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Basics on what is DCS and who are the manufacturers of this technology
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DCS EVOLUTIONDCS EVOLUTION--CENTRALISED CONTROLCENTRALISED CONTROL
DCS EVOLUTIONDCS EVOLUTION--DISTRIBUTED CONTROLDISTRIBUTED CONTROL
DCS EVOLUTIONDCS EVOLUTION--FIELDBUS CONTROLFIELDBUS CONTROL
DCS EVOLUTIONDCS EVOLUTION-- WEB CONTROLWEB CONTROL
DCS EVOLUTIONDCS EVOLUTION--WEB CONTROL APPLICATIONWEB CONTROL APPLICATION
ABB DCS ARCITECTUREABB DCS ARCITECTURE
ABB DCS HARDWAREABB DCS HARDWARE
CONTROL SYSTEMS TRENDCONTROL SYSTEMS TREND
1) PLC1) PLC
2) DCS2) DCS
3) PC 3) PC -- Based ControlBased Control..
•• PLCPLC : : Introduced in the late 1960 to replace Relays and HardIntroduced in the late 1960 to replace Relays and Hard--wired wired
Programming.Programming.
DCSDCS : : Introduced in the MidIntroduced in the Mid--1970 to 1970 to
replace pneumatic controls by using replace pneumatic controls by using
computers.computers.
•• PCPC--Based ControlBased Control :: Introduced by the early 1980s to avoid the Introduced by the early 1980s to avoid the
proprietary PLC & DCS systems.proprietary PLC & DCS systems.
DCS EVOLUTIONDCS EVOLUTION
•• LOCAL CONTROLLOCAL CONTROL :: Initially control was performed local to the equipment Initially control was performed local to the equipment
control. The control. The ADVANTAGEADVANTAGE was low wiring costs .was low wiring costs .DISADVANTAGESDISADVANTAGES were were --
not much control, monitoring, alarming & history.not much control, monitoring, alarming & history.
•• CENTRALISED CONTROLCENTRALISED CONTROL:: With the advent of minicomputer, sensors and With the advent of minicomputer, sensors and
actuators were into the Central Control (Computer).actuators were into the Central Control (Computer).
•• DISTRIBUTED CONTROLDISTRIBUTED CONTROL:: With the advent of microcomputer, Distributed With the advent of microcomputer, Distributed
control systems were installed in the plants near to the controlcontrol systems were installed in the plants near to the control room via room via
proprietary digital communications lines called as Data Hiway. Fproprietary digital communications lines called as Data Hiway. First DCS was irst DCS was
developed by Honeywell,U.S in 1975.developed by Honeywell,U.S in 1975.
The The ADVANTAGESADVANTAGES were greatly reduced wiring costs, much more limited were greatly reduced wiring costs, much more limited
failure and less cost to add more points. failure and less cost to add more points.
The The DISADVANTAGESDISADVANTAGES were that wiring costs were that wiring costs were that wiring costs were that wiring costs
were still significant and there was lack of interoperability amwere still significant and there was lack of interoperability among controllers of ong controllers of
various manufacturers due to the proprietary protocols. Hence thvarious manufacturers due to the proprietary protocols. Hence the user was e user was
locked into a single vendor. locked into a single vendor.
DCS System Installations in RCFDCS System Installations in RCF
1. Yokogawa 1. Yokogawa -- CS 3000 : Ammonia IICS 3000 : Ammonia II
2. Yokogawa 2. Yokogawa -- CS 3000 : A N PCS 3000 : A N P
3. Yokogawa 3. Yokogawa -- CS 3000 : N N A PCS 3000 : N N A P
4. Moore 4. Moore -- APACS APACS : Methyl amine: Methyl amine
5. Fisher 5. Fisher -- Rosemant Rosemant -- Delta V field Bus : S T PDelta V field Bus : S T P
6. Honeywell 6. Honeywell -- GUS : Ammonia I SynthesisGUS : Ammonia I Synthesis
7. Yokogawa 7. Yokogawa -- Centum Excel : Steam Generation PlantCentum Excel : Steam Generation Plant
8. Moore 8. Moore -- APACS : SuphalaAPACS : Suphala
9. Yokogawa 9. Yokogawa -- Micro Excel : Methanol Micro Excel : Methanol
10. Yokogawa 10. Yokogawa -- Micro Excel : S A P/C N AMicro Excel : S A P/C N A
11. ABB 11. ABB -- Freelance 2000 : A B CFreelance 2000 : A B C
12. Honeywell 12. Honeywell -- TDC 3000 : Ammonia ITDC 3000 : Ammonia I
13. Honeywell 13. Honeywell -- GUS : Ammonia/Urea GUS : Ammonia/Urea -- ThalThal
14. Fox 14. Fox boroboro -- I/A series : D M A C I/A series : D M A C -- ThalThal
15. Fisher 15. Fisher -- Rosemant RS3 : P G RRosemant RS3 : P G R
16. Fisher 16. Fisher -- Rosemant RS3 : Steam Generation Rosemant RS3 : Steam Generation -- ThalThal
17. Moore 17. Moore -- APACS : Water Treatment PAPACS : Water Treatment Plant lant --ThalThal
DCSDCS
•• The importance of DCS systems to increase as global competitive The importance of DCS systems to increase as global competitive dynamics in food and beverage, specialty metals, pulp and paper,dynamics in food and beverage, specialty metals, pulp and paper,pharmaceutical and fire chemical processing.pharmaceutical and fire chemical processing.
•• The DCS has networking capabilities which are useful for businesThe DCS has networking capabilities which are useful for business s management.management.
•• The DCS has capacity for processing large number of I/O points. The DCS has capacity for processing large number of I/O points.
TYPES OF DCSTYPES OF DCS ::
1) Conventional DCS .1) Conventional DCS .
2) PLC based DCS.2) PLC based DCS.
3) Hybrid DCS.3) Hybrid DCS.
4) Open DCS System4) Open DCS System
CONVENTIONAL DCSCONVENTIONAL DCS
This is a pure This is a pure ““Process onlyProcess only”” control system. Usually purchased from control system. Usually purchased from one vendor. This DCS arranged into three categories:one vendor. This DCS arranged into three categories:
•• Small Small -- Less than $ 100,000.Less than $ 100,000.
•• Medium Medium -- Greater than $100,000 & Less than $500,000.Greater than $100,000 & Less than $500,000.
•• Large Large -- Greater than $500,000.Greater than $500,000.
PLC Based DCSPLC Based DCS..This is a network of PLCThis is a network of PLC’’s used to perform the task of s used to perform the task of
conventional DCS and programmable functionality when required.conventional DCS and programmable functionality when required.
Hybrid DCSHybrid DCS..Performs both process and sequential control.Performs both process and sequential control.
Open DCS SystemOpen DCS System..
This is FieldThis is Field--Bus Control. Advantages are lower wiring cost and Bus Control. Advantages are lower wiring cost and less failure, smaller expansion costs and multi vendor interoperless failure, smaller expansion costs and multi vendor interoperability ability DCS and PLC can be more closely and efficiently interconnected.DCS and PLC can be more closely and efficiently interconnected.
Honeywell TDC 3000 DCS ArchitectureHoneywell TDC 3000 DCS Architecture
AMC
AMC
US#1 US#2 HM
LCN A
B
HG
A BData Hiway
Field
Field
EC Link
Hiway Gateway (HG)Hiway Gateway (HG)
•• LCN Module. Provides a two way communication link between the LoLCN Module. Provides a two way communication link between the Localcal
Control Network and data hiway.Control Network and data hiway.
•• 68020 based high performance intelligence module.68020 based high performance intelligence module.
•• Converts data and protocol between Local Control Network and datConverts data and protocol between Local Control Network and data hiway.a hiway.
•• Scans the hiway for alarm conditions.Scans the hiway for alarm conditions.
•• Synchronize time keeping for hiwaySynchronize time keeping for hiway--based process connected boxes.based process connected boxes.
•• One HG is required for each data hiway that is connected to the One HG is required for each data hiway that is connected to the LCN. Up to LCN. Up to 20 data hiway pairs can be connected to an LCN. 20 data hiway pairs can be connected to an LCN.
•• Connects following hiway resident boxes to LCNConnects following hiway resident boxes to LCN
1.1. AMCsAMCs
2.2. CPC ( critical process controller ).CPC ( critical process controller ).
3.3. DHP.DHP.
4.4. Hiway traffic director etcHiway traffic director etc……
HG FunctionsHG Functions ::
1.1. Data access :Data access :-- gets box data requested from LCN modules.gets box data requested from LCN modules.
2.2. Event processing :Event processing :-- sends process and box alarm to LCN modulessends process and box alarm to LCN modules
3.3. Database configuration :Database configuration :-- 3000 points per hg can be configured.3000 points per hg can be configured.
Data HiwayData Hiway
Data hiway provides communication link between Data hiway provides communication link between hiway hiway gateway,gateway,
preferred access devices and process connecting box. Data hiwapreferred access devices and process connecting box. Data hiway y operates atoperates at
250 kbps.250 kbps.
It is redundant pair of 75 ohm coax cable conneIt is redundant pair of 75 ohm coax cable connected to box. cted to box. It may be It may be
20,000 feet long. 20,000 feet long.
There are 3 kinds of devices on the data hiway,There are 3 kinds of devices on the data hiway,
1.1. Respond only devices Ex:Respond only devices Ex:-- AA--MC (Advanced Multifunction MC (Advanced Multifunction controller)controller)
2.2. Polled devices Ex:Polled devices Ex:-- PIUPIU’’s (Process interface unit)s (Process interface unit)
3.3. Preferred access devicesPreferred access devices
History ModuleHistory Module
•• LCN Module. Stores process and system LCN Module. Stores process and system information that can be displayed.information that can be displayed.
•• Based on microprocessors 68020.Based on microprocessors 68020.
•• Winchester disk for data storage.Winchester disk for data storage.
•• Communicates with all Modules on the LCN.Communicates with all Modules on the LCN.
•• Stores history and general information.Stores history and general information.
Universal StationUniversal Station
Universal station (US) communicates with all modulUniversal station (US) communicates with all modules on the es on the LCN, processLCN, process
connected devices on the hiway via hiway gateway and UCN via neconnected devices on the hiway via hiway gateway and UCN via network twork interface moduleinterface module
(NIM).(NIM).
The following are the features of US,The following are the features of US,
•• Intelligent man/machine interface in the TDC 3000 system.Intelligent man/machine interface in the TDC 3000 system.
