Report(Part 3)

8/6/2019 Report(Part 3)

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CHAPTER 1

INTRODUCTION

1.1 S IMULATION OF FOUNDATION FIELDBU S DEVICE S

Simulation is the imitation of some r eal thing or pr ocess. The act of simulating something

gene r ally entails r e pr esenting cer tain k ey cha r acte r istics or b ehavio r s of a selected physical or

a bstr act system. Her e thedevices which we simulate ar efor automation indust r y. Simulation is

ver y im por tant in automation indust r y for var ious facto r s lik e:

1. Err or r eduction

2. Economic Efficiency

3. Time Efficiency

4. Per for mance Efficiency

Pr ocess cont r ol is the basic need of the automation indust r y. For pr ocess cont r ol system we

r equi r e field bus devices. The Foundation Field bus devices pr ovide seve r al functionalities lik e

fetching the in put f r om senso r s; mani pulate that in put by diffe r ent algo r ithms acco r ding to

our r equi r ement and finally giving the corr ect out put. So in or der to design an indust r y

successfully the fir st thing we need is to simulate the functionalities of foundation field bus

device. Once the functionalities ar e pr o per ly simulated we can go for the designing diffe r ent

str ategies for pr ocessing and finally give the o ptimum design for efficient work ing of the

indust r y automatically.


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1.2 ABOUT THE ORGANI S ATION

Honey well Inter national, Inc. (NY SE: HON) is a majo r conglome r ate com pany that pr oduces

a var iety of consume r pr oducts, enginee r ing ser vices, and aer os pace systems for a wide

var iety of custome r s, f r om pr ivate consume r s to majo r corpor ations and gove r nments.

Honey well is a For tune 100 com pany with a work for ce of a ppr oximately 128,000, of which

a ppr oximately 58,000 ar e em ployed in the United States. The com pany is headqua r ter ed in

Morr istown, New J er sey. Its curr ent chief executive office r is David M. Cote. The com pany

and its corpor ate pr edecesso r s wer e par t of the Dow J ones Indust r ial Aver age Index f r om

Decem ber 7 , 1925 until Fe br uar y 9, 2008 .

The curr ent "Honey well Inter national Inc." is the pr oduct of a mer ger in which Honey well

Inc. was acqui r ed by the much lar ger AlliedSignal in 1999 . The com pany headqua r ter s wer e

consolidated to AlliedSignal's headqua r ter s in Morr isto wn, New J er sey; however the

com bined com pany chose the name "H oney well" b ecause of its su per ior br and r ecognition.

Honey well has many br ands that consume r s may r ecognize. Some of the most r ecogniza ble

pr oducts ar e its line of home ther mostats (par ticula r ly the iconic r ound ty pe), Garr ett

turbocha r ger s, and automotive pr oducts sold unde r the names of Pr eston, Fr am, and Autolite.

Diver se, ingenious, committed and integ r ated thats Honeywell Technology Solutions Lab

(HTSL) . A p lace wher e technology and peo ple str ik e a per fect balance to delive r unsu rpassed

value to custome r s by pr oviding innovative and total solutions enhancing the comfo r t, safety,

secu r ity, efficiency and r elia bility of the envi r onment they live, tr avel and work . A SE I

CMMI L evel 5 com panies, this is a place wher e commitment to quality and the s pir it of

innovation is intr insic to its cultu r e.


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HTSL believes that to gr ow, one needs to constantly em br ace and ada pt to change. K ee ping

this philoso phy in mind, HTSL has come a long way f r om its ear ly days in 1994 , when

Dr .Kr ishna Mikk ilineni, the Managing Dir ecto r of HTSL led the com pany with a bout half a

dozen peo ple. Fr om being an off-sho r e develo pment cente r , today, HTSL pr ovides value to

Honey well businesses thr ough Pr oduct Solutions & A nalytics, New Pr oduct Intr oduction,

Advanced R esea r ch and Technology and IT & B usiness Pr ocess Solutions. The Pr oduct

Solutions team is su ppor ted by cor e enginee r ing functions lik e Platfo r ms & Solutions

s pecialists, Pr ogr am Management, Pr ocess & B lack B elt, Solutions Assu r ance & ileitis Focus

and Str ategy and Mark et Sensing.

1.3 NEED FOR THE PROJECT

Simulation is needed when we ar e dealing with ver y cr itical pr oduct in which mar gin of err or

is nil. Such an ar ea is automation indust r y. Once the whole design is im plemented it is ver y

difficult to handle any new or unk nown err or . Because of this we fir st work in a simulated

envi r onment to eithe r eliminate the err or else find a way to handle that err or . One of the

advantages of having foundation field bus devices ar e that they ar e easy to maintain.

Simulation of field bus devices ar e needed because of follo wing:

1. Error Reduction: It is much safe r to tr y diffe r ent possi bilities in simulation

envi r onment for o ptimization of design. Final dr aft of the design is made (in

simulation envi r onment ) afte r testing for all possi ble err or s that might occu r in r eal

envi r onment. It hel ps in r educing the err or in indust r y by 99%

2. Profitable: It is much mor e economical to tr y diffe r ent possi bilities in simulation

envi r onment for o ptimized design than in r eal envi r onment. Only the devices needed

acco r ding to the final design ar e pur chased. This saves a lot of money for the

or ganization.


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3. Time Efficiency: It is much faste r to tr y diffe r ent possi bilities in simulation

envi r onment for o ptimization of design.

4. Optimization: By tr ying diffe r ent com binations of str ategy in simulation we can

select the most efficient or o ptimized str ategy for the indust r y and im plement that

dir ectly in r eal envi r onment.

1.4.OBJECTIVE S

y To mak e the automation indust r y err or f r ee in the r eal envi r onment.

y To r educe the cost immensely by im plementing the whole idea in simulation r athe r than

dir ectly in r eal envi r onment.

y To im pr ove the efficiency of the pr oduct by finding the o ptimized in the design.


