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Animated ppts on distributed control system.ppts with full on animation .Animation is present in every slide very interesting and good explanation of distributed control system
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EVOLUTION OF DCS
Different stages of evolution of Control system are :
• Manual or Field control• Pneumatic Single loop control system.• Electronic single loop control system• Centralized control system• Distributed control system.
DISTRIBUTED CONTROL SYSTEM
DEFINATION :-
• A Control System In Which Different Intelligent Devices
(Controllers) Are Functionally & Geographically Distributed
To Control The Process And Integrated On Same
Communication Loop.
ADVANTAGES OF DCS SYSTEM
REDUNDANCY:- The System Consists Of Critical Equipments Which Have Been
Supported By Active Stand By System Which Results In
Increased Reliability.
RELIABILITY :- Ability Of A System To Operate Efficiently Under Pre-
Determined Operating Conditions.
ADAPTABILITY:- Ability Of A System To Operate Under Adverse Operating
Conditions Accept Changes And Also Provide Easy Machine
Human Interface.
ARCHITECTURE’S OF DCS
• The master less deterministic type on single network
(Node Server)
• The client server type with master less characteristic
on single network
• The client server type with server as master and
interlink between clients on two separate networks.
NODE SERVER
• A network with deterministic master less type of protocol has a real master less node hierarchy, which means that all the nodes, i.e., all controllers as well as operator stations will have the same priority and shall be always communicating to the network together. In this case, the failure of any one operator station, i.e. any one node will lead to the “ non operation of that node only and the rest of the system stays healthy ” , thereby maintaining the healthiness of the network.
All healthy nodes and all are at same
hierarchy
NODE SERVER MASTERLESS TYPE DCS
Bus1
Bus2
Node 1
Node 4
Node 3
Node 2
Node 6
Node 5
All healthy nodes and all are at same
hierarchy
Node 1
Node 4
Node 3
Node 2
Node 6
Node 5
NODE SERVER MASTERLESS TYPE DCS
Bus1
Bus2failure
Failure of Bus-2 causes Bus-1 to take over without making any difference to
nodes
failure
FAILURE OF A NODE WILL LEAD TO THE FAILURE OF THE PARTICULAR NODE ONLY. OPERABILITY IS
INTACT FROM ALL OTHER NODES
Still Healthy Nodes keep
system healthy
NODE SERVER MASTERLESS TYPE DCS
Bus1
Bus2
CLIENT SERVER WITH SINGLE NETWORK
A special case of Client-server architecture with servers and all its clients connected directly to the same network. In this architecture both the controllers and the operator stations are clients to the server but communicating directly to the network. All the data required are being stored in a common distributed database at the server which keeps the complete history of the operations and process data.
In normal operation all the operations and process data are being communicated from/to the operator stations/ controllers are routed through the server, but failure of the server will lead to a direct communication of the operator stations to the controllers. The complete controllability of the controllers from the operator stations stays intact and the only difficulty faced is the loss of the historical trending capability of the control system.
CLIENT SERVER WITH SINGLE NETWORK
Server healthy means all nodes (clients)
communicating to the server
Server Client 1
Client 4
Client 2 Client 3
Client 5
CLIENT-SERVER ARCHITECTURE TYPE DCS BUT MASTER LESS FOR OPERABILITY
Bus1
Bus2
Server healthy means all nodes (clients)
communicating to the server
server Client 1
Client 4
Client 2 Client 3
Client 5
CLIENT- SERVER ARCHITECTURE TYPE DCS BUT MASTERLESS FOR OPERABILITY
Failure of Bus-2 causes Bus-1 to take over without making any difference to
nodes
Bus1
Bus2failure
Even after failure of server, the clients
keep communicating in between and hence
operability is intact
Client 4
Client 3
Client 5
Failure
Failure of server renders failure of communication
between clients and server
Client 2Client 1Server
CLIENT SERVER ARCHITECTURE TYPE DCS BUT MASTERLESS FOR OPERABILITY
Bus1
Bus2
CLIENT SERVER WITH TWO SEPEATE NETWORKS
A network with client server architecture will have servers as an interconnection point between the controller nodes and the human machine interface nodes (HMIs). Both the controllers and the HMIs are clients to the server. The failure of the server will lead to a highly dangerous situation of complete loss of controllability of the network. No process information from the controller will be communicated to the operator station and instructions from the operator station also cannot be communicated back to the controller.
