log for one variable. For Example, Log$HSFC1000,MEASURE-1-o

REPORT LOG

An executed report, or part of a report if the encapsulation

feature is used.

Message

Alarm, event, and console message.

LOG TYPES


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NUMERIC LOGS

Numeric Values are stored in numeric logs.

Data source for numeric logs:

tag,attribute

TC600,MEASURE

tag-fcm,attribute

LP500-MTH,RESULT

instance,attribute

AI_ONE,value


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Much of historical storage is accomplished by primary

logs. These logs get their directory from a source.

PRIMARY NUMERIC LOGS

FC200,MEASURE

$HSFC200,MEASURE-1-o

Primary Log

Storage Rate:20 Sec'sTime Period :3 hours

Naming convention for logs.


$HS - indicates it is a history object

FC200,MEASURE - Identifies the object that supplies the data

1 - position in the log hierarchy, always 1 for basic primary logs

o - lower case letter oh , original log

r - restored from the archives


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Numeric logs can exist in hierarchies. The hierarchy is

called a composite log.

COMPOSITE NUMERIC LOGS

FC200,MEASURE


Primary Log

Storage Rate:20 Sec's

Time Period :3 hours

Secondary Log



Secondary Log





Primary log gets data from a data source. A secondary log

gets data from another log.


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Storage rate of a secondary log must be a multiple of the

storage rate of its source log.

Each component log of a composite log is an object.

A composite log is assigned an access name with the

History Builder

This access name is defaulted to the object source name.

COMPOSITE NUMERIC LOGS - 2


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One data source or log can provide data for multiple logs

The secondary logs can be in different nodes. This

provides an easy method to configure redundancy.

COMPOSITE NUMERIC LOGS - 3

FC200,MEASURE

Primary Log

Primary Log

FC200,MEASURE

Primary Log

Secondary Log

Secondary Log


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A message log can be produced to store CCF and TCL

alarm and event, console log, and alarm acknowledgment

message.

Only one message log is needed for History in a node.

This is an asynchronous log. Messages are sent to it when

the messages are produced.

MESSAGE LOGS


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Reports can be stored in report log.

Report logs are asynchronous.

You have flexibility in Creating report logs. Among the

options are:

You can send all reports to the same log.

You can make a specific log for each specific report type.

REPORT LOGS


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AdvaInform Reports

AdvaInform Reports is used to generate process reports thatcontain information from any node in the system including historical

information from the IMS database


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Controller Sub System(CSS)


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TYPES OF CSS

SINGLE LOOP CONTROLLER

MOD - 30

MULTILOOP CONTROLLER

C - CONTROLLER

SC - CONTROLLER

AC - 460

AC - 450


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OVERVIEW OF C - CONTROLLER00

SLOT NOS. MODULES

1,3,5 Controllers

2,4,6 I/O Transfer Modules

7 Backup Controller Module

8 I/O Extender Module

9 Backup Memory Module

10,11 D/F Module

12.13.14 I/O Interface Modules

16,17 Bypass Relay Modules

18,19 DCN Interface Modules

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19


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OVERVIEW OF SC CONTROLLER

SLOT NOS. MODULES

1,4,7 Controllers

2,5,8,11 Field Bus Module

3,6,9 I/O Transfer Modules

10 Backup Controller Module

12 I/O Extender Module

13 Backup Memory Module

14,15 D/F Module

16.17.18 ,19 I/O Interface Modules

20,21 Bypass Relay Modules

22,23 DCN Interface Modules

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

16 17 18 19 20 21 22 23


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In C and SC controller sub system following Redundancy

are available

1:1

3:1

11:1

In AC460 controller sub system following Redundancyare available

1:1

CONTROLLER REDUNDACNY


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CONTROLLER INPUT AND OUTPUT

In C - Controller, following I/O combinations are available

(Direct I/Os)

Analog Input - 16

Analog Output - 8

Digital Input/Output - 48

In SC-Controller, following I/O Combinations are available

(Remote I/Os)

Analog Input - 120

Analog Output - 60 Digital Input / Output - 960

Frequency Input - 180

Pulse Input / Output - 180

Thermocouple - 180

CONTROLLER BOOTUP


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CONTROLLER BOOTUP

PRIMARY CONTROLLER MODULE COLD START PROM - Based diagnostics checkout memory,CPU,I/O functionality, etc.

processor is initialized. Output channels are zeroed.

PROM - Based Fundamental communications identifies this module to

the system configurator as being ready for download. System services

package is downloaded. If request by configuration, application packages are downloaded

(CCF,TCL,TLL)

The Control Module enters the AVAILABLE state

ACTIVATE STATE

Control Module goes through startup sequence: Start Runtime Diagnostics

Upload Database to backup memory

Start control Module I/O

Start TCL Runtime

If, While running the above tasks, no h/w, s/w, or other problems are

encountered, the control module enters the ACTIVE State.


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PRIMARY CONTROLLER FAILURE

Failed Controllers outputs are held at last known Value.

Backup Memory knows about the failure within milliseconds

Within Milliseconds, the Following is accomplished:

I/O Transfer relays for failed controller are energized.

Process Output data Values from backup memory are sent to the the

backup controller ( by way of the P-BUS).

Backup Controller output drives are turned on, and failed controller

output drives are turned off

Within 1 to 2 seconds, the following is accomplished:

Database, TCL, and TLL data downloaded from Backup memory to

Backup Controller.

Backup Controller Initializes, then goes from READY to ACTIVE.

The Backup Controller completely assumes the identity of the failed

Controller, including backup memory update.


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PRIMARY CONTROLLER RESTART

Controller replaced (With the power on): Goes through Entire Startup procedure (as explained above).

Enters the READY state, and stays there,

Human decision made at console diagnostic display to SWITCH

BACK Controller:

Backup Controller put into HOLD state for 1-2 Seconds.

Replacement Primary controller receives database from backup

memory.

Database Transfer Complete :

Primary controller outputs turned on and backup controller outputs

turned off.

I/O Transfer relays de-energized.

Primary Controller becomes ACTIVE

Backup Controller enters DOWN state and starts to re-boot


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Taylor Remote I/O (TRIO)

T l R I/O (TRIO)


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Taylor Remote I/O (TRIO)

TRIO for the Advant OCS with MOD 300 Software is a family of

modular,intelligent, and highly reliable process I/O blocks.

TRIO blocks are used to interface field input and output signals to

Multibus Nodes, SC Controller Subsystems, and Advant Controllers.

TRIO blocks can be individually installed on machines, mounted injunction boxes, or grouped in racks and panels. Their small size and

rugged construction are designed to accommodate mounting several

thousand feet from the control system.

Each block has its own communications capability and microprocessor,

and has 6 to 32 circuits for connecting to input and output devices.

Blocks can be connected to the field bus in any sequence, and analog

and digital types can be freely intermixed.

A variety of different blocks are available to meet virtually any process

I/O application requirement.


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Overview of AC460 Controller SubSystem



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THANK U ALL

FROM ,

JAYAPAL A P

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DCS_Overview[1].pp