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CHAPTER 2

LITERATURE REVIEW

2.1 AUTOMATION

Automation is the use of cont r ol systems and info r mation technologies to r educe the need for

human work in the pr oduction of goods and ser vices. In the sco pe of indust r ialization,

automation is a ste p b eyond mechanization. Wher eas mechanization pr ovided human

o per ato r s with machine r y to assist them with the muscula r r equi r ements of work , automation

gr eatly decr eases the need for human senso r y and mental r equi r ements as well. Automation

plays an incr easingly im por tant r ole in the wor ld economy and in daily ex per ience.

Automation has had a nota ble im pact in a wide r ange of indust r ies beyond manufactu r ing

(wher e it began ). Once-u biquitous tele phone o per ato r s have been r e placed lar gely by

automated tele phone switch boar ds and ans wer ing machines. Medical pr ocesses such as

pr imar y scr eening in elect r oca r diog r a phy or r adiog r a phy and la bor ato r y analysis of human

genes, ser a, cells, and tissues ar e carr ied out at much gr eater s peed and accu r acy by

automated systems. In gene r al, automation has been r es ponsi ble for the shift in the wor ld

economy f r om indust r ial jo bs to ser vice jo bs in the 20th and 21st centu r ies.

Automation dur ing the 70's and 80'smayno w b e o bsolete, wor n out, or left without s par es and

su ppor t as manufactu r er s concent r ate on newer pr oducts. Ther efo r e su pplier s of pr ocess lines

and k ey equi pment who must continue to satisfy custome r ex pectations and k ee p p lant u p and

r unning must also develo p har dwar e and soft war e solutions that can mode r nize legacy cont r ol

platfo r ms while k ee ping thei r functionality intact.


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2.1.1 Mechanical Automation

After the indust r ial r evolution mechanical automation came into existence as the need of

massive plants and facto r ies wher e synch r onization and pr ecision of work w er e ver y

im por tant lik e petr ochemical plants. Her e a small human err or may lead to huge losses not

only in ter ms of money but also life. So mechanical automation came into existence wher e

some k inds of ala r ms, audio or visual, wer e used to fulfill the purpose. But still this was not

sufficient with the incr ease in the size of the indust r ies which was gr owing enor mously day

by day.

2.1.2 S oftware Automation

Soft war e indust r y was gr owing par allel to the mechanical indust r y and soon its use and

im plementation wer e found ever ywher e. As the mechanical indust r y was gr owing eno r mous

in size mechanical automation was found sho r t to fulfill its need. So came the evolution of

soft war e automation wher e few num ber s of technical ex per ts can cont r ol and manage the

whole indust r y sitting at one place, in one r oom.

Soft war e automation in the sim plest sense is im plemented by the use of micr ocont r oller s and

a pr ogr am that contains the logic for it. The pr ogr ammed logic tak es car e of the

synch r onization and pr ecision of the work needed to be im plemented. This sim ple

im plementation has gr own with time and one of such is called cont r ol system.

2.2 CONTROL SYS TEM

Contr ol systems execute one or mor e cont r ol functions, which cause the pr ocess to o per ate

within the nor mal o per ating limits. Contr ol functions can be executed manually or


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automatically. Oper ator s su per vise the pr ocess using the cont r ol system inte r face, r es pond to

its indications and ala r ms, and, when necessa r y, use it to act on the pr ocess.

2.2.1

Distributed ControlS

ystem

Within the pr ocess indust r y, cont r ol functions ar e used to achieve pr oduction and pr oduct

quality tar gets, r educe man power r equi r ements, r educe human err or s, and im pr ove pr ocess

u ptime. In the ear ly year s, cont r ol functions wer e mostly pneumatic and wer e physically

mounted on cont r ol valves, I- beams, and the walls of plants, it was tr uly dist r i buted cont r ol in

the field. By the time the fir st dist r i buted cont r ol system (DC S) was intr oduced in the late

1970 s, cont r ol functions had been r elocated into cent r al cont r ol r ooms with thei r long steel

panel boar ds of cont r olle r s, indicato r s, alar m panels, and switches and lights.

Des pite its name, the intr oduction of the DCS actually caused cont r ol to become fur the r

cent r alized by placing multi ple cont r ol functions into one micr o pr ocesso r based cont r olle r ,

thus the r equi r ements for r edundant cont r olle r s was bor n. Today we have digital o pen

cont r ol systems that ar e far mor e r o bust and ca pa ble in ter ms of per for mance and diagnostics

than thei r DC S pr edecesso r s, but that doesnt mean they can be r elied on to per for m cont r ol

and safety functions.

2.2.2 Process Control S ystem

In the ear ly days of pr ocess automation, the pr ocess cont r ol system (PCS) consisted of

pneumatic tr ansmitte r s and cont r oller s thato per ated the cont r ol valve by adjusting its out put

air signal to the positione r on the valve. These pneumaticcont r olle r s wer e used to per for m

r elatively sim ple cont r ol functions. Over time, the PCS evolved into pr ogr amma ble logic

cont r oller s (PLC) and dist r i buted cont r ol systems (DC S), which ar e based on pr ogr amma ble

elect r onic (PE) technology. PE technology br ought an incr eased a bility to execute


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mor econt r ol functions on a single platfo r m. This pr ocessing ca pa bility allowed the

im plementation of statistical pr ocess cont r ol, pr edictive cont r ol algo r ithms, and othe r

advanced cont r ol techniques, r esulting intr emendous pr oductivity and quality im pr ovements.

The integ r ity of the PCS har dwar e has steadily im pr oved over the year s with incr eased

inte r naldiagnostics allowing these systems to be configu r ed to o btain the desi r ed pr ocess

r elia bility. The ca pa bilityto im plement r edundant com ponents thr oughout the system,

including in put/out put modules and main pr ocesso r s, has fur ther enhanced r elia bility.

Extensive inte r nal and exte r nal diagnostics have also beeninco rpor ated into the field device

design, pr oviding mor e r a pid fault detection.