serverClient 2Client 1 Client3
Client 4Client 5
CLIENT SERVER ARCHITECTURE TYPE DCS WITH SERVER AS MASTER
Network I /Bus1
Network I /Bus2
Network II /Bus1
Network II /Bus2
serverClient 2Client 1 Client3
Client 4Client 5
CLIENT SERVER ARCHITECTURE TYPE DCS WITH SERVER AS MASTER
Network I /Bus1
Network I /Bus2
Network II /Bus1
Network II /Bus2
failure
Failure of Bus-1 causes Bus-2 to take over without making any difference to
nodes
serverClient 2Client 1 Client3
Client 4Client 5
failure
Data lost
Data lost
ErrorErrorError
Failure of the server will lead to failure of complete network and loss of operability
STEAM GENERATION PLANT OF NFL PANIPAT
• Steam generation plant has three Boilers of BHEL make, each having MCR (Max. Capacity Rating) of 150 T/hr respectively, producing superheated steam at a Pressure of 100 Kg/cm2 & at a temperature of 500 0 C
• All the three boilers are controlled by DCS.
SGP DCS SYSTEM
• Distributed control system for steam generation plant is being procured from M/s ABB . The system is known as
“ WORKSTATION BASED SYMPHONY
HARMONY INDUSTRIAL IT SYSTEM”.• The control and monitoring philosophy has been split in
to two categories i.e. closed loops and Open loops ( mainly indications).• The closed loops are being powered , monitored and
controlled in the DCS whereas the open loops are being powered and configured in the MUX system and monitored in the DCS system.
SGP DCS SYSTEM NODE DISTRIBUTION
• There are total 10 nodes in system which are directly connected to C-NET.
Sr.No No. of nodes Used for
1 Three (3) Three Boilers
2 One(1) Common section
3 One(1) EWS
4 Five(5) OWS
• The EWS & OWS are also to Ethernet switch through O- NET cable.
• Two printers are on O-NET.
SGP DCS SYSTEM PANEL CONFIGURATION
• DCS system panels for each boiler comprises of four panels, one is system panel, and the rest three are termination panel.
• AI terminates through HMS panel whereas AO terminate directly , DI/DO terminate through relays.
• System panel have three set of controllers in redundant,one for OLCS, one for CLCS & last for MUX. System panel communicates using NIS & NPM. Similarly OWS communicate on C-NET using NIS & ICT.
DATA FLOW
BOILER-1 BOILER-2 BOILER-3 COMMON
NIS NISNISNIS
NPM NPM NPM NPM
NODE-4NODE-1
NODE-2
NODE-3
ITC ITC ITC ITC ITC ITC
NIS NIS NIS NIS NIS NIS
LINE-1
LINE-2
NODE-5NODE-10
NODE-6NODE-9 NODE-7NODE-8
REDUNDENT C - NET
O-NET
C-NET
C-NET is a unidirectional, high speed serial data network that operates at a 10 – megahertz communication rate. It supports a central network with up to 250 system NODE connections.
SYSTEM CARDS• THERE ARE DIFFERENT TYPES OF CARDS IN SYSTEM PANEL FOR
VARIETIES OF INPUTS/OUTPUTS-
1)TEMPERATURE CARD FOR THERMOCOUPLE/RTD,( IMAS123)
2)ANALOG INPUT CARD FOR 4-20 ma, (IMFEC12)
3)ANALOG OUTPUT CARD FOR 4-20 ma(IMASO11)
4)DI CARD FOR CONTACT INPUT (IMDSI 13)
5) DO CARD FOR CONTACT OUTPUT (IMDS0 14)
6) NETWORK INTERFASE SLAVE (NIS-21)
7) NETWORK PROCESS MODULE (NPM-12)
8) BRC 300 ( CONTROLLER)
9) MFP 12 ( CONTROLLER)
10) ITC- (FOR COMMUNICATING WITH THE COMPUTER)
DCS SYSTEM
• 4-20 mA out of smart Txs., Superimposed with hart signal, are terminated to HMS. Here, HART Signal and 4-20 mA signals are separated using patch cards. 4-20 mA goes to terminate to AI cards through DCS Marshelling cabinet.
