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