Today, most pr ocess units ar e highly de pendent on automated cont r ol systems. Oper ator s r ely

on the PCS and its o per ato r inte r face for pr ocess info r mation dur ing nor mal o per ation, for

alar ms dur ing pr ocess excu r sions, and for tr ou bleshooting pr ocess cont r ol pr o blems. The PCS

is now so s pecializedthat ty pically only a few site per sonnel ar e k nowledgea ble in the cont r ol

system design details and ar er es ponsi ble for im plementing solutions to o ptimize the PCS in

or der to gar ner im pr ovements in quality, pr oduction, and cost. PCS technology pr ovides

significant benefits with its ca pa bilities and flexi bility, but italso intr oduces new and mor e

com plex failu r es. This cr eates an envi r onment wher e, if administ r ative cont r ols ar e not in

place, the PCS exists in an almost endless state of flux wher e cont r ol loo ps ar er outinely

placed in manual mode, alar ms ar e disa bled or r eset by o per ator s based on per sonal choice,

and pr ocess cont r ol s pecialists im plement the newest in cont r ol algo r ithms while the pr ocess

unit is ino per ation.

2.2.3 Foundation Fieldbus Devices

Automation is the use of cont r ol systems and info r mation technologies to r educe the need for

human work in the pr oduction of goods and ser vices. A com plex automated indust r ial


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system- such as a manufactu r ing assem bly line -usually needs an or ganized hier ar chy of

cont r oller systems to function. In this hier ar chy ther e is usually a Human Machine Inter face

(HMI) at the to p, wher e an o per ato r can monito r or o per ate the system. This is ty pically

link ed to a middle laye r of pr ogr amma ble logic cont r oller s (PLC) via a non-time-c r itical

communications system (e.g. Ethe r net). At the bottom of the cont r ol chain is the f ieldbus

which link s the PLCs to the com ponents which actually do the work such as senso r s,

actuato r s, elect r ic moto r s, console lights, switches, valves and contacto r s.

Foundation Fieldbus is an all-digital, ser ial, two-way communications system that ser ves as

the base-level network in a plant or facto r y automation envi r onment. It is an o pen

ar chitectu r e, develo ped and administe r ed by the Field bus Foundation.

It's tar geted for a pplications using basic and advanced r egulato r y cont r ol, and for much of the

disc r ete cont r ol associated with those functions. Foundation field bus technology is mostly

used in pr ocess indust r ies, but nowadays it is being im plemented in powerplants also.

This pr oject aims to simulate the foundation field bus devices by develo ping the functional

bloc k s of those devices in the simulated envi r onment.


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CHAPTER 3

S OFTWARE AND HARDWARE REQUIREMENT S ANDS PECIFICATION

3.1 S OFTWARE REQUIREMENT S

Oper ating System : Windo ws Ser ver 2008

DBM S : MySQ L

IDE : Micr osoft Visual Studio 2008

Other : Ex per ion PK S (Honey wells)

3.2 HARDWARE REQUIREMENT S

Pr ocesso r /RAM /HDD : Intel Pentium 4 or a bove/ 1GB RAM /80 GB H ar d Disk

3.3.FUNCTIONAL S PECIFICATION

The functional s pecifications for the functional bloc k s ar e pr ovided by Fieldbus Foundation

Organization .The Field bus Foundation is a glo bal not-fo r - pr ofit corpor ation consisting of

leading pr ocess end user s and automation com panies. The functional s pecification of the

function bloc k s which I develo ped ar e as follo ws.

3.3.1 Output S plitter Block

The out put s plitter bloc k pr ovides the ca pa bility to dr ive two cont r ol out puts f r om a single

in put. Each out put is a linea r function of some por tion of the in put. Back calculation su ppor t

is pr ovided using the same linea r function in r ever se. Cascade initialization is su ppor ted by

adecision ta ble for com binations of in put and out put conditions.


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This bloc k w ould nor mally be used in s plit r anging or sequencing of multi ple valve

a pplications. A ty pical s plit r ange a pplication has bothvalves closed when the s plitte r in put is

50% . One valve o pens fully as the in put dr o ps to 0%. The othe r valve o pens as the in put r ises

a bove50% . A ty pical sequencing a pplication has both valves closed at 0% in put. One valve

o pens fully as the in put r ises to 50%, and the othe r stays shut. The second valve o pens as the

in put r ises a bove 50% , and the fir st valve may r emain o pen or shut off quic k ly.

Because this bloc k is in the cont r ol path, it is a ble to pass limit and cascade initialization

info r mation back to the u pstr eam block . Fig 3.3.1.1 shows out put s plitter b loc k .

Fig 3.3.1.1 O ut put S plitte r

The r elationshi p of each out put to the in put may be defined by a line. Each line may be

defined by its end points. Exam ples of gr a phical r e pr esentations of OUT_1 and OUT_2 vs. SP

ar e shown below in figu r e 3.3.1.2 for a s plit r ange and a sequencing a pplication.


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Fig 3.3.1.2Gr a phical R e pr esentations of OUT_1 and OUT_2 vs. SP

Ther e is no limiting a pplied to the SP. The SP may be used in Auto modefo r testing. The

o per ato r would use the out put of the PID to accom plish the same purpose. Each downstr eam

bloc k can be tak en out ofcascade if it becomes necessa r y to gain cont r ol of them.

The exam ples shown do not show the full r ange of possi bilities. The lines could over la p lik e

an X, or both star t f r om the or igin but havediffe r ent slo pes. The end points do not have to lie

within 0-100% . Limits in the exte r nal bloc k s may affect the useful r ange of a line. Unitsof

per cent ar e used in the exam ples because the common a pplication of this bloc k is to valves,

but any units may be used to suit thea pplication.

The follo wing par amete r s may be used to s pecify the out put s plitte r o per ation:

X11 , Y11 , X12 , Y12

X21 , Y21 , X22 , Y22

Wher e Xnj is the value of SP associated with OUT_ n and Xn1 and Xn2 r efer to the 1st and

2nd coo r dinates of the nth cur ve r es pectively. Ynjis the value of OUT_ n and Yn1 and Yn2

r efer to the 1st and 2nd coo r dinates of the nth cur ve r es pectively.