•• Stands on the LCN. Communicates with all Modules on LCN, processStands on the LCN. Communicates with all Modules on LCN, processconnected devices on the Hiway via Hiway Gateway.connected devices on the Hiway via Hiway Gateway.
•• Provides comprehensive facilities to the process operator, proceProvides comprehensive facilities to the process operator, process ss engineer and maintenance technician on the Universal Window.engineer and maintenance technician on the Universal Window.
US provides comprehensive facilities to the followUS provides comprehensive facilities to the following people,ing people,
•• Process engineerProcess engineer
•• Process operatorProcess operator
•• Maintenance technician.Maintenance technician.
AMCAMC
•• TDC 3000 controller TDC 3000 controller
1.1. Based on Motorola 68000 Microprocessor.Based on Motorola 68000 Microprocessor.
2.2. Faster execution and control with 500 ms processing rate.Faster execution and control with 500 ms processing rate.
•• Multifunction Multifunction –– Modulating, sequence, logic, I/O monitoring Modulating, sequence, logic, I/O monitoring
communication and diagnostic.communication and diagnostic.
•• Faster peer to peer communication over EC link ( 500 kbits/sec )Faster peer to peer communication over EC link ( 500 kbits/sec )..
•• Proven control techniquesProven control techniques
1.1. Full function algorithms.Full function algorithms.
2.2. Process oriented programming.Process oriented programming.
•• Configured as a box on TDC 3000 Data Hiway. Supported byConfigured as a box on TDC 3000 Data Hiway. Supported by
1.1. LCN devices LCN devices –– US, AM, HM.US, AM, HM.
HONEYWELL HONEYWELL -- GUSGUS
HM
NIM
HPM
HPM
HPM
Local Control Network
US#1 US#2 US#3 US#4
Printer PrinterDrive’s
- -
High Performance Manager
History Module
Network Interface Module
Universal
Station
A
B
Un
iver
sal
Contr
ol
Net
wo
rk
Honeywell System DescriptionHoneywell System Description
•• Global User StationGlobal User Station
•• History ModulesHistory Modules
•• Network Interface ModulesNetwork Interface Modules
•• Communication Subsystem Communication Subsystem -- Local Control Network & Universal Local Control Network & Universal
Control NetworkControl Network
•• High Performance Process ManagerHigh Performance Process Manager
Global User StationGlobal User StationOverviewOverview
The TPS system provides an integrated interface between the procThe TPS system provides an integrated interface between the process ess
and the end user. This interface is named as the Global User Staand the end user. This interface is named as the Global User Station (GUS).tion (GUS).
GUS is an important part in the Honeywell Total planGUS is an important part in the Honeywell Total plant Solutions t Solutions
offerings. It provides access to plant wide process network, plaofferings. It provides access to plant wide process network, plant or nt or
organization wide intranet or even Internet.organization wide intranet or even Internet.
The following hardware is available to enhance the fThe following hardware is available to enhance the functionality of the unctionality of the
GUS:GUS:
•• Integrated Keyboard for Operators as well as Engineer.Integrated Keyboard for Operators as well as Engineer.
•• Matrix printer supported by Windows NT.Matrix printer supported by Windows NT.
•• 8 * CD8 * CD--ROMROM
•• 100MB ZIP Drive100MB ZIP Drive
•• 3.53.5”” Floppy DriveFloppy Drive
GUS has following functionality's :GUS has following functionality's :
•• The The ““Human Human ”” interface allows effective interaction of the Operator through interface allows effective interaction of the Operator through
the use of operating displaysthe use of operating displays
•• Engineering functions such as data point building, display buildEngineering functions such as data point building, display building and report ing and report
building are available.building are available.
•• Communication with other LCN modules is accomplished.Communication with other LCN modules is accomplished.
•• Communication on Ethernet.Communication on Ethernet.
Honey well GUS Hardware:Honey well GUS Hardware:
•• Processor : Pentium ProProcessor : Pentium Pro / 200MHZ/ 200MHZ
•• Memory : 64MB RAM ECCMemory : 64MB RAM ECC
•• Cache : 256KB ECCCache : 256KB ECC
•• Storage : 2 GB hardStorage : 2 GB hard disk drive, CD ROM, disk drive, CD ROM,
Cartridge DriveCartridge Drive
•• Video : 21Video : 21”” high resolution screen 1280 * 1024 high resolution screen 1280 * 1024
PixelsPixels
•• Colours : 256 colorColours : 256 color palettepalette
•• Keyboard : Integrated Keyboard : Integrated keyboard with mousekeyboard with mouse
•• PIN Connection : Built in EthernPIN Connection : Built in Ethernetet
•• Cursor Control : QWERTY & MousCursor Control : QWERTY & Mouse/Touch Screen e/Touch Screen
Peripherals supportedPeripherals supported
•• PrinterPrinter
•• 8 * CD8 * CD--ROMROM
•• 1/41/4”” Steamer TapeSteamer Tape
•• 3.53.5”” Floppy DriveFloppy Drive
•• 100 Mb ZIP Drive100 Mb ZIP Drive
•• Annunciator relay on the consoleAnnunciator relay on the console--based keyboardbased keyboard
Honeywell GUS softwareHoneywell GUS software
•• Operating System : Windows NT versiOperating System : Windows NT version 4.0on 4.0
•• Base System : Provides reaBase System : Provides real time data l time data
exchange exchange
between the network and all GUS between the network and all GUS
functions. functions.
History ModulesHistory Modules
The History Modules is the bulk module that can be utilizeThe History Modules is the bulk module that can be utilized by all module d by all module
connectedconnected
to the Local Control Network. It is as the name implies the masto the Local Control Network. It is as the name implies the mass memory of the s memory of the
TPSTPS
System. The memory components of this module are one 1.8 gigabySystem. The memory components of this module are one 1.8 gigabyte te
Winchester discs.Winchester discs.
It is controlled by an M68040 microprocessor. This provides theIt is controlled by an M68040 microprocessor. This provides the module with module with
significantsignificant
computing power that this used to structure much of the incomincomputing power that this used to structure much of the incoming data and g data and
format it intoformat it into
a form for easy retrieval. a form for easy retrieval.
The history in the model is provided by the History ModThe history in the model is provided by the History Module. Process ule. Process
variables arevariables are
available for hourly, shift, daily and monthly average calculatavailable for hourly, shift, daily and monthly average calculation and recording.ion and recording.
All system event history such as process alarms, system All system event history such as process alarms, system status changes, status changes,
and errorand error
messages are stored into the History Modules.messages are stored into the History Modules.
Other modules have access to data in the History ModulesOther modules have access to data in the History Modules for their for their
functions. functions.
The History Module provides two functions, storage only and dataThe History Module provides two functions, storage only and data structuring structuring
HM functions and Historization parameterHM functions and Historization parameter
HM functionsHM functions ::
It can automatically backup the control databases It can automatically backup the control databases in the HG, AM, CG.in the HG, AM, CG.
HM can store,HM can store,
•• Continuous process history.Continuous process history.
•• Event journal (history).Event journal (history).
•• Active system files.Active system files.
•• Static system files.Static system files.
•• On process analysis program (maintenance aid)On process analysis program (maintenance aid)
HM Historization parametersHM Historization parameters ::
There can be up to 10 HMThere can be up to 10 HM’’s on the LCN. There can be maximum of 150 s on the LCN. There can be maximum of 150
groups pergroups per
HM. Each group can have up to 20 points. All points in the groHM. Each group can have up to 20 points. All points in the group must be in the up must be in the
samesame
unit. unit.
Network Interface Module (NIM)Network Interface Module (NIM)
The Network Interface Module (NIM) provides the link between tThe Network Interface Module (NIM) provides the link between the local Control he local Control
Network and the Universal Control Network. As such it make the Network and the Universal Control Network. As such it make the transition from transition from
thethe
transmission technique and protocol or the Local Control Networtransmission technique and protocol or the Local Control Network to the k to the
transmissiontransmission
technique and the protocol of the Universal Control Network. Thtechnique and the protocol of the Universal Control Network. The NIM provides e NIM provides
accessaccess
by LCN modules data from UCN resident devices. The NIM is availby LCN modules data from UCN resident devices. The NIM is available in the able in the
redundantredundant
configuration to provide continued operation in the event of thconfiguration to provide continued operation in the event of the primary failure. It e primary failure. It
cancan
also do event processing.also do event processing.
There can be up to 10 redundant NIM pairs per LCN. A NThere can be up to 10 redundant NIM pairs per LCN. A NIM can host upto IM can host upto
8000 tag8000 tag
names and supports a data transfer rate of 2400 parameters per names and supports a data transfer rate of 2400 parameters per second. second.
Communication Subsystem Communication Subsystem
Local Control Network (LCN)Local Control Network (LCN)
The backbone of every TPS system is a comThe backbone of every TPS system is a communication network, munication network,
known asknown as
Local Control Network. The LCN is a LAN through which TDC 3000 Local Control Network. The LCN is a LAN through which TDC 3000 modules modules
communicate with each other. The LCN is a broadcast type of LAN.communicate with each other. The LCN is a broadcast type of LAN. It is high speedIt is high speed
redundant communication bus that connect all the control room eredundant communication bus that connect all the control room equipment. All quipment. All
informationinformation
is transferred on the network at 5 million bits per sec.,serialis transferred on the network at 5 million bits per sec.,serially. It is based on the ly. It is based on the
IEEE 802.4IEEE 802.4
Token passing and Bus Standard.Token passing and Bus Standard.