• Termination of this 4-20 mA depends on whether this is field powered or system powered.
MULTIPLEXER SYSTEM
• Supplied by MTL,England.• Multiplexers are used for cable saving. Here non
critical signals have been taken through MUX.• There are four MUX stations for each boiler
installed in field itself.• All the twelve MUX stations having redundant
supply . MUX -1 & 2 for each boiler caters mainly AI whereas MUX-3 & 4 caters mainly DI/DOS.
MULTIPLEXER SYSTEM
• The MUX uses redundant EBIM (Ethernet bus interface module) processing data at very high speed of 100 Mbps, whereas the controller (MFP12) used in DCS system for third party communication is Modbus compatible, hence MOXA switches are used to convert Ethernet to Modbus.
MULTIPLEXER SYSTEM
• Hence redundant Ethernet cable have been laid from each of the MUX to redundant MOXA switches from MOXA, Ethernet Cable been laid for HMS/MUX PC where WORKBENCH Software is loaded for status monitoring of all MUX modules.
• Also RS-485 Cable laid from MUX-1 & 2 having AIs only to HMS PC, through RS-485 to RS-232 Converter, for catering smart transmitters with the help of CORNERSTONE Software loaded on the same HMS/MUX PC.
SER-SEQUENCE OF EVENT RECORDER
• There is one SER of 512 points comprising of two SER Stations - EL1 & EL2.
SER Stations DI Cards No of events handling capacity
EL1 9 288
EL2 7 224
NIS NPM
BRCSLAVETU
C-NET
BRC
C-NET
SLAVETU
TO FIELD
FROM FIELD
DATA FLOW BETWEEN BRC AND C – NET
CAPTIVE POWER PLANT IN NFL PANIPAT
• In NFL Panipat We have Captive power plant which has MCR 230 T/hr at Pressure of 100Kg/cm2 and at a temperature of 500oC
• In NFL Panipat we have Two Turbo Generators (TG’s) each having a capacity of 15MW
• Boiler of CPP and Turbine of TG’s is controlled by DCS.
CPP DCS SYSTEM
1. Distributed control system for CPP was originally procured from
M/s ABB The system was “ BAILEY NETWORK 90”
2. Later on it was up graded with Symphony Harmony Industrial IT
System for turbine side
3. The boiler side is up graded with INFY 90 System.
4. In this way CPP have to separate DCS System.
5. Both systems are connected to a pair of redundant server.
6. CPP DCS System is Client server based Architecture.
NODE DISTRIBUTION OF CPP DCS SYSTEM
1. It Has 16 (Sixteen) Nodes connected to C – NET
Sr.No. No. of Nodes Used for
1 Three(3) Automatic Boiler Controller(ABC)
2 Four(4) Burner management system(BMS)
3 Three(3) Sequence (SEQ)
4 Two(2) Turbine of TG 1 & 2.
5 One(1) Common Section
6 Two(2) RTDS 1 & 2
7 One(1) EWS
OPERATING STATIONS DISTRIBUTION OF CPP DCS SYSTEM
Four Operating Station Are Connected Through
Redundant O – Net To RTDS 1 & 2.
A. Two Stations Are Loaded with History.
B. One Station Is Loaded with Configuration Software.
The Operating Station System Is Windows 2000
Professional Based.
HIS P HIS R CLIENT COMPOSER
RTDS1 RTDS2EWS
O-NET
ABC SEQ BMS TG-1 TG-2 COM
C - NET
ARCHITECTURE OF CPP DCS SYSTEM
COMPARISON OF DCS OF SGP & CPP OF NFL PANIPAT
SGP• Architecture is
Node Server based.
• Operating system is Window XP Professional based.
• All critical loops are redundant
• DCS is PGP based
CPP• Architecture is
Client server based.
• Operating system is Windows 2000 professional based.
• All critical loops are not redundant .
• DCS is PPB based.