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Fig 3.3.1.3 IN_ARRAY & OUT_ARRAY

By s pecifying the coo r dinates as shown in figu r e 3.3.1.3, the end points of the lines ar e

defined. Thecontents of the r es pective Xs ar e held in theIN_ARRAY p ar amete r and the

contents of the r es pective Ys ar e held in the OUT_ARRAY p ar amete r . If a set of points ar e

s pecified suchthat a r egion of the in put r ange is not s pecified, then the corr es ponding OUT_ n

may be set to the closest end point of the in put value, eithe r high or low, when the s pecified

r egion is exceeded. A configu r ation err or shall be set in BLOCK_ ERR and the actual mode of

the block shall go to Out of Ser vice if the X values have any ofthe follo wing conditions: X21

< X11 , X12


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OUT_1 may bedete r mined by the LOCKVAL setting. If X12 < X , OUT_1 may be

dete r mined by the LOCKVAL setting.

In the figur e 3.3.1.4 LOCKVAL = tr ue:

Fig 3.3.1.4 OUT w ith LOCKVAL Tr ue

In figu r e 3.3.1.5 LOCKVAL = false:

Fig 3.3.1.5 OUT w ith LOCKVAL F alse


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Conside r the configu r ation in figu r e 3.3.1.6

Fig 3.3.1.6 OUT PUT SPLITT ER C onfigu r ation

Wher e:P ID1 = Up str eam dr iving cont r oller , S plitte r = S plit r ange function bloc k being

desc r i bed, AO = R eceive r of OUT_1 for 0 -50% r ange of SP, PID2 = R eceive r of OUT_2 for

50-100% r ange of SP

CAS _IN of the S plitter r eceives the OUT of PID1 . BKCAL_IN of PID1 r eceives

BKCAL_OUT of the S plitter . CAS _IN of the AOr eceives OUT_1 of the S plitter and PID2

r eceives OUT_2 of the S plitte r . BKCAL_IN_1 of the S plitter r eceives BKCAL_OUT of the

AOand BKCAL_IN_2 of the S plitter r eceives BKCAL_OUT of PID2 .

The s plitter r equi r es s pecial handling for cascade initialization because it has two inde pendent

out puts. When a downst r eam block indicatesto the s plitte r that it wants to initialize, by

asse r ting IR ( initialization r equest ) on its BKCAL_OUT , one of two things shall ha ppen.

Under some cir cumstances, it is possi ble to pass an initialization r equest f r om a downst r eam

bloc k back u p to the bloc k u pstr eam of the s plitter ,so that all thr ee bloc k s balance for

bum pless tr ansfe r to cascade mode. Otherwise, the r equested s plitter out put shall go to the

r equestedvalue by placing an inte r nal offset between that out put and the out put of the cur ve,

and then r am ping that offset to zer o in BAL_TIM Eseconds afte r the cascade is made u p.


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The s plitter nor mally r uns with both out puts connected to block s in cascade mode. If one or

both of the bloc k s is not in cascade mode,s pecial limiting action shall be tak en. S pecifically,

if one bloc k indicates that it is not in cascade by NI ( not invited ) status on itsBKCAL_OUT ,

then the BKCAL_OUT of the s plitte r shall asse r t limits at the r ange extr emes of the bloc k

that is still in cascade mode.Even if the u pstr eam cont r oller does not want to o per ate in that

r ange, ther e should be no r eset windu p w hen it can move into the r ange. If both downst r eam

bloc k s show NI , then the s plitte r can only wait until one of them r equests cascade

initialization. BKCAL_OUT of thes plitte r can hold the u pstr eam block at the value of the SP.

The actual mode shall be IMan.

When cascade initialization is r equested, by IR su bstatus on a BKCAL_IN , it is fir st

necessa r y to dete r mine if the othe r BKCAL_IN has NIsu bstatus. If so, the value at the

BKCAL_IN asse r ting IR is tak en as the Y value for its cur ve, and the r esulting X value is

sent onBKCAL_OUT to PID1 . If the othe r su bstatus is OK , then the inte r nal offset and

BAL_TIM E shall be used. If both bloc k s have IR su bstatus, then one out put shall be

pr ocessed until its cascade is closed. The choice is based on the pr esence of limit status in

BKCAL_IN .If BKCAL_IN_1 is limited, then if BKCAL_IN_2 is not limited then OUT_2 is

pr ocessed fir st, else OUT_1 is pr ocessed fir st.Cascade initialization is also r equi r ed when the

bloc k tr ansitions f r om Auto to Cas mode.

The BKCAL_OUT status shall show limited high if an incr ease in SP cannot be effectively

passed on to eithe r out put because theBKCAL_IN_ n of both out puts indicates that a move in

the needed dir ection is limited. Simila r ly, limited low shall be set if a decr ease inSP cannot be

effectively passed on to eithe r out put. The slo pe of the limited line(s) affects the limit

dir ection. BKCAL_OUT shall alsosho w limit status at the X extr emes X11 and X22 .


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Su b-status values r eceived at CAS _IN shall be passed to both out puts, exce pt for those used

in the cascade handsha k e. IFS shall go to both out puts. The status o ption IFS if Bad CAS _IN

is availa ble.

If the status Option to Pr o pagate Fault Backwar d is selected in the out put bloc k s downstr eam

of the s plitter block , then the s plitte r block shall pr o pagate the BKCAL_IN status of Bad,

Device failu r e or G ood Cascade, Fault State Active or Local Overr ide only if the status

of both BKCAL_IN s contain a pr o pagated fault status.

MODE S S UPPORTED: OOS, IMAN , AUTO & CA S

3.3.2 Multiple Discrete Input Block

The MDI b loc k mak es availa ble for the FF net work eight disc r ete var ia bles of the I/O

su bsystem thr ough its eight out put par amete r sOUT_D1 /8. Fig 3.3.2.1 show multi ple disc r ete

in put bloc k .