Each LCN device that is connected to the LEach LCN device that is connected to the Local Control Network is ocal Control Network is
called acalled a
module. Up to 64 modules may be connected to the Local Contromodule. Up to 64 modules may be connected to the Local Control Network in a l Network in a
TPSTPS
system. The Local Control Network is designated as the primary system. The Local Control Network is designated as the primary and the other as and the other as
the backthe back
Universal Control Network (UCN)Universal Control Network (UCN)
The Universal Control Network is a high sThe Universal Control Network is a high speed, high security peed, high security
processprocess
control network based on open system interconnection standards.control network based on open system interconnection standards. It It
features a 5features a 5
megabit/second, carrier band, token bus network compatible withmegabit/second, carrier band, token bus network compatible with IEEE and IEEE and
ISOISO
standards. It is used as the real time redundant Communicationsstandards. It is used as the real time redundant Communications backbone backbone
forfor
process connected devices such as the High Performance Process process connected devices such as the High Performance Process ManagerManager
(HPM), Advanced Process Manager . The UCN supports peer(HPM), Advanced Process Manager . The UCN supports peer--toto--peerpeer
communication for sharing data and allowing greater cocommunication for sharing data and allowing greater co--ordination of ordination of
controlcontrol
strategies among network devices. The UCN uses redundant costrategies among network devices. The UCN uses redundant co--axial cables axial cables
and canand can
support up to 32 redundant devicessupport up to 32 redundant devices
UCN supports 2 types of devicesUCN supports 2 types of devices
Communication Subsystem Communication Subsystem
High Performance Process Manager High Performance Process Manager
(HPM)(HPM)
The High Performance Process Manager is the latest in the ProgreThe High Performance Process Manager is the latest in the Progression of ssion of
HighHigh
Performance control products offered by Honeywell for the applicPerformance control products offered by Honeywell for the application toation to
Improve controlling of existing and new industrial processes. HiImprove controlling of existing and new industrial processes. High gh
PerformancePerformance
Process Manager is a fully integrated member of the TPS family. Process Manager is a fully integrated member of the TPS family. It is It is
capablecapable
of :of :
•• performing data acquisition and control functionsperforming data acquisition and control functions
•• fully communicating with operators and engineers at the GUSs andfully communicating with operators and engineers at the GUSs and
universal Work stations. universal Work stations.
•• Supporting higherSupporting higher--level strategies available on the Local Control level strategies available on the Local Control
Network through the Application Module and Host Computers.Network through the Application Module and Host Computers.
The High Performance Process Manager uses a powerful multiThe High Performance Process Manager uses a powerful multi--processor processor
architecturearchitecture
with separate microprocessors dedicated to perform specific taswith separate microprocessors dedicated to perform specific tasks. The HPM ks. The HPM
consistsconsists
of two modules Communication and Control Module (CCM) and the Iof two modules Communication and Control Module (CCM) and the I/O /O
subsystemsubsystem
the I/O subsystem consist of up to 40 Smart I/O Modules (SIOM)the I/O subsystem consist of up to 40 Smart I/O Modules (SIOM). All control . All control
operation are performed within the communication and control modoperation are performed within the communication and control module. The ule. The
process process
engineer has complete flexibility of choice within the maximum Hengineer has complete flexibility of choice within the maximum HPM design PM design
limits.limits.
These selections are implemented using the interactive tools prThese selections are implemented using the interactive tools provided by ovided by
both theboth the
GUS and Universal Work Station. The I/O processors, for exampleGUS and Universal Work Station. The I/O processors, for example, provide , provide
suchsuch
functions as engineering unit conversion and alarm limit checkifunctions as engineering unit conversion and alarm limit checking ng
independent of theindependent of the
communication and control modules.communication and control modules.
High Performance Process Manager Overview
YOKOGAWA CENTUM EXCEL ARCHITECTUREYOKOGAWA CENTUM EXCEL ARCHITECTURE
EOPS
/1
EOPS
/2
ENGG.
STATION
EFGWEFMSEFCD
Closed loop
control signal
Through I/O NEST
HF BUS : High frequency Bus: no. of station on HF Bus are 32
EOPS : Extended Operator station: Hard disk capacity of EOPS is 80 MB
EFCD : Extended field control
station : 80 laps per controller
EFMS : Extended field mauture
station Max 255 inputs
EFGN : Extended field gateway unit
ENGS : Engineering station
NIO : Nest I/O bus.
Monitoring signals
Through I/O NESTThird party system with PLC,
Gas Analyser etc. thr RS 232C port
At the rate of 9600 bps
HF BUS
(1 Mbps)
A
B
I/O #1
ncst
I/O #2
ncst
I/O #3
I/O #4
I/O #5
ncst
A B
NIO Bus
Micro-XL
HIS HISPRTPRT
HIS
Windows NT Based Centum CS Configuration
NIU NIU
Ethernet Connectivity (optional)
Inkjet
PrinterDM
Printer
FCS
RIO BUS
OPERATOR/ENGINEERING
STATION
OPERATOR STATION SUB-SYSTEM
INTERPLANT
NETWORK PC
(OPTIONAL)
DUAL “V NET”
10 Mbps
HIS – Human Interface Station.
FCS – Field Control Station.
NIU – Node Interface Unit.
RIO Bus – Remote I/O Bus.
Centum CS 3000 System OverviewCentum CS 3000 System Overview
Centum CS 3000 is an integrated production control system Centum CS 3000 is an integrated production control system for medium for medium and large controland large control
applications. This system is a synthesis of the latest technoloapplications. This system is a synthesis of the latest technology with gy with YokogawaYokogawa’’s experiences experience
and specialist knowand specialist know--how.how.
Centum CS 3000 system featuresCentum CS 3000 system features ::
•• Synthesis of DCS with Personal computers.Synthesis of DCS with Personal computers.
•• Online Documentation.Online Documentation.
•• Powerful Operation and Monitoring Functions.Powerful Operation and Monitoring Functions.
•• Two Types of Control Station.Two Types of Control Station.
•• Compact I/O Modules.Compact I/O Modules.
•• Powerful Control and Communication Functions.Powerful Control and Communication Functions.
•• Efficient Engineering.Efficient Engineering.
•• Virtual Test functions donVirtual Test functions don’’t require Control Station hardware.t require Control Station hardware.
•• FullFull--Featured Batch Package.Featured Batch Package.
•• CENTUM CS microCENTUM CS micro--XL Integration ( to be released ).XL Integration ( to be released ).
Centum CS 3000 System Overview
Centum CS 3000 is an integrated production control system for medium and large control
applications. This system is a synthesis of the latest technology with Yokogawa’s experience
and specialist know-how.
Centum CS 3000 system features :
•Synthesis of DCS with Personal computers.
•Truly open system for integrating multi-vendor solutions.
•High Reliability of computed process data by the unique fault tolerant control processor.
•Powerful built in “RISC PROCESSOR” with high speed and dynamic error correcting code.
•Remote I/O concept enables geographically distribution of I/O Modules thereby reducing
cabling cost.
•1:1 Redundancy at almost all the system levels except for control processor which employs a
special Redundancy with 4 identical CPU’s.
•Powerful Control Tools and Communication Functions.
•Virtual Test functions don’t require Control Station hardware.
•Full-Featured Batch Package.
•Built in security features to prevent mal-operations.
•CENTUM CS micro-XL Integration ( to be released ).
HIS HISPRTPRT
HIS
CS3000 – System Configuration
NIU NIU
Ethernet Connectivity (optional)
Inkjet
PrinterDM
Printer
FCS
RIO BUS
OPERATOR/ENGINEERING
STATION
OPERATOR STATION SUB-SYSTEM
INTERPLANT
NETWORK PC
(OPTIONAL)
V NET
10 Mbps
HIS – Human Interface Station.
FCS – Field Control Station.
NIU – Node Interface Unit.
RIO Bus – Remote I/O Bus.
CGW – Communication gateway unit
BCV – Bus Converter
Remote Domain System
CS, CS 1000
Centum – XL, -V, -MXL
CGW
BCV
CENTUM CS 3000 NETWORKCENTUM CS 3000 NETWORK
FCS FCS FCS
HIS
HIS HIS
V net
CENTUM CS3000 SYSTEM SPECIFICATIONCENTUM CS3000 SYSTEM SPECIFICATION
•• NO. OF TAGS MONITOREDNO. OF TAGS MONITORED 1,00,0001,00,000
•• TOTAL NO. OF STATIONTOTAL NO. OF STATION 256256
•• NO. OF DOMAINSNO. OF DOMAINS 1616
•• NO. OF STATIONS IN A DOMAINNO. OF STATIONS IN A DOMAIN 6464
•• NO. OF HIS / DOMAINNO. OF HIS / DOMAIN 16 NOS16 NOS
CENTUM CS3000 SYSTEM SPECIFICATIONCENTUM CS3000 SYSTEM SPECIFICATION
•• Max. no. of stations : 256 /Max. no. of stations : 256 / systemsystem
•• Max. no. of DomainsMax. no. of Domains : 16 / system: 16 / system
•• Numbering of DomainsNumbering of Domains :: 1 to 641 to 64
•• Domain No. CS3000 DomainDomain No. CS3000 Domain
(V net Domain)(V net Domain) : 1 to 16: 1 to 16
•• Max. no. of stations/Domain : 64Max. no. of stations/Domain : 64
•• Domain No.Virtual Domain Domain No.Virtual Domain
(Non V net Domain)(Non V net Domain) :: 17 to 6417 to 64
•• Station NO. HIS : 1 tStation NO. HIS : 1 to 64 in descending o 64 in descending order order
•• Station NO. FCSStation NO. FCS : 1 to 64 in ascending order: 1 to 64 in ascending order
•• Max. No. of ICS / Domain Max. No. of ICS / Domain : 16: 16
•• Max. No. of NIU / FCS : 8Max. No. of NIU / FCS : 8
•• Max. No. of IOU / FCS : 40 Max. No. of IOU / FCS : 40 ( Max. 5/ IOU)( Max. 5/ IOU)
•• Max. length of Vnet Max. length of Vnet : 20 Km: 20 Km
•• Max. length of RIO bus : 20 Km Max. length of RIO bus : 20 Km (750m ~ (750m ~ 20Km)20Km)
Centum CSCentum CS--3000 Communication3000 Communication
V netV net
V net is 10 mbps real time control bus which links station V net is 10 mbps real time control bus which links station such as FCS , HIS , BCV such as FCS , HIS , BCV
andand
CGW. It can be dual redundant. It can be up to 500m using coaxiCGW. It can be dual redundant. It can be up to 500m using coaxial cable alone, or al cable alone, or
up to 20up to 20
Km when repeater are used or optical fiber is used.Km when repeater are used or optical fiber is used.
•• 10BASE2 cable10BASE2 cable
used by HIS, maximum segment length = 185 mused by HIS, maximum segment length = 185 m
•• 10BASE5 cable10BASE5 cable
used by stations other than HIS(FCS,CGW etc.) maximum segused by stations other than HIS(FCS,CGW etc.) maximum segment length = 500 ment length = 500
mm
V net Communication V net Communication
FCS FCS
HIS
V net
HIS
Protocol : IEEE802.4
Access Control : Token Passing
Trans. Speed : 10 Mbps
Trans. Distance: 500m to 20Km
Media : Coaxial/optical fiber
V net specificationV net specification
Token passing Token passing Proto type Proto type
DualDual--redundantredundantRedundancyRedundancy
500M 500M ––20Km Max20Km MaxTransmission DistanceTransmission Distance
10 Mbps10 MbpsCommunication rateCommunication rate
Bus type or MultiBus type or Multi--drop typedrop typeTypeType
Coaxial or fiber optical Coaxial or fiber optical
cablecableTransmission routeTransmission route
SPECIFICATIONSPECIFICATIONITEMITEM
VV-- net Featuresnet Features
•• Real time control bus. ( Dual redundant possible )Real time control bus. ( Dual redundant possible )
•• Cable : 50 ohm coax. cable with BNC connector ( 10Base2 Cable : 50 ohm coax. cable with BNC connector ( 10Base2
comp. )comp. )
•• Communication speed : 10 Mbps.Communication speed : 10 Mbps.