COMPANY ABB YOKOGAWA
S.NO. MODEL
Advant with 460 controller
Syphony Harmony IT Infi-90 CS 3000 CS 1000
1HMI Architecture Node Server option
Node Server option Client Server Node Server Client Server
2Operating System Window Based Window Based Window Based Window Based Window Based
Window NT Window NT or XP Window NTWindow NT,XP,2000 Window NT,2000
3 Data Bus Using C-Net 10 MbpsUsing C-Net 10 Mbps
Using C-Net 10 Mbps
Using V-Net 10 Mbps
Using VL-Net 10 Mbps
4 Redundancy
A) Power Supply Yes Yes Yes Yes Yes
B) System Bus Yes Yes Yes Yes Yes
C) Controller Yes Yes Yes Yes optional with extra
D) I/O Module optional with extraPresent in critical loop
optional with extra
Present in critical loop optional with extra
E) Server Yes Yes Yes Yes Yes
F) Memory(system) Yes Yes
optional with extra Yes optional with extra
DCS COMPARISON OF VARIOUS MODELS OF VARIOUS COMPANIES
COMPANY ABB YOKOGAWA
S.NO. MODEL
Advant with 460 controller
Syphony Harmony IT Infi-90 CS 3000 CS 1000
5 Processor
A) System User Defined User Defined User Defined User Defined User Defined
B) Controller 68040/25 MHz, Motorola
32- bit, Motorola RISC
32- bit, Motorola RISC VR5432(133MHz) Proprietary
C) Controller Memory Up to 8Mb 16Mb 16Mb 32Mb
6Online Replacement Yes Yes Yes Yes Yes
7Online Configuration Yes Yes Yes Yes Yes
8 System Memory User Defined User Defined User Defined User Defined User Defined
9 I/O capacity >10000 tags posibleSutable for large plant
only for medium plant Up to 100000 I/O
only for medium plant
10 Web Connection Possible with isolation
Possible with isolation
Possible with isolation
Possible with isolation
Possible with isolation
11 Scan time<200ms Possible Possible Possible Possible Possible
DCS COMPARISON OF VARIOUS MODELS OF VARIOUS COMPANIES
COMPANY FOXBORO HONEYWELL SIEMENS
S.NO. MODEL IA Series Experience PKS TPS with gus Teleperm XP Telemerm ME
1 HMI Architecture Node Server option Client ServerNode Server option Node Server Client Server
2Operating System Window Based Window Based Window Based Window Based DOS Based
Window NT,XP,2000 Window NT,XP,2000 Window NT STRUK
3 Data BusUsing Device-Net 10 Mbps
Using LAN Up to 100 Mbps
Using LCN 5 Mbps
UsingCS-272 <10Mbps
4 Redundancy
A) Power Supply Yes Yes Yes Yes Yes
B) System Bus Yes Yes Yes Yes Yes
C) Controller Yes Yesoptional with extra
optional with extra optional with extra
D) I/O Module Present in critical loop optional with extraoptional with extra
optional with extra optional with extra
E) Server Yes Yes Yes Yes optional with extra
F) Memory(system) Yes optional with extra Yes Yes optional with extra
DCS COMPARISON OF VARIOUS MODELS OF VARIOUS COMPANIES
COMPANY FOXBORO HONEYWELL SIEMENS
S.NO. MODEL IA Series Experience PKS TPS with gus Teleperm XP Telemerm ME
5 Processor
A) System User Defined User Defined User Defined User Defined INTEL PII
B) Controller N/A C 200 N/A Virtual ProcessorINTEL 80188(20MHz)
C) Controller Memory 4000Kb 156Kb
6Online Replacement Yes Yes Yes Yes Yes
7Online Configuration Yes Yes Yes Yes Yes
8 System Memory User Defined User Defined User Defined User Defined User Defined
9 I/O capacity Up to 100000 I/O Up to 100000 I/O 10000 tags only for medium plant
10 Web ConnectionPossible with isolation
Possible with isolation
Possible with isolation
Possible with isolation N/A
11 Scan time<200ms Possible Possible Possible Possible Possible
DCS COMPARISON OF VARIOUS MODELS OF VARIOUS COMPANIES