Fig 3.3.2.1 M ulti ple Discr ete In put

The multi ple disc r ete in put (MDI) function bloc k pr ocesses multi ple disc r ete in put f r om field

device and mak es them availa ble to othe r function block s at its out put (OUT_D1 /8). Channel

num ber is used to select the measu r ement value. Figur e a bove illust r ates the pr ima r y in puts

and out puts of the MDI function block .


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The MDI b lock su ppor ts standa r d block ala r ms, status calculation, and mode cont r ol. In

Automatic mode, bloc k s each out put par amete r (OUT_D x) shows value and status. In

Manual mode, OUT_D x may be set manually. The Manual mode is r eflected on the out put

status.

When setting u p the MDI b lock , channel must be set to a valid value. This ensu r es that the

bloc k leaves OOS mode and goes to assigned tar get mode.

Under nor mal conditions, a Good: Non- Cascade status is passed thr ough to OUT_D x. Status

indication in the OUT_D x out put par amete r s de pends on the I/O su bsystem and the

tr ansduce r bloc k , that is manufactu r er s pecific. The block also su ppor ts the Status Action on

Failu r e and BLOCK_ ERR indications. When the bloc k is set to Manual mode, OUT_D x is

set to Good: Noncascade, Constant status.

Status indication in the OUT_D x out put par amete r s de pends on the I/O su bsystem and the

tr ansduce r b loc k , that is manufactu r er s pecific. For exam ple, if ther e is individual detection of

senso r failu r e, it can be indicated in the status of r elated OUT_D x par amete r . Pr o blem in

theinte r face to the I/O su bsystem can be indicated in the status of all OUT_D x as BAD

Device Failur e.

A b loc k ala r m will be gene r ated wheneve r the BLOCK_ ERR has an err or b it set.

S UPPORTED MODE S : OOS, MAN & AUTO

3.3.3 Multiple Analog Input Block

The MAI b lock mak es availa ble for the FF network eight analog var ia bles of the I/O

su bsystem thr ough its eight out put par amete r s OUT_1 /8, whose values must be ex pr essed in

enginee r ing units. Fig 3.3.3.1 shows multi ple analog in put bloc k .


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Fig 3.3.3.1 M ulti ple Analog In put

The multi ple analog in put (MAI) function bloc k pr ocesses multi ple analog in put f r om field

device and mak es them availa ble to othe r function bloc k s at its out put (OUT_1 /8). Channel

num ber is used to select the measu r ement value. Figur e a bove illust r ates the pr ima r y in puts

and out puts of the MAI function block .

The MAI b lock su ppor ts standa r d block ala r ms, status calculation, and mode cont r ol. In

Automatic mode, bloc k s each out put par amete r (OUT_ x) shows value and status. In Manual

mode, OUT_ x may be set manually. The Manual mode is r eflected on the out put status.

When setting u p the MAI b lock , channel must be set to a valid value. This ensu r es that the

bloc k leaves OOS mode and goes to assigned tar get mode.

Under nor mal conditions, a Good: Non- Cascade status is passed thr ough to OUT_ x. Status

indication in the OUT_ x out put par amete r s de pends on the I/O su bsystem and the tr ansduce r

bloc k , that is manufactu r er s pecific. The bloc k also su ppor ts the Status Action on Failu r e and

BLOCK_ ERR indications. When the bloc k is set to Manual mode, OUT_ x is set to Good:

Noncascade, Constant status.

Status indication in the OUT_ x out put par amete r s de pends on the I/O su bsystem and the

tr ansduce r b loc k , that is manufactu r er s pecific. For exam ple, if ther e is individual detection of


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senso r failu r e, it can be indicated in the status of r elated OUT_ x par amete r . Pr o blem in

theinte r face to the I/O su bsystem can be indicated in the status of all OUT_ x as BAD

Device Failur e.

A b loc k ala r m will be gene r ated wheneve r the BLOCK_ ERR has an err or b it set.


3.3.4 Arithmetic Block

The Ar ithmetic functional bloc k is intended for use in calculating measu r ements by

com binations of signals f r om senso r s to give out put for desi r ed ar ithmetic function. Fig

3.3.4.1 show multi ple analog out put block .

Fig 3.3.4.1 Ar ithmetic

This block is designed to per mit sim ple use of po pular measu r ement math functions. The use r

does not have to k now how to wr ite equations. The math algo r ithm is selected by name,

chosen by the use r for the function to be done.


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The follo wing algo r ithms ar e availa ble:

1. Flow com pensation, linea r .

2. Flow com pensation, squa r e r oot.

3. Flow com pensation, a ppr oximate.

4. BTU flow.

5. Tr aditional Multi ply Divide.

6. Aver age.

7. Tr aditional Summe r .

8. Four th or der p olynomial.

9. Four th or der p olynomial based on PV

10. Sim ple HTG com pensated level.

Figur e 3.3.4.2 gives a pictor ial idea of the over all algo r ithm of Ar ithmetic block :

Fig 3.3.4.2 Schematic diag r am of Ar ithmetic

IN and IN_LO in puts ar e dedicated to a r ange extension function that r esults in a PV, with

status r eflecting the in put in use. The r ange extension function has a gr aduated tr ansfe r ,


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cont r olled by two constants r efer enced to IN. An inte r nal value, g, is zer o for IN less than

RANG E _LO . It is one when IN is gr eate r than R ange _HI . It is inte rpolated f r om zer o to one

over the r ange of RANG E _LO to RANG E _HI . The equation for PV follo ws:

PV = g * IN + (1 g) * IN_LO (3.1)

If the status of IN_LO is unusa ble and IN is usa ble and gr eate r than RANG E _LO , then g

should be set to one. If the status of IN is unusa ble, and IN_LO is usa ble and less than

RANG E _HI , then g should be set to zer o. In each case the PV should have a status of Good

until the condition no longe r a pplies. Otherwise, the status of IN_LO is used for PV if g is

less than 0.5, while IN is used for g gr eater than or equal to 0.5.