•• High reliable token passing communicationHigh reliable token passing communication
( performance guaranteed )( performance guaranteed )
•• Std. max. length : 185 m.Std. max. length : 185 m.
•• Max. length : 20 Km ( with optical fiber )Max. length : 20 Km ( with optical fiber )
1.6 Km ( with coax. Repeater )1.6 Km ( with coax. Repeater )
BNC Connector
VL net I/F card ( PCI )
VL net
cable
EthernetEthernet
HIS and ENG, HIS and supervisory systems can be HIS and ENG, HIS and supervisory systems can be connected by anconnected by an
Ethernet LAN; supervisory computers and personal Ethernet LAN; supervisory computers and personal computers on the Ethernetcomputers on the Ethernet
LAN can access messages and trend data in the CS 3000 LAN can access messages and trend data in the CS 3000 system. The Ethernetsystem. The Ethernet
can also be used for sending trend data files from the HIS can also be used for sending trend data files from the HIS to supervisoryto supervisory
computers, or for equalizing the data in the two HIS station computers, or for equalizing the data in the two HIS station ( rather than using( rather than using
the V net control bus to do this ). A system with only one the V net control bus to do this ). A system with only one HIS with engineering HIS with engineering
functions installed, does not need Ethernet functions installed, does not need Ethernet –– but in general but in general Ethernet ( and Ethernet ( and
corresponding network engineering ) is required.corresponding network engineering ) is required.
Ethernet SpecificationEthernet Specification
CSMA/CD TypeCSMA/CD TypeProto typeProto type
Not availableNot availableRedundancyRedundancy
500m 500m –– 2.5 Km max.2.5 Km max.Transmission DistanceTransmission Distance
10 Mbps10 MbpsCommunication RateCommunication Rate
Bus type or MultiBus type or Multi––drop typedrop typeTypeType
Coaxial or Fiber optical cableCoaxial or Fiber optical cableTransmission RouteTransmission Route
SPECIFICATIONSPECIFICATIONITEMITEM
TYPES OF HISTYPES OF HIS
•• Console type HISConsole type HIS
•• Desk top type HISDesk top type HIS
•• PHIS Yokogawa brand OPSPHIS Yokogawa brand OPS
HIS HardwareHIS Hardware
•• CPUCPU Pentium 166Pentium 166
•• Main memoryMain memory 96MB or larger(for op & 96MB or larger(for op &
monitoring only)monitoring only)
•• Hard diskHard disk 1 GB or larger1 GB or larger
•• DisplayDisplay 256Colors min. resolution 800*600256Colors min. resolution 800*600
1024*768 recommend(1280*1024 best)1024*768 recommend(1280*1024 best)
•• Serial portSerial port RS232C*1 or more (for operation RS232C*1 or more (for operation
keyboard)keyboard)
•• Parallel portParallel port 1 port for printer or more1 port for printer or more
•• OSOS Windows NT 4.0 Workstation Windows NT 4.0 Workstation
•• Operator stationsOperator stations Max. 8 stations Max. 8 stations
Field Control Station ConfigurationField Control Station Configuration
HIS
Sub system
Sub system
I/O Unit
I/O Unit
HIS HIS
V net
Ethernet
Node
Interface
Unit
RIO Bus
Node
Compact FCS Standard FCS
Connection to Centum CS 3000 SystemConnection to Centum CS 3000 System
FCS FCS
Exapilot communication data
Process data read/write
V-net
HIS ENG Exaopc
Exapilot client
(engineering, operation)
Exapilot server
(engineering, operation)
Exapilot client
(engineering,
operation)
Ethernet
Features of Features of ExapilotExapilot
•• Standardize and Automate Manual ProceduresStandardize and Automate Manual Procedures
•• Improve Plant Operating EfficiencyImprove Plant Operating Efficiency
•• Improve safety of Plant OperationImprove safety of Plant Operation
Features of Event Analysis PackageFeatures of Event Analysis Package
•• Analysis DCS Event History to Help You Enhance Efficiency.Analysis DCS Event History to Help You Enhance Efficiency.
•• Enhance Process Stability: Balance Process Events and Operator AEnhance Process Stability: Balance Process Events and Operator Actions.ctions.
•• When, Where, What (3W) Filters Help You Narrow Focus of AnalysisWhen, Where, What (3W) Filters Help You Narrow Focus of Analysis..
OPEN DCS SYSTEMOPEN DCS SYSTEM
Safety Barrier
Pressure TX.
Control Valve
Terminator
H M I
Ethernet
Field Bus Power Supply Flow Trans.
Field busField bus
It is a standardized digital communication protocol between a pIt is a standardized digital communication protocol between a process rocess Control field devices Control field devices
and the Control room. It is a simple pair of wires to power and and the Control room. It is a simple pair of wires to power and carry the carry the communicationcommunication
signal between the field devices and the Control room.signal between the field devices and the Control room.
FEATURESFEATURES : :
•• Drastic reduction in cable, conduits cable trays, marshallive raDrastic reduction in cable, conduits cable trays, marshallive racks, and cks, and connectors etc.connectors etc.
•• Drastic reduction in installation cost.Drastic reduction in installation cost.
•• Fewer non field devices.Fewer non field devices.
•• More reliability due to the smaller number of devices.More reliability due to the smaller number of devices.
•• More efficient operation due to better accuracy (no A/D and D/A More efficient operation due to better accuracy (no A/D and D/A conversion).conversion).
•• Easy integration into plant management system.Easy integration into plant management system.
•• Flexibility for different suppliers are interoperable and intercFlexibility for different suppliers are interoperable and interchangeable.hangeable.
•• Major reduction in maintenance cost.Major reduction in maintenance cost.
FieldField--bus Benefitsbus Benefits
WiringScrew
Terms
Wire
(pair)
I/O
Cards
IS
Barriers
Traditional
Field bus
3500’ 168 2 2
640’ 64 1 1
Savings
Savings %
Savings $
2860’ 104 1 1
82% 63% 50% 50%
$ 3000 Material
$ 2000 Labor
$ 5000 Total
Typically comments from a plant personal :
•Easy to identify what’s out there.
•Consistent calibration procedure.
•Two days versus four days to commission system.
•Familiar with twisted pair wiring – comfortable.
FunctionBlock(s)
FunctionBlock(s)
TransducerTransducer(Servo)(Servo)BlockBlock
FOUNDATION™
fieldbus
Basic Components
ResourceBlock
ResourceResourceBlockBlock
Valve
FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary
BlocksBlocks
FunctionBlock(s)
FunctionBlock(s)
TransducerTransducerBlockBlock
ResourceBlock
ResourceResourceBlockBlock
FOUNDATION™
fieldbus
Temperature
Transmitter
FOUNDATIONFOUNDATION™™ fieldbus Vocabularyfieldbus Vocabulary
BlocksBlocks
Basic Components
FOUNDATIONFOUNDATION™™ fieldbus Vocabulary fieldbus Vocabulary
H1 and H2H1 and H2
•• H1 SegmentH1 Segment–– Moderate speedModerate speed
–– Use existing wiringUse existing wiring
–– Bus poweredBus powered
–– Can be intrinsically Can be intrinsically safesafe
–– Low power 2 wire Low power 2 wire devicesdevices
–– 4 wire devices4 wire devices
–– Replace analog & Replace analog & proprietary digitalproprietary digital
•• H2 SegmentH2 Segment–– High speedHigh speed
–– Link multiple H1 Link multiple H1 SegmentsSegments
–– I/O subsystem busI/O subsystem bus
–– Replace Replace proprietary proprietary networksnetworks
–– New wiringNew wiring
FOUNDATIONFOUNDATION™™ fieldbus Vocabulary fieldbus Vocabulary
New Approach for H2New Approach for H2
•• 100 Meg Ethernet technology with extensions100 Meg Ethernet technology with extensions–– Improve time to marketImprove time to market
–– High speedHigh speed
–– Mandatory redundancyMandatory redundancy
–– Widely available technology and siliconWidely available technology and silicon
–– Widely available toolsWidely available tools
–– Limited incremental developmentLimited incremental development
–– Many suppliersMany suppliers
–– High volume for low costHigh volume for low cost
–– Works with installed equipmentWorks with installed equipment
–– Evergreen technologyEvergreen technology
•• Better than ANY other solution!Better than ANY other solution!
H2 Segment 100 Meg Ethernet
PLCH1/H2Bridge
ControlModule
H1/H2 BridgeReplaces
Traditional I/O
H1/H2 BridgeReplaces
Traditional I/O
Server
H1 Segment
H1 Segment
H1 Segment
FOUNDATIONFOUNDATION™™ fieldbus Vocabulary fieldbus Vocabulary
H1/H2 BridgesH1/H2 Bridges
FOUNDATIONFOUNDATION™™ fieldbus Standardsfieldbus Standards
Organizations Organizations
•• IECIEC–– International ElectroInternational Electro--technical Commissiontechnical Commission
•• ISAISA–– International Society for Measurement and Control International Society for Measurement and Control
(formerly: Instrument Society of America)(formerly: Instrument Society of America)•• SP50SP50
•• CENELECCENELEC–– European standards body European standards body
•• Parallel (competitive?) Working Groups to IECParallel (competitive?) Working Groups to IEC
FewerTerminationsFewerTerminations
Fewer IS barriersFewer IS barriers
Marshaling
JunctionBox
IS (Ex i)Barriers
H1 I/OTerminations
H1 Fieldbusall-digital
H1 Fieldbusall-digital
H1 I/OInterface
Controller
Similar I/O CardsSimilar I/O Cards
Cost savings:• wiring• I/O cards &
cables• terminations• IS barriers• marshaling
Cost savings:• wiring• I/O cards &
cables• terminations• IS barriers• marshaling
Fewer TerminationsFewer Terminations
Reduced WiringReduced Wiring
FOUNDATIONFOUNDATION™™ fieldbus Topography fieldbus Topography
H1 Fieldbus InstallationsH1 Fieldbus Installations
Barriers
FOUNDATIONFOUNDATION™™ fieldbus Topography fieldbus Topography
Intrinsic SafetyIntrinsic Safety
DeltaV System ArchitectureDeltaV System Architecture
PrinterPrinter
8 port Hub
primary
8 port Hub
Redundant
Serial
P
S
D
I
D
O
D
I
A
O
A
I
A
I
Co
ntr .