Bloc k has 5 in puts: IN. IN_LO , IN_1 , IN_2 and IN_3 . Out of these 5 in puts thr ee in puts

IN_1 , IN_2 and IN_3 ar e auxilia r y in puts. These thr ee in puts ar e com bined with PV in a

selection of four th ter m math functions that have been found useful in a var iety of

measu r ements.

Six constants ar e used for the thr ee auxilia r y in puts. Each has a BIA S _IN_ i and a

GAIN_IN_ i. Her e the bias is added and then sum is multi plied by gain. The r esult is an

inte r nal value called t _ i in the function equations. The equation for each auxilia r y in put is the

follo wing:

t_i = (IN_i + BI AS_IN_i) * G A IN_IN_i (3.2)

The ten diffe r ent mathematical algo r ithms ar e defined as follo ws:

1. Flow com pensation, linea r . Used for density com pensation of volume flow.

f unc = f * PV (3.3)

f = t_1 / t_2 [limited] (3.4)


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2. Flow com pensation, squa r e r oot. Usually, IN_1 is pr essu r e, IN_2 tem per atur e, and

IN_3 is the com pr essi bility facto r Z .

f unc = f * PV (3.5)

f = sqrt (t_1 / t_2 / t_3) [limited] (3.6)

3. Flow com pensation a ppr oximate. Both IN_2 and IN_3 w ould be connected to the

same tem per atu r e.

f unc = f * PV (3.7)

f = sqrt (t_1 * t_2 * t_3 * t_3) [limited] (3.8)

4. BTU flow, wher e IN_1 is inlet tem per atu r e, and IN_2 the outlet tem per atu r e.

f unc = f * PV (3.9)

f = (t_1 - t_2) [limited] (3.10)

5. Tr aditional Multi ply Divide.

f unc = f * PV (3.11)

f = (t_1 / t_2) + t_3 [limited] (3.12)

6. Aver age.

f unc = ( PV + t_1 + t_2 + t_3) / f (3.13)

wher e, f = num ber of in puts used in com putation (unusa ble in puts ar e not used ).

7. Tr aditional Summe r .

f unc = PV + t_1 + t_2 + t_3 (3.14)

8. Four th or der p olynomial. All in puts exce pt IN_LO ar e link ed togethe r .


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f unc = PV + t_1 ** 2 + t_2 ** 3 + t_3 ** 4 (3.15)

9. Four th or der polynomial based on PV

f unc = PV + G A IN_IN_1*( PV **2) + G A IN_IN_2*( PV **3) +

G A IN_IN_3*( PV ** 4) (3.16)

10. Sim ple HTG com pensated level, wher e PV is the tank base pr essu r e, IN_1 is the to p

pr essu r e, and IN_2 is the density corr ection pr essu r e, and GAIN is the height of the

density ta p.

f unc = ( PV -t_1) / ( PV - t_2) (3.17)

Difficulties with the function, such as division by zer o and r oots of negative num ber s, should

be handled gr acefully:

1. Division by zer o should pr oduce a lar ge num ber of the pr o per sign. Infinity cannot be

used, as it has a s pecial meaning for unused limits. So we can use COM P _HI_LIM .

2. R oots of negative num ber s should pr oduce the r oot of the a bsolute value, with a

negative sign.

After the value of func is calculated, it is multi plied by GAIN , and then BIAS is added to the

r esult. Finally, high and low out put limits ar e a pplied, and the r esult is the ter m PR E _OUT . If

the mode is Auto, PR E _OUT b ecomes OUT .

The algo r ithm shall neve r change the mode, even when in puts go bad. The out put of the

calculation function shall always be dis played in PR E _OUT . If the mode is Auto, PR E _OUT

becomes OUT .



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3.3.5 Multiple Discrete Output Block

The MULTI PLE DISCR ETE OUT PUT (MDO) b loc k mak es availa ble to the I/O su bsystem

its eight in put par amete r s IN_D1 /8. Fig 3.3.6.1 shows multi ple disc r ete out put bloc k .

Fig 3.3.5.1 M ulti ple Discr ete Out put

The Multi ple Discr ete Out put (MDO) function bloc k pr ocesses disc r ete in put values and if

any of the in put is in fault state besides a delay time it holds pr eset values for each point.

This function block k ee ps the fault state featu r es s pecified for the DO b lock . It includes

o ption to hold the last value or a pr eset value whenin Fault State, individual pr eset values for

each point, besides a delay time to go into the Fault State.

The actual mode will be LO only due to the r esou r ce bloc k ( SET_F STAT E par amete r). If an

in put par amete r has a bad status, that par amete r will be in Fault State, but the mode

calculation of the block will not be affected.Standa r d tr ansition is in and out of OOS.

The par amete r , FSTAT E _ STATU S, shows that points ar e in Fault State.

The MDO b loc k does not su ppor t back calculation, or the Cas mode.

S UPPORTED MODE S : OOS, LO & AUTO


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3.3.6 Multiple Analog Output

The MULTI PLE ANALOG OUT PUT (MAO) b lock mak es availa ble to the I/O su bsystem its

eight in put par amete r s IN_1 /8. Fig 3.3.6.1 shows multi ple analog out put block .

Fig 3.3.6.1 M ulti ple Analog Out put

The Multi ple Analog Out put (MAO) function block pr ocesses analog in put values and if any

of the in put is in fault state besides a delay time it holds pr eset values for each point.

This function block k ee ps the fault state featu r es s pecified for the AO b lock . It includes

o ption to hold the last value or a pr eset value whenin Fault State, individual pr eset values for

each point, besides a delay time to go into the Fault State.

The actual mode will be LO only due to the r esou r ce bloc k ( SET_F STAT E par amete r). If an

in put par amete r has a bad status, that par amete r will be in Fault State, but the mode

calculation of the block will not be affected.

The FSTAT E _ STATU S par amete r shows that points ar e in Fault State.

The MAO b loc k does not su pp or t back calculation, or the CAS mode.