Co
ntr .
P
S
Bl an
k
Bl an
kH
I
Bl an
k
Bl an
k
Bl an
k
D
O
Bl an
k
PLC For
8 DI &
8 DO
H1
Connector
1
Operator stationEngineering station
8 wide carrier for
I/O subsystem
2 wide carrier for
Power/Controller
Power supply
Controller
Fieldbus Transmitter
3244MVF1NAB4
Pressure Transmitter
3051TG2A2B21AB4M5FF
Smart valve positioner
FSDVC0400-201
I/O extension cable
RS232 Modbus
Fieldbus Power
DCS communication system HierarchyDCS communication system Hierarchy
MIS
SCHED.
SUP.
DDC
SUP.
DDC DDC DDC
S A A A A AS S S S S S
PLANT
Level 5
Management
Low data rates
Superior responsibility
Level 1
Sensors (S)
& Actuators (A)
High data rates
Low responsibility
Level 2
Direct digital
Control (DDC)
Level 3
Supervisory control
Level 4
Scheduling
High
Low
History of Process Control SignalHistory of Process Control Signal
Around 50 years ago, most plant used 3Around 50 years ago, most plant used 3--15psi pneumatic signal to control their 15psi pneumatic signal to control their
process.process.
The last change change in signal standard was the open protocolThe last change change in signal standard was the open protocol HART digital HART digital
communicationscommunications
format. The HART protocol provides simultaneous digital communiformat. The HART protocol provides simultaneous digital communications with the 4cations with the 4--20 20
mAmA
output.output.
The next protocol change will be fieldbus. FieldThe next protocol change will be fieldbus. Fieldbus is entirely digitalbus is entirely digital--there is there is
no analogno analog
Signal. Fieldbus also allows migration of control functions to fSignal. Fieldbus also allows migration of control functions to field devices.ield devices.
Process control Timeline Process control Timeline –– The Evolution of Signal StandardThe Evolution of Signal Standard
Signal standards have evolved over the years, starting with the Signal standards have evolved over the years, starting with the 33--15 psi 15 psi
standard.standard.
There are also other communication methods, but they have not gThere are also other communication methods, but they have not gained widespread ained widespread
acceptance.acceptance.
With many standard there is typically a slow transition period aWith many standard there is typically a slow transition period as plant s plant
engineers andengineers and
managers test period does gain widespread acceptance. However, managers test period does gain widespread acceptance. However, once the benefits of once the benefits of
thethe
Fieldbus become tested and proven, more plant will install FielFieldbus become tested and proven, more plant will install Fieldbus because of its dbus because of its
Digital plus Analog: HART with 4-20mA
Digital: Fieldbus
Analog: 4-20mA
Pneumatic: 3-15 psi
1940 1950 1960 1970 1980 1990 2000 2010
I/O Bus Network ProtocolI/O Bus Network Protocol
I/O Bus Network
Discrete
Byte-wide
Data
Bit-wide
data
Several Hundred
Data Bytes
Analog
Device bus network Process bus network
Protocol StandardProtocol Standard
Device bus network
Process bus network
Field Bus Foundation
(Field Bus std.)
Profibus Trade Organization
(Profibus std.)
Byte-Wide
Data
Bit-Wide
Data
CAN Bus
Inter Bus-S
Device net
SDS
Seriplex
Inter Bus Loop
ASI
Fieldbus ArchitectureFieldbus Architecture
Fieldbus is more than just a new signal communications protocol,Fieldbus is more than just a new signal communications protocol, but a whole new way but a whole new way
toto
control the process. With the release of the low fieldbus (H1),control the process. With the release of the low fieldbus (H1), the entire fieldbus will the entire fieldbus will
bebe
defined. Most of the recent published literature has focused ondefined. Most of the recent published literature has focused on the intricate details of the intricate details of
thethe
fieldbus architecture, especially those layers that have not befieldbus architecture, especially those layers that have not been released. However, en released. However,
except except
physical layer and the user layer, these layer are transparent physical layer and the user layer, these layer are transparent to the engineers and the to the engineers and the
manager.manager.
Physical Layer
Data Layer
Application Layer
User Layer
Sy
stem
ma
na
gem
ent
Net
wo
rk M
an
ag
emen
t
Maintenance
information
system
Workstation
sta
ck
PumpLevel
Transmitter
ValveMultivariable
Transmitter
Open System Interconnected Reference Open System Interconnected Reference
ModelModel
Application
Presentation
Session
Transport
Network
Data link
Physical
MBAP, SMB, FTP, SMTP, FMS,
IEC 61158, ANSI/ISA S50.2,IEEE 1451
TCP, SPX, UDP
IP, IPX, NetBeui
HDLC, ETHERNET, ANSI/ISA S50.02
EIA-485, ETHERNET,ANSI/ISA S50.02
Physical – Provides the standard for transmitting raw
electrical signals over the communication channels.
Data link – Contains the rule for interpreting electrical
signals as data, error checking and physical addressing
Network – Describes the rule for routing messages
through a complex network and deals with congestion.
Transport – Establishes a dependable end-to-end
connection between two host.
Session – provides Management and Synchronization
of complex data transaction.
Presentation – Establishes protocol for data format
conversion, encryption and security.
Application – Contains protocol that accomplish task
such as e-mail, file transfer or reading a set of registers
from a PLC.
For the purpose of Process control, the top and bottom four layers are used.
Layers 5 and 6 are important to large commercial networks.
Field BusField Bus
Field Bus is a biField Bus is a bi--directional digital communication that interconnects smart fielddirectional digital communication that interconnects smart field
devices todevices to
control system or to instrument located in the control room.control system or to instrument located in the control room.
Field Bus is based on the OSI (Open System Interconnect), which Field Bus is based on the OSI (Open System Interconnect), which was developed by was developed by
the ISOthe ISO
(International Standard Organization) to represent the various f(International Standard Organization) to represent the various functions required in unctions required in
anyany
Communication network.Communication network.
Connects the Connects the
equipmentequipmentPhysicalPhysical1 1
Establishes the data Establishes the data
link connectionlink connectionLinkLink22
Establishes network Establishes network
connectionsconnectionsNetworkNetwork33
Secures the transport Secures the transport
connectionconnectionTransportTransport44
Handles the dialogueHandles the dialogueSessionSession55
Converts dataConverts dataPresentationPresentation66
Provides formatted Provides formatted
datadataApplicationApplication77
FunctionFunctionLayerLayer
Field BusField Bus
The OSI model consists of seven layers. However for real time aThe OSI model consists of seven layers. However for real time application pplication layers 3 to 6 are layers 3 to 6 are
not considered since they deal with transference of data amongnot considered since they deal with transference of data among networks. networks. For suchFor such
application following layers are used:application following layers are used:
•• LAYER 1 LAYER 1 -- PHYSICAL LAYERPHYSICAL LAYER
Defines the type of signal, transmitting medium, data tranDefines the type of signal, transmitting medium, data transmission smission speed, etc.speed, etc.
•• LAYER 2 LAYER 2 –– DATALINK LAYERDATALINK LAYER
Define the interface between the physical layer and the applicatDefine the interface between the physical layer and the application layer. ion layer. It establishesIt establishes
how the messages shall be structured and normalizes the ushow the messages shall be structured and normalizes the use of e of multiple masters.multiple masters.
•• LAYER 3 LAYER 3 –– APPLICATION LAYERAPPLICATION LAYER
Defines how data is specified, its addresses and its representatDefines how data is specified, its addresses and its representation. ion. The Fieldbus was invented by an Indian engineer Mr. Ram Ramchandran
( M.S in Comp. Tech , Texas)
PHYSICAL LAYERPHYSICAL LAYER
The Physical layer defines the medium that transport the messageThe Physical layer defines the medium that transport the messages frames, the signal s frames, the signal shape andshape and
amplitude limits, data transfer rate, and power distribution.amplitude limits, data transfer rate, and power distribution.
Technical Characteristics:Technical Characteristics:
Physical MediumPhysical Medium
Three types are defined: wires, optic fiber, and radio signals. Three types are defined: wires, optic fiber, and radio signals. The The specification forspecification for
wire has been already approved.wire has been already approved.
Bit rate for wire mediaBit rate for wire media
31.25 Kbps (H1)31.25 Kbps (H1)
1 megabits and 2.5 megabits (H2).1 megabits and 2.5 megabits (H2).
H1 and H2 are classification of the two hanks of Field Bus targeH1 and H2 are classification of the two hanks of Field Bus target applications. t applications. H1 hasH1 has
low speed and utilizes existing wires. H2 has high speed and maylow speed and utilizes existing wires. H2 has high speed and may require require independentindependent
wires to power up field devices.wires to power up field devices.
Number of devices per link (31.25Kbps)Number of devices per link (31.25Kbps)
2 to 32 devices, without power and no IS (intrinsic safety).2 to 32 devices, without power and no IS (intrinsic safety).
2 to 6 with power and IS.2 to 6 with power and IS.
Maximum distanceMaximum distance
Up to 1900 meters for 31.25Kbps, without repeaters. Up to 750 meUp to 1900 meters for 31.25Kbps, without repeaters. Up to 750 meters for 1ters for 1
megabits. Up to 500 meter for 2.5 megabits.
PHYSICAL LAYERPHYSICAL LAYER
Signal ModulationSignal Modulation
Manchester bi phase L synchronous.Manchester bi phase L synchronous.
Physical layer preamblePhysical layer preamble
on transmissions, the physical layer will add to the data sent bon transmissions, the physical layer will add to the data sent by the layer y the layer
above aabove a
preamble and one start delimiter in the beginning of the frame apreamble and one start delimiter in the beginning of the frame and one end nd one end
delimiterdelimiter
at the end delimiter at the end of the of the frame.at the end delimiter at the end of the of the frame.
DATA LINK LAYERDATA LINK LAYER
The Data Link Layer will assure the integrity of the message by The Data Link Layer will assure the integrity of the message by using the frame check using the frame check
sequence:sequence:
Two bytes added to the frames and a polynomial calculation of alTwo bytes added to the frames and a polynomial calculation of all frame data.l frame data.
The Data Link Layer also checks to see that the data reaches theThe Data Link Layer also checks to see that the data reaches the devices correctly.devices correctly.
Technical characteristicsTechnical characteristics
Medium Access: Medium Access: There are three forms to access the network:There are three forms to access the network:
•• Token passing:Token passing:
Token is the right to initiate a transaction on the bus. A devicToken is the right to initiate a transaction on the bus. A device must have the e must have the
token to token to
initiate a conversation. As soon it finishes it will return the initiate a conversation. As soon it finishes it will return the token to the LAS token to the LAS
(Link(Link
Active Scheduler). The LAS send the token to the unit that requeActive Scheduler). The LAS send the token to the unit that requested in either sted in either
in ain a
prepre--configured way or via scheduling.configured way or via scheduling.
•• Immediate response:Immediate response:
A master station will give an opportunity to the station to replA master station will give an opportunity to the station to reply with one frame.y with one frame.
•• Requested token:Requested token:
a device request a token by using a code in any of the response a device request a token by using a code in any of the response sent to the sent to the
bus. The bus. The
APPLICATION LAYER AND MANAGEMENTAPPLICATION LAYER AND MANAGEMENT
The Application Layer provides a simple interface to the end useThe Application Layer provides a simple interface to the end userr’’s application. s application. Basically , it Basically , it
defines how to read, write , interpret and execute a message odefines how to read, write , interpret and execute a message or command. A r command. A big part of this jobbig part of this job
is to define the message syntax. The contents include the requeis to define the message syntax. The contents include the requested message, sted message, action taken, andaction taken, and
the response message.the response message.
The management defines how to initialize the network : tag assiThe management defines how to initialize the network : tag assignment, gnment, address assignment, address assignment,
clock assignment, clock synchronization, distributed applicatioclock assignment, clock synchronization, distributed application scheduling n scheduling across the network across the network
or association of the input and output parameters of the functior association of the input and output parameters of the function blocks. It on blocks. It also controls the also controls the
operation of the network with statistic of faults and detectionoperation of the network with statistic of faults and detection of the addition of of the addition of the new elementthe new element
or the absence of a station. The system always look for the newor the absence of a station. The system always look for the new stations on stations on the bus by pollingthe bus by polling
the possible station addresses.the possible station addresses.
Digital Communication ProtocolDigital Communication Protocol
ISOISO -- International Standard Organization. Responsible for developingInternational Standard Organization. Responsible for developing
thethe
model that the communication specimodel that the communication specification are based upon as fication are based upon as
well as well as
standards for each layer of communstandards for each layer of communication specification.ication specification.
IEEEIEEE -- Institute of Electrical and Electronics Engineers. Formed the IInstitute of Electrical and Electronics Engineers. Formed the IEEE EEE
802802
project for defining standards forproject for defining standards for network media and access network media and access
methods.methods.
SP72 SP72 -- Institute Society of America, Standards and Practice committee Institute Society of America, Standards and Practice committee
Number 72Number 72
Developing EIA1393 companion standDeveloping EIA1393 companion standard for process control ard for process control
messaging.messaging.
SP50SP50 -- Institute Society of America, Standards and Practice committee Institute Society of America, Standards and Practice committee
Number 50Number 50
Developing standards for digital cDeveloping standards for digital communication between field ommunication between field
devices.devices.
F.I.PF.I.P -- Factory Information Protocol, approved French National StandardFactory Information Protocol, approved French National Standard..
ProfibusProfibus -- Process Fieldbus, approved German National Standard.Process Fieldbus, approved German National Standard.
HART COMMUNICATION PROTOCOLHART COMMUNICATION PROTOCOL
Why HART protocolWhy HART protocol ? ?
44--20 ma is tried, tested and widely used standard but only limited20 ma is tried, tested and widely used standard but only limited amount of amount of informationinformation
is sent by a 4is sent by a 4--20 ma signal.20 ma signal.
HART (Hiway Addressable Remote Transducer) protocol enhances tHART (Hiway Addressable Remote Transducer) protocol enhances these hese operations byoperations by
transmitting digital data along with the 4transmitting digital data along with the 4--20 ma signal 20 ma signal –– without interfering with without interfering with it !it !
HART permits twoHART permits two--way communications. It also has all digital mode that allowsway communications. It also has all digital mode that allows
instrument to be connected to a single cable, cutting installinstrument to be connected to a single cable, cutting installation costs ation costs dramatically.dramatically.
Features :Features :
1.1. Field proven concept that is easy to understand and use.Field proven concept that is easy to understand and use.
2.2. Compatible with existing 4Compatible with existing 4--20 ma systems.20 ma systems.
3.3. Simultaneous pointSimultaneous point--toto--point 4point 4--20 ma and digital communication.20 ma and digital communication.
4.4. Alternative multiAlternative multi--drop mode.drop mode.
5.5. Measured variables, tag no. , range and span settings, device Measured variables, tag no. , range and span settings, device information, diagnostics and simple messages transmitted.information, diagnostics and simple messages transmitted.
6.6. Digital response time of 500 msec; burst mode response of 300 msDigital response time of 500 msec; burst mode response of 300 msec.ec.
7.7. Open architecture; freely available to any vendor and every userOpen architecture; freely available to any vendor and every user..
Method of Operation :Method of Operation :
The Hart protocol operates using the FSK principal. The digitaThe Hart protocol operates using the FSK principal. The digital data is l data is made up from two made up from two
frequencies frequencies ––1200 Hz and 2200 Hz representing bits 1 and 0 1200 Hz and 2200 Hz representing bits 1 and 0 respectively. Sinusoidalrespectively. Sinusoidal
waves of these frequencies are superimposed on the DC analogwaves of these frequencies are superimposed on the DC analog signal signal cables to give cables to give
simultaneous analog and digital communicationssimultaneous analog and digital communications
HART Protocol Structure :HART Protocol Structure :
HART follows the basic Open Systems Interconnection (OSI) refeHART follows the basic Open Systems Interconnection (OSI) reference rence model, developedmodel, developed
by the International Organization for Standard (ISO). The HARby the International Organization for Standard (ISO). The HART protocol T protocol uses a reduceduses a reduced
OSI model, implementing only layers 1,2 and 7OSI model, implementing only layers 1,2 and 7
HART COMMUNICATION PROTOCOL
OSI reference modelOSI reference model
Open Systems InterconnectionsOpen Systems Interconnections
HART COMMUNICATION PROTOCOL
Bell 202Bell 202Connects the Connects the PhysicalPhysical11
HART protocol HART protocol
regulationsregulationsEstablishes the Establishes the
data link data link
connectionconnection
LinkLink22
Establishes Establishes
network network
connectionsconnections
NetworkNetwork33
Secures the Secures the
transport transport
connectionconnection
TransportTransport44
Handles the Handles the
dialoguedialogueSessionSession55
Converts dataConverts dataPresentationPresentation66
HART instructionsHART instructionsProvides formatted Provides formatted
datadataApplicationApplication77
HARTHARTFUNCTIONSFUNCTIONSLAYERLAYER
Layer 1, the physical layer, operates on the FSK principleLayer 1, the physical layer, operates on the FSK principle
Data transfer rate: 1200 bit/sData transfer rate: 1200 bit/s
Logic Logic ““00”” frequency: 2200 Hzfrequency: 2200 Hz
Logic Logic ““11”” frequency: 1200 Hzfrequency: 1200 Hz
the vast majority of existing wiring is used for this type ofthe vast majority of existing wiring is used for this type of digital communication.digital communication.
Layer 2, the link layer establishes the format for a hart messaLayer 2, the link layer establishes the format for a hart message. HART is a ge. HART is a
master/slavemaster/slave
protocol. protocol.
the structure of these messages is given below:the structure of these messages is given below:
SD SD –– start character. AD start character. AD –– display terminal and field display terminal and field
addresses.addresses.
CD CD –– HART instruction. BC HART instruction. BC –– Byte count.Byte count.
Status Status –– Field device and communication status (only from field device tField device and communication status (only from field device to o
master)master)
The individual characters are : 1 start bit, 8 data bits, 1The individual characters are : 1 start bit, 8 data bits, 1 bit for odd parity and 1 bit for odd parity and 1
HART PROTOCOL LAYERS
ParityParityDatDat
aaStatuStatu
ssBCBCCDCDADADSDSDPreamblPreambl
ee
Layer 7, the application layer, brings the HART instruction inLayer 7, the application layer, brings the HART instruction into play. The master to play. The master
sendssends
messages with requests for specified values, actual values anmessages with requests for specified values, actual values and any other data or d any other data or
parametersparameters
available from the device. The field device interprets these available from the device. The field device interprets these instruction as defined instruction as defined
in the in the
HART protocol. The response message provides the master with tHART protocol. The response message provides the master with the status he status
informationinformation
and data from the slave.and data from the slave.
For slave devices, logical uniform communication is provided bFor slave devices, logical uniform communication is provided by the following y the following
commandcommand
sets:sets:
Universal commands Universal commands –– understood by all field devices.understood by all field devices.
Common practice commands Common practice commands –– provide functions which can be carried out by provide functions which can be carried out by
many,many,
though not all, field devices.though not all, field devices.
DriveDrive--specific commands specific commands –– provide functions which are restricted to an provide functions which are restricted to an
individualindividual
HART PROTOCOL LAYERS
DATA TRANSMISSIONDATA TRANSMISSION
Types of data transmission : Frequency shiftTypes of data transmission : Frequency shift keying (FSK)keying (FSK)
Transfer rate : 1200 bTransfer rate : 1200 bit/s.it/s.
‘‘00’’ bit information frequency : 2200 Hzbit information frequency : 2200 Hz
‘‘11’’ bit information frequency : 1200 Hzbit information frequency : 1200 Hz
Signal structure : 1 startSignal structure : 1 start bit, 8 data bits, 1 bit for bit, 8 data bits, 1 bit for odd parity, 1 stop bit.odd parity, 1 stop bit.
Transfer rate for simple variables : Approximately 2/sTransfer rate for simple variables : Approximately 2/s (poll/response)(poll/response)
DATA INTEGRITYDATA INTEGRITY
Physical layer : Error rate destination circuit : 1Physical layer : Error rate destination circuit : 1/(10^5)/(10^5)
Link layer : Recognizes : all groups up to 3 cLink layer : Recognizes : all groups up to 3 corrupt bits and orrupt bits and practically all longerpractically all longer
and multiple groups.and multiple groups.
Application layer : Communication status terminated in a Application layer : Communication status terminated in a response response message.message.