S UPPORTED MODE S : OOS, LO & AUTO


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CHAPTER 4

DE S IGN PHA S E

In Soft war e Enginee r ing a c lass diagram desc r i bes the str uctu r e of the system by showing its

attr i butes and o per ations (or methods ). Follo wing ar e the class diag r am of each bloc k that I

have develo ped:

4.1 OUTPUT S PLITTER BLOCK

Fig 4.1.1 O ut put S plitter C lass


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4.2 MULTIPLE DI S CRETE INPUT BLOCK

Fig 4.2.1 MDI C lass


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4.3 MULTIPLE ANALOG INPUT BLOCK

Fig 4.3.1 MAI C lass


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4.4 ARITHMETIC BLOCK

Fig 4.4.1 Ar ithmetic Class


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4.5 MULTIPLE DI S CRETE OUTPUT BLOCK

Fig 4.5.1 MDO C lass


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4.6 MULTIPLE ANALOG OUTPUT BLOCK

Fig 4.6.1 MAO C lass


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CHAP TE

P LE E T A T

Fi 5.1SI MFFD Imp l men t ti n


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As you can see in the Fig 5.1 the or der of execution is FIM LINK CM . Fir st the FIM is

loaded which in tur n activates the LINK . After that the Contr ol Module (CM) w hich we want

to execute is loaded.

Field Inter face Module (FIM) as the name im plies is an inter face module between the field,

wher e devices ar e located, and the Human Machine Inter face (HMI) w her e we cont r ol and

analyze the work ing of the system. These FIM have link s on which the cont r olle r s and the

devices ar e connected.

A C ontr ol Module (CM) contains the str ategy which is com bination of diffe r ent functional

bloc k s. The str ategies ar e logics made acco r ding to the tas k w e want to per for m. Figur e 5.2

shows how com bination of functional bloc k s mak es a str ategy:

Fig 5.2 A Str ategy


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The functional bloc k s that ar e par t of a str ategy is tak en f r om the devices attached to the same

LINK on which the CM of that str ategy is pr esent. It is ver y im por tant for corr ect execution

that devices and the CM using functional f r om those devices ar e pr esent on the same link .

A device contains diffe r ent functional bloc k s. The selection of functional bloc k s pr esent

inside a device is totally u p to the manufactu r er of that device. So any functional bloc k s can

be com bined to manufactu r e a device. But it is always logical to select those functional

bloc k s whose com bination may fulfill a purpose.

Now w hen a CM is loaded, initialization of the all the functional bloc k s occu r . Initialization

ha ppens only once dur ing the execution cycle.

After the CM is loaded execution of functional bloc k s star t. The execution of functional

bloc k is per iodic and ha ppens after a fix per iod of time s pecified dur ing configu r ation of CM.

Figur e 5.3 shows the Execution per iod of a CM.

Fig 5.3 Execution Per iod in CM


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The execution time may be br ok en into thr ee ste ps:

1. Pr e- pr ocessing - sna p of par amete r values.

2. Execution - Function block out puts ar e dete r mined.

3. Post- pr ocessing - Bloc k out put values, alar m and associated tr end par amete r s ar e u pdated.

This is shown in figu r e 5.4. It is im por tant that the in put par amete r values used in a function

bloc k not change dur ing execution. Also, the out puts it pr ovides to othe r function bloc k s must

be time coincident. To su ppor t this, a co py of the in put par amete r s will be ca ptur ed, or

sna pped, at the beginning ofexecution and the block out put values will be u pdated only at the

com pletion of function block execution.

Fig 5.4Ste ps of Execution Time

When the execution of a functional block star ts fir st the GetVar() and Sto r eVar() functions of

the corr es ponding functional bloc k class (mentioned in the class diag r am ) ar e executed to

fetch the values r equi r ed by the bloc k s var ia ble. After this the values of the par amete r s ar e

fixed for the execution of the algo r ithm for that par ticula r time. Since the bloc k s ar e executed


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per iodically, if the value of any par amete r changes it will be r eflected in the next execution of

that functional bloc k .

Now the block algo r ithm execution will star t. Once the values ar e fetched to the bloc k they

need to be validated, so a wr ite _ handle r() function is called. This function validates only

those var ia blesfo r w hich the value is fetched. For Eg: If we have a boolean var ia ble then we

need to validate that the value fetched is eithe r 0 or 1 . Simila r ly if a var ia ble is su pposed to

tak e values f r om 1-9 then we mak e sur e that no othe r valua ble is acce pta ble out of this r ange.

If the value ente r ed is not acce pta ble an err or message should be dis played.

Once the values ar e validated we can execute the algo r ithm fur ther for that functional bloc k .

Now w e chec k for the mode in which the bloc k w ill be executing. All bloc k s have a mode

par amete r , which dete r mines the sou r ce of the data to be used for the block . All block s must

per mit the Out of Ser vice (OO S) mode. To be useful, a bloc k must su ppor t at least one othe r

mode.

The per mitted modes a pply to the tar get mode. A wr ite r equest to the tar get mode will be

r ejected if it does not match the per mitted list. Aconfigu r ation device must not allow a mode

to be per mitted that is not su ppor ted. The actual mode is not const r ained by the

per mittedmode, because some modes ar e r equi r ed for initialization.

Diffe r ent ty pes of modes ar e:

1. Out of Ser vice (OO S) T his mode sto ps the execution of the bloc k . When the mode

is changed to any othe r mode it will r esume the execution of the bloc k acco r ding to

the algo r ithm.

2. Local Overr ide (LO) T his mode is set when ther e is fault in the har dwar e of the

system.


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3. Initialization Manual (IMAN) T his mode is set when the tar get mode is not

r eacha ble because of some bloc k configu r ation err or .

4. Manual (MAN) T his mode is set when the user wants to give the out put dir ectly to

the next bloc k . This mode is chosen mostly when we want to give cer tain value as

in put for pr ocessing to the next bloc k .

5. Automatic (AUTO) I n this mode the algo r ithm is executed as intended, without any

err or or interr u ption by the user .