HART PROTOCOL – TECHNICAL DATA
MODBUSMODBUS
The MODBUS protocol describes an industrial commuThe MODBUS protocol describes an industrial communication and nication and
distributeddistributed
control system developed by control system developed by GouldGould--ModiconModicon. MODBUS is a Master/Slave. MODBUS is a Master/Slave
communications protocol, whereby one device (Master), controlcommunications protocol, whereby one device (Master), controls all serial s all serial
activities byactivities by
selectively polling one or more slave devices. The protocol pselectively polling one or more slave devices. The protocol provides for one master rovides for one master
devicedevice
and up to 247 slave devices on a common line. Each device is and up to 247 slave devices on a common line. Each device is assigned an assigned an
address toaddress to
distinguish it from all other connected device.distinguish it from all other connected device.
Only a master initiates a transaction. TransactioOnly a master initiates a transaction. Transactions are either a ns are either a
query/response type,query/response type,
or a broadcast/noor a broadcast/no--response type. A transaction comprises a single query and response type. A transaction comprises a single query and
singlesingle
response frame or a single broadcast frame.response frame or a single broadcast frame.
Certain characteristic of a MODBUS protocol are fCertain characteristic of a MODBUS protocol are fixed such as frame ixed such as frame
format, frameformat, frame
sequences, handling of communication errors and exception consequences, handling of communication errors and exception conditions, and the ditions, and the
functions functions
performed.performed.
RSRS--232 Communication232 Communication
RSRS--232 is an asynchronous communication network. Normally, a binary232 is an asynchronous communication network. Normally, a binary
system is system is
used to transmit data in ASCII (American Standard Code for Infoused to transmit data in ASCII (American Standard Code for Information rmation
Interchange)Interchange)
format. This code translates human readable code (letter/numberformat. This code translates human readable code (letter/numbers) into s) into ““computer computer
readablereadable””
code(1code(1’’s and 0s and 0’’s).s).
There are 2 types of RSThere are 2 types of RS--232 devices. The first is called a DTE (Data Terminal232 devices. The first is called a DTE (Data Terminal
Equipment) device and a common example is a computer. The otherEquipment) device and a common example is a computer. The other type of device is type of device is
calledcalled
DCE (Data Communication Equipment) device and a common example DCE (Data Communication Equipment) device and a common example is a modem.is a modem.
In RSIn RS--232 the first thing a terminal send is start bit. This start bit232 the first thing a terminal send is start bit. This start bit is a is a
synchronizingsynchronizing
bit added just before each character being send. The last thingbit added just before each character being send. The last thing send is a stop bit. send is a stop bit.
This stop bitThis stop bit
informs to the receiving terminal that the last character has jinforms to the receiving terminal that the last character has just being send.ust being send.
RSRS--232 communication is done through Serial port which usually has 232 communication is done through Serial port which usually has a 9a 9--pinpin
configuration. The pin and their purposes are shown below.configuration. The pin and their purposes are shown below.
RS-232 Communication
Ring indicator (RI) *only for modems*Ring indicator (RI) *only for modems*99
Clear to Send (CTS)Clear to Send (CTS)88
Request to send (RTS)Request to send (RTS)77
Data set ready (DSR)Data set ready (DSR)66
Signal ground (GND)Signal ground (GND)55
Data terminal ready (DTR)Data terminal ready (DTR)44
Transmit data (TD)Transmit data (TD)33
Receive data (RD)Receive data (RD)22
Frame groundFrame ground11
PURPOSEPURPOSE99--PINPIN
PC-to-PC Communication through Serial Port
CD 10
RXD 20
TXD 30
DTR 40
GND 50
DSR 60
RTS 70
CTS 80
RI 90
01 CD
02 RXD
03 TXD
04 DTR
05 GND
06 DSR
07 RTS
08 CTS
09 RI
9-Pin D Connector
PC-to-PC Communication through LPT1 Port1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
FlavoursFlavours of Internet Telephonyof Internet Telephony
The
Internet
The
Internet
The
Internet
PC
PC
PC
Phone
PhonePhone
Local ISP Local ISP
Local ISP Local ISP
Voice Gateway
Local ISP
Voice GatewayLocal ISP
Voice Gateway
PC-to-PC
PC-to-Phone
Phone-to-Phone
Dial-up or
Leased Line
Access
Code
APACS APACS -- Operation PlatformOperation Platform
Database OwnershipDatabase Ownership
Operator Console Engineer Console Operator Console
Controller Module
Transmitter Interlock I/P Valve
I/O ModulesI/O Level
•TAGS
•Range
•Engineering Unit
•Diagnostics
Console Level
Controller Level
TODAYS INDUSTRIAL SYSTEMSTODAYS INDUSTRIAL SYSTEMS
H M IPlanning
H M I
1 2 3 4 5 6
Application
Drivers
Devices
PLCI/O
DCS
-----------------------
PC Based Industrial SystemsPC Based Industrial Systems
H M IPlanning
H M I
1 2 3
Devices
PLCI/O
DCS
OPC Client
Application
OPC
Server
----------------------------------
Enterprise Automation SchemesEnterprise Automation Schemes
Windows NT
Windows NT
Embedded
Real System
Control
network
Corporate
IT Network
Server
Windows NT (Windows NT (““New technologyNew technology””))
FEATURESFEATURES::
•• A true 32 bit processing.A true 32 bit processing.
•• A very reliable operating system.A very reliable operating system.
•• Real operating system.Real operating system.
TECHNICAL ASPECTTECHNICAL ASPECT::
•• Multiprocessing, Multithreading and partitioned memory space.Multiprocessing, Multithreading and partitioned memory space.
•• Security Security -- C2 compliance.C2 compliance.
•• InIn--built networking.built networking.
•• Internationalization .Internationalization .
•• Human interface as Windows 95.Human interface as Windows 95.
•• Object Object -- based : DCOM/OLE based : DCOM/OLE -- ActiveX.ActiveX.
•• for special need of the process industries. DCOM and OLE are notfor special need of the process industries. DCOM and OLE are not robust, robust,
deterministic and secure.deterministic and secure.
•• Client Client -- Server architecture.Server architecture.
Transparent interTransparent inter--connectivity to typical business systems in plants:connectivity to typical business systems in plants:
1) ODBC : It provides access to most SQL databases1) ODBC : It provides access to most SQL databases..
2) ActiveX/OLE : Supports data access between appl2) ActiveX/OLE : Supports data access between application and ication and
embedding ofembedding of
one applications funone applications function within another.ction within another.
3) DDE : Dynamic Data Exchange supports simple data exch3) DDE : Dynamic Data Exchange supports simple data exchange ange
betweenbetween
applications such as plant data poapplications such as plant data populating an Excel spread pulating an Excel spread
sheets.sheets.
Windows NT Interconnectivity
Windows NT featuresWindows NT features
Windows NT is gaining ground in open control because of the foWindows NT is gaining ground in open control because of the following advantages :llowing advantages :
•• User acceptance.User acceptance.
•• Corporate interoperabilityCorporate interoperability
•• Ease of use.Ease of use.
•• Connectivity.Connectivity.
•• Scalability for small and large application.Scalability for small and large application.
However, Windows NT has the following disadvantages :However, Windows NT has the following disadvantages :
•• Needs a lot memory and processing power.Needs a lot memory and processing power.
•• Optimized for office, not control, requirements.Optimized for office, not control, requirements.
•• Requires a disk drive which may fail.Requires a disk drive which may fail.
•• Depends on single vendor.Depends on single vendor.
•• Reboots at unexpected timesReboots at unexpected times
•• Unstable operating system.Unstable operating system.
Embedded control Operating System Embedded control Operating System -- QNXQNX
QNX realQNX real--time operating system, has evolved from the firsttime operating system, has evolved from the first--ever microever micro--kernel kernel
operatingoperating
system for PCs into one of the best selling and most trusted opesystem for PCs into one of the best selling and most trusted operating systems for rating systems for
missionmission
critical application. Today, QNX is the real time operating systcritical application. Today, QNX is the real time operating system in industrial em in industrial
automation,automation,
hand held devices, controllers and soft PLCshand held devices, controllers and soft PLCs
QNX is recognized as :QNX is recognized as :
•• The fastest and most dependable real time operating system.The fastest and most dependable real time operating system.
•• The most proven high speed, deterministic real time kernel.The most proven high speed, deterministic real time kernel.
•• Having a hard real time engine that gives PLCHaving a hard real time engine that gives PLC--style control.style control.
•• Enabling data acquisition with milliseconds resolution.Enabling data acquisition with milliseconds resolution.
•• Providing a faultProviding a fault--tolerant architecture on which you can run control, events, tolerant architecture on which you can run control, events,
alarms in a virtually crashalarms in a virtually crash--proof environment. proof environment.
Windows NT Windows NT -- for Process controlfor Process controlWindows NT features :Windows NT features :
•• A true 32 bit processing.A true 32 bit processing.
•• A very reliable operating system.A very reliable operating system.
•• Real operating system.Real operating system.
•• Multiprocessing, Multithreading and partitioned memory space.Multiprocessing, Multithreading and partitioned memory space.
•• Security Security -- C2 compliance.C2 compliance.
•• InIn--built networking.built networking.
•• Internationalization.Internationalization.
•• Human interface.Human interface.
•• ObjectObject--based DCOM/OLE :based DCOM/OLE :
The sending object is shown as client and receiving objThe sending object is shown as client and receiving object is known as ect is known as server. Theserver. The
MS technology allows any developer to produce small, seMS technology allows any developer to produce small, self contain objects lf contain objects that havethat have
““packagedpackaged”” visual component and specific action. These components are visual component and specific action. These components are calledcalled
““ActiveXActiveX”” objects. NTobjects. NT’’s OLE technology is part of Microsofts OLE technology is part of Microsoft’’s Distributeds Distributed
Component Object Model (DCOM) operating across networksComponent Object Model (DCOM) operating across networks. Anyone can . Anyone can developdevelop
ActiveX Object using VC++ or even VB on a PC. For speciaActiveX Object using VC++ or even VB on a PC. For special needs of the l needs of the processprocess
control industries DCOM and OLE are not secure, determinicontrol industries DCOM and OLE are not secure, deterministic and robust stic and robust enough.enough.
EthernetEthernet
Ethernet was originally designed by Digital, Intel andEthernet was originally designed by Digital, Intel and Xerox (DIX) in the early Xerox (DIX) in the early
19701970’’ss
and has been designed as a broadcast system. The original formaand has been designed as a broadcast system. The original format for Ethernet was t for Ethernet was
developeddeveloped
in Xerox Palo Alto Research center (PARC), California in 1972. in Xerox Palo Alto Research center (PARC), California in 1972. The two inventors The two inventors
were were
Robert Metcalf and David Boggs.Robert Metcalf and David Boggs.
Ethernet version 1.0 and 2.0 followed until the IEEE 8Ethernet version 1.0 and 2.0 followed until the IEEE 802.3 committee re02.3 committee re--
jigged the jigged the
Ethernet II packet to form the Ethernet 802.3 packet. Nowadays Ethernet II packet to form the Ethernet 802.3 packet. Nowadays you will see either you will see either
Ethernet II (DIX) format or Ethernet 802.3 format being used.Ethernet II (DIX) format or Ethernet 802.3 format being used.
The The ‘‘EtherEther’’ part of Ethernet denotes that the system is not meant to be part of Ethernet denotes that the system is not meant to be
restricted only to restricted only to
one medium type, copper cables, fiber cables and even radio wavone medium type, copper cables, fiber cables and even radio waves can be used.es can be used.
Briefly, stated Ethernet what is referred to as the PhBriefly, stated Ethernet what is referred to as the Physical layer and the Dataysical layer and the Data--
link layerslink layers
protocols. The physical layer defines the cable types, connectoprotocols. The physical layer defines the cable types, connectors and electrical rs and electrical
characteristics.characteristics.
The Data link layer defines the format an Ethernet frames, the The Data link layer defines the format an Ethernet frames, the error checking error checking
method and themethod and the
10Base510Base5
Traditionally, Ethernet is used over Traditionally, Ethernet is used over ‘‘thickthick’’ coaxial cable called 10Base5 ( coaxial cable called 10Base5 (
the 10 the 10
denotes 10 Mbps, base means that the signal is baseband i.e, tadenotes 10 Mbps, base means that the signal is baseband i.e, takes the whole kes the whole
bandwidthbandwidth
of the cable, 5 denotes 500m maximum length ). The minimum lengof the cable, 5 denotes 500m maximum length ). The minimum length th
between stationsbetween stations
is 2.5m.is 2.5m.
The cable is run in one long length forming a The cable is run in one long length forming a ‘‘Bus TopologyBus Topology’’. The . The
segments aresegments are
terminated by 50 ohm resistor and the shield should be groundedterminated by 50 ohm resistor and the shield should be grounded at one end at one end
only.only.
10Base210Base2
Thin Ethernet (Thinnet) uses RGThin Ethernet (Thinnet) uses RG--58 cable and is called 10Base2 (the 2 58 cable and is called 10Base2 (the 2
denotesdenotes
200 mtr maximum length cable). Each station connects to the Thin200 mtr maximum length cable). Each station connects to the Thinnet by way net by way of
EthernetEthernet
10BaseT10BaseT
Nowadays, it is becoming increasingly important to useNowadays, it is becoming increasingly important to use Ethernet across Ethernet across
Unshielded Unshielded
Twisted Pair (UTP) or Shielded Twisted Pair (STP), this being cTwisted Pair (UTP) or Shielded Twisted Pair (STP), this being called 10BaseT (the Talled 10BaseT (the T
denotes twisted pair). UTP is installed in star wire format anddenotes twisted pair). UTP is installed in star wire format and Ethernet Hubs with Ethernet Hubs with
UTP ports UTP ports
(RJ45) centrally located. Also there should be no more than a 1(RJ45) centrally located. Also there should be no more than a 11.5db signal loss and 1.5db signal loss and
thethe
minimum distance between devices is 2.5 meters.minimum distance between devices is 2.5 meters.
The advantages of the UTP/STP technology are gained froThe advantages of the UTP/STP technology are gained from the flexibility of m the flexibility of
thethe
system, with respect to moves, changes, fault finding, reliabilsystem, with respect to moves, changes, fault finding, reliability and security.ity and security.
10BaseF10BaseF
10BaseF standard developed by IEEE 802.3 committee defi10BaseF standard developed by IEEE 802.3 committee defines the use of Fiber nes the use of Fiber
forfor
Ethernet. 10BaseFB allows up to 2 Km per segment and is defineEthernet. 10BaseFB allows up to 2 Km per segment and is defined for Backbone d for Backbone
EthernetEthernet
The following table shows the RJ45 pin outs for 10BaseT :The following table shows the RJ45 pin outs for 10BaseT :
Brown/WhiteBrown/White88
White/BrownWhite/Brown77
Green/WhiteGreen/WhiteReceiveReceive66
White/BlueWhite/Blue55
Blue/WhiteBlue/White44
White/GreenWhite/GreenReceiveReceive33
Orange/WhiteOrange/WhiteTransmitTransmit22
White/OrangeWhite/OrangeTransmitTransmit11
ColourColourFunctionFunctionRJ45 PinRJ45 Pin
Ethernet Ethernet
PCPC--toto--PC Communication through PC Communication through
EthernetEthernet
RJ45 RJ45
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
Controller ControllerController
Controller
Workstation Workstation Workstation Workstation
Switched Hub
Segmented (star) topology Bus topology
Ethernet TopologyEthernet Topology
Wireless LANWireless LAN
Wireless LAN is based on standard IEEE 802.11b which throughput Wireless LAN is based on standard IEEE 802.11b which throughput of up to 11Mbps in of up to 11Mbps in
the the
2.4 2.4 GhzGhz band. Similar Wireless Personal Area Network (WPAN) are Bluetooband. Similar Wireless Personal Area Network (WPAN) are Bluetooth and th and
Infrared.Infrared.
Ethernet works on the CSMA/CD technology but wireless LAN haEthernet works on the CSMA/CD technology but wireless LAN has difficulty of s difficulty of
detecting detecting
collision in Radio frequency. Therefore they are using CSMA/CA (collision in Radio frequency. Therefore they are using CSMA/CA (Collision Sense MultipleCollision Sense Multiple
Access / Collision Avoidance) technology to transmit data. PhysiAccess / Collision Avoidance) technology to transmit data. Physical Layer is either cal Layer is either
Photonic or Photonic or
Radio frequency.Radio frequency.
Process control Software characteristicsProcess control Software characteristics
The most important feature of process control system is that it The most important feature of process control system is that it needs to be needs to be
reliable. reliable. The The
process control system used has to be completely crashprocess control system used has to be completely crash--proof and any changes in proof and any changes in
thethe
system need to be made onsystem need to be made on--line.line.
The process control needs to be made The process control needs to be made real time,real time, which means that it can which means that it can
update the I/O update the I/O
data table and process the control program in the time requireddata table and process the control program in the time required by the process.by the process.
A process control system that is A process control system that is deterministic deterministic refers to whether the operating refers to whether the operating
system system
allows the highest priority task to work without interruption fallows the highest priority task to work without interruption from task with lower rom task with lower
priority.priority.
Software offerings in the automation and the process control fSoftware offerings in the automation and the process control fields must be ields must be
versatileversatile andand
openopen enough to address the needs of different applications.enough to address the needs of different applications.
Finally the chosen solution must deliver tangible, quantifiablFinally the chosen solution must deliver tangible, quantifiable values such as : e values such as :
1.1. Reducing project implementation time and cost.Reducing project implementation time and cost.
2.2. Improving timeImproving time--toto--market.market.
3.3. Achieving higher production and quality.Achieving higher production and quality.
4.4. Cutting maintenance and training cost.Cutting maintenance and training cost.
PCPC--based control system featuresbased control system features
Unlike the other systems, PCs provide a more open architectureUnlike the other systems, PCs provide a more open architecture making them ideal making them ideal
for for
improving, optimizing and integrating the overall automation primproving, optimizing and integrating the overall automation process, as well as ocess, as well as
conductingconducting
control task.control task.
In addition PCs offer the following features :In addition PCs offer the following features :
•• Lower cost.Lower cost.
•• Ease of use.Ease of use.
•• Graphical user interface.Graphical user interface.
•• Easy integration of logic, motion and process control.Easy integration of logic, motion and process control.
•• Simplified application development.Simplified application development.
•• Software portabilitySoftware portability
•• Independence from proprietary control system.Independence from proprietary control system.
Using PCs enable the following functions,Using PCs enable the following functions,
•• Millisecond time stamping which is essential to utilities.Millisecond time stamping which is essential to utilities.
•• Real time control.Real time control.
•• Sequence of events.Sequence of events.
•• Alarming.Alarming.
•• Data collection.Data collection.
PLC conceptual overviewPLC conceptual overview
Process
Graphics
History &
Trend
Alarm &
Events
SCADA
configuration
editor
Other Aspect
system
ABB Siemens Allen
Bradley
GE
Fanuc….
opc Modbus comliProtocol
xx
Protocol
yy
SCADA
server
OPC server
OP Client SCADA Control
Aspect
Real-time
database
PLC Programming StandardsPLC Programming Standards
The open, manufacturerThe open, manufacturer--independent programming standard for independent programming standard for
automation isautomation is
IEC 61131IEC 61131--3. You can thus choose what configuration interface you wish to 3. You can thus choose what configuration interface you wish to use use
whenwhen
writing your application :writing your application :
•• Ladder DiagramLadder Diagram
•• Instruction ListInstruction List
•• Function Block DiagramFunction Block Diagram
•• Sequential Function ChartSequential Function Chart
•• Structured TextStructured Text
All users, be they plant electrician or coAll users, be they plant electrician or computer scientists, thus have mputer scientists, thus have
a configuration interface in which they can feel at home.a configuration interface in which they can feel at home.
Industrial IT TrendsIndustrial IT Trends
The availability of information is becoming increasingly crucialThe availability of information is becoming increasingly crucial in the view of growing in the view of growing
globalglobal
competition. In future, a decisive competitive edge can only becompetition. In future, a decisive competitive edge can only be achieved by providing achieved by providing
thethe
right information at the right time, in the right place and in right information at the right time, in the right place and in the right form for the right the right form for the right
person. person.
these leadingthese leading-- edge application are continuously optimized and repositioned.edge application are continuously optimized and repositioned.
Industrial IT consists of five components:Industrial IT consists of five components:
1.1. Engineering ITEngineering IT
2.2. Operation ITOperation IT
3.3. Production ITProduction IT
4.4. Optimization ITOptimization IT
5.5. Evolution / InformationEvolution / Information
ASSET OPTIMIZATION
Industrial IT TrendIndustrial IT Trend
Sales &
Marketing
Planning &
Scheduling
Plant &
Process Eng.
Operation &
Maintenance Distribution
Real-time
Automation &
Information
e-PR
OD
UC
TIV
ITY
Business
Systems
Plant