6. Cascade (CA S) T his mode is used when the bloc k is de pendent on the status of

out puts of othe r block s to which it is connected.

After this ste p the in put par amete r ar e pr ocessed acco r ding to the functionality of that bloc k

and then we get the out put of that bloc k .

After the execution of algo r ithm ther e is post- pr ocessing of functional block in which the

out put value with its status is made availa ble to the next bloc k . Along with this ala r m

par amete r s ar e also activated if needed. For Eg: If we set the limit of out put 100 as HI or 200

is HI_HI then corr es ponding ala r m will be set in the bloc k . Figur e 5.5 shows diffe r ent alar ms

and it pr o per ties.

Fig 5.5 A lar ms

Following figu r e 5.6 shows the flow of execution of common functions in a functional bloc k .


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Fi 5. F l w of Execu tion


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CHAPTER 6

TE S TING

The purpose of testing is to discove r err or s. Testing is the pr ocess of tr ying to discove r ever y

conceiva ble fault or w eak ness in a work pr oduct. It pr ovides a way to chec k the functionality

of com ponents, su b assem blies, assem blies and/o r a finished pr oduct. It is the pr ocess of

exer cising the code develo ped with the intent of ensu r ing that it meets the r equi r ements and

use r ex pectations and does not fail in an unacce pta ble manne r .

6.1 UNIT TE S TING

Unit testing involves the design of test cases that validate that the inter nal pr ogr am logic is

functioning pr o per ly, and that pr ogr am in puts that pr oduce valid out puts. All decision

br anches and inte r nal code flow should be validated. It is the testing of individual soft war e

units of the a pplication. It is done after the com pletion of an individual unit befor e

integ r ation. This is a str uctu r al testing, that r elies on k nowledge of its const r uction and is

invasive. Unit tests per for m basic tests at com ponent level and test a s pecific business

pr ocess, a pplication, and/o r system configu r ation. Unit tests ensu r e that each unique path of a

business pr ocess per for ms accu r ately to the documented s pecifications and contains clea r ly

defined in puts and ex pected r esults.


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6.2 TE S T CA S E S

Following figu r es show the test cases of functional block s develo ped:

6.2.1 Output S plitter Block

Fig 6.2.1.1 O ut put S plitte r T est Cases (i)

Fig 6.2.1.2 O ut put S plitte r T est Cases (ii)


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Fig 6.2.1.3 O ut put S plitte r T est Cases (iii)

6.2.2 Multiple Discrete Input Block

Fig 6.2.2.1 MDI T est Cases

6.2.3 Multiple Analog Input Block

Fig 6.2.3.1 MAI T est Cases


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6.2.4 Arithmetic Block

Fig 6.2.4.1 Ar ithmetic Test Cases (i)

Fig 6.2.4.2 Ar ithmetic Test Cases (ii)


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Fig 6.2.4.3 Ar ithmetic Test Cases (iii)

6.2.5 Multiple Discrete Output Block

Fig 6.2.5.1 MDO T est Cases


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6.2.6 Multiple Analog Output Block

Fig 6.2.6.1 MAO T est Cases


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CHAPTER 7

FUTURE S COPE OF PROJECT

This pr oject is curr ently develo ping inde pendent functional bloc k s in simulation envi r onment

for foundation field bus devices. This develo pment in futu r e can be used for designing and

develo ping in r eal envi r onment.

We can tr y and mak e it mor e time efficient in futu r e by a ble to do fast installation of

foundation field bus devices as com par e to now.It means we should be a ble to do the testing

and then dir ectly por t to the r eal time envi r onment. We k now the fact that err or r eduction by

this is near ly 99% . In futu r e we can tr y and eliminate ever y possi bility of err or and mak e it

100% err or f r ee, thus mak ing it mor e r elia ble than ever .

As per the mark et ther e is huge mark et for o per ator tr aining. Curr ently the com pany itself

pr ovides o per ator to the custome r . In futu r e we should be a ble to pr ovide tr aining se par ately.

One of the majo r enhancements that can be done is maintenance. As per foundation field bus

devices ar e conside r ed, they need ver y much maintenance which is one the majo r r eason of

using them in indust r y. But we need to pr ovide better maintenance for the whole system. This

is one the ar ea which will be beneficial to o per ato r .


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CHAPTER 8

CONCLU S ION

This pr oject has cr eated a way to simulate the enti r e pr ocess which will be used in r eal

envi r onment in futu r e. The main advantage with this is that the systemis o ptimized. Not only

this, but also the out puts her ear e mor e accu r ate as the err or s ar e r educed to almost nil (99%) .

It is economically mor e efficient and saves loads of time.

The building of the diffe r ent functional block s is carr ied out inde pendently which hel ps

vendo r s to com bine these functional block s as per the need of client. The tr ansition f r om

simulated envi r onment to r eal envi r onment is made ver y r elia ble and efficient.

The develo pment of inde pendent functional bloc k s is an iter ative pr ocess. After each

develo pment the bloc k s ar e sent for r evie ws and testing. The block s have to pass all the

integ r ation testing wher e it is com bined with othe r bloc k s to chec k for err or f r ee execution.

The bloc k s may be r egula r ly sent to the develo per s in case of any err or s.

The only question which needs to be as k ed is with r ega r d to maintenance of the systemin the

r eal envi r onment which is a ver y challenging tas k .


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CHAPTER 9

BIBLIOGRAPH Y ANDREFERENCE S

1. Vanisri S athyanarayan andS achinPargi, simulation o f f ield devices, f unctional

speci f ications, ver sion 1.1, Honey well Technology Solutions La b .

2. S hashi Kumar M. Kolavi and Vanisri S athyanarayan, simulation o f f ield devices,

So f tware maintenance document, ver sion 1.3, Honey well Technology Solutions La b.

3. Ratnakar Nawathe, P lant Inter f ace, f unctional speci f ication, ver sion 0.1,Honey well

Technology Solutions La b.

4. Angela S ummers , The Evolution o f P lant Automation, Control Global, SIS-TECH

Solutions.

Documents

Report(Part 3)