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Basic Loop
Controller
I/P
Transmitter
I/P
Convertor
PV MV
SV
4-20 mA
4-20 mA
Pneumatic Signal(0.2 to 1 g/cm2 or ! to 1" #si$
%inal Control &lement
Basic ControlLoop
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Process Control Systems
Process control systems are classifiedinto
Analog Control Systems
Digital Control Systems
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Analog Control System
Signal
Conversion
I/P
4-20 mA 'C
1 to "V 'C
#erational Am#li)ier
Set Point
%inal Control &lement
Transmitter
Analog Control System
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Digital Control System
I/P
4-20 mA 'C
A / '
1 to "V 'C
' / A
'igitalut#ut
*nit
In#ut
*nit
Memor+
*nit
Control
*nit
Arit,metic
*nit
Set
Point
Processor
Digital ControlSystem
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* First control
computers* First DDC * First mini
computers* First distributed
DDC using
microprocessors
* First one-loop
DDC controllers* Integrated systems
Ge.r Sl. r
!apid gro"t# o$
process Industries
DL SSI
L.SSI LSI uP
%nergy crisis
&ransition to
steady gro"t#'
Demand $or
conser(ation
o$ resources
Appearance o$
)A LA and FA
&Impro(ed man-
mac#ine inter$ace
+ LSI ,bit P
* /ulti produce batc#
applications
* Integrated FA system
* CI/
* multimedia
* Pentium Processor
* !e(olution in in$o tec#
* Internet
* "indo"s 0 gaining prominence
* )b1ect lin2ing
* )DBC
* !DB/S
3% %IG3I%S 3% 0I0%I%S3% S%+%0I%S3% SI4I%SB%5)0D
666
* se o$ $actory
management
computers
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5%7C)/
Factory /anagement Computer System
3P8666
Computer Control System
CCS5)DIC 966 5)DIC 9666
/anu$acturing Line Control System
5%7/AC
Centrali:ed DDC System
5)DIC ;66 5)DIC 6 5S 966
%CS %BS I S%!I%S
Analog Control System
CS9666
CS,666
CS
3% %IG3I%S 3% 0I0%I%S3% S%+%0I%S3% SI4I%SB%5)0D
666
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Digital Control System
Digital Control Systems are furtherclassified into
Centralized Control Systems
Distributed Control Systems
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Centralie
Processing*nit
CP*
Centrali:ed Control System
Input
Signals
$rom
Field
Set Points
)utput
Signalsto
Field
Centralie Control Centralie Monitoring
P+9
P+
P+n
P+,
/+9
/+
/+n
/+,
S+9 S+ S+, S+n
Centralized Control System
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Centralized Control System
Drawbacks Of CCS:
If the CPU fails the entire lant
gets affected!"edundancy concet is nota#ailable!
Redundancy is having two controllers. Onewould be active and the other would bestandby. If the active controller fails, thestandby controller taes over.
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Distributed Control System
Input
Signals
$rom
Field
'istriute Control Centralie Monitoring
Set Points
Communication
Bus
)utput
Signals
to Field
/+9
/+>
%CS
P+9
P+>
S+9S+>
/+8
/+9<
%CS
P+8
P+9<
S+8 S+9<
/+9?
/+n
%CS
P+9?
P+n
S+9? S+n
PS
PS
Distributed Control System
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!asic Com"onents of DCS
$CS %$ield Control Station&: #sed to control the "rocess. $ll the instruments
and interlocs created by software reside in thememory of the %CS. $ll the field instruments lie
transmitters and control valves are wired to the%CS. OPS %Oerator Station&: #sed to monitor the "rocess and to o"erate
various instruments.
Communication 'us: #sed to communicate between the %CS and theOPS
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$dvantages of DCS
Control function is distributed among multi"le CP#s&%ield Control Stations'. (ence failure of one %CSdoes not affect the entire "lant.
Redundancy is available at various levels.
Instruments and interlocs are created by software. )eneration and modifications of the interlocs are
very fle*ible and sim"le. Information regarding the "rocess is "resented to
the user in various formats. %ield wiring is considerably less. +aintenance and trouble shooting becomes very
easy. Cost effective in the long run.
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C()*U+ Series %DCS& (#olution
1st CENTUM1st CENTUM
nd CENTUMnd CENTUM
CENTUM !CENTUM !
CENTUM"#LCENTUM"#L
CENTUM CSCENTUM CS
CENTUM CS$%%%CENTUM CS$%%%
1&'(1&'(
1&)11&)1 1&)*1&)*
1&))1&))1&&$1&&$
1&&)1&&)
CENTUM has developed as a true open syste
+orld ,irst DCS+orld ,irst DCS
%%)%%)CENTUM !-CENTUM !-
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CS,---.System Configuration
CS, CS 1000
CENTUM-XL, -V
MXL
BCV
CGW
Remote Domain System
V net
HI
S
ooo
!CS
L!CS
Et"e#net
HIS $ ENG
FFCS KFCS
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C()*U+ CS ,--- . +a/or Comonents
$CS %$ield Control Station& Reliable controller. Cost-effective and ca"able IO subsystem.
0IS %0uman Interface Station& /he o"erator station based on 0indows 1P or 0indows2333.
&!oth are selectable.' (IS "rovides easy 4 fle*ible o"eration.
()1 %(ngineering Station& 5ngineering Station is used to do the engineering builder for
all the stations lie (IS, %CS, C)0, !C6 etc. 57) is a PC
loaded with 5ngineering software. /he (IS can be loaded with engineering software so that itcan be used as (IS as well as 57).
C12: Communication )ateway #nit used to communicatewith su"ervisory com"uters.
'C3: !us Converter is used to lin two domains.
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C()*U+ CS ,--- . )etworks
3.)et %Communication 'us&
Real-time control bus.
6-75/ is a used for communication between(IS, %CS, !C6 4 C)0.
+a*imum 89 Stations can be connected on the 6-net.
(*0(")(* %Communication 'us&
5thernet is a standard networ in CS:333
to connect (IS, 57) and su"ervisory com"uters . /ransmission s"eed;
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CS,--- $IO System Configuration.O#er#iew
ooo
.S.+.S.+
! net! net
-LC-LC
,C/0,CN,C/0,CN
EternetEternet
-23,4BUS"D-!1-23,4BUS"D-!1
Discrete I/O Drive
De5iceNetDe5iceNet
Photoelectricdevice
3-C3-C
Ser5eSer5e
rr
,,C,,CSS
EternetEternet
Sa6etySa6ety
SysteSyste
mm 3ter3ter
SysteSyste
mm
Subsystem
.ate7ay
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$IO
%IO means %%ield networ II OO.
%IO is Process IO modules.
$ ind of com"act, cost-effective,reliable IO devices, targeted as theindustrial standard IO of ne*t-
generation. %IO includes the latest networ
technologies and field e*"erience.
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-o7er supply unit
C-*%1 C-U module
Eigt ,43 slotsEigt ,43 slots
EC*%1 ESB bus coupler8Note9
Note: To I/O slots are to !e used "or NIU e#tens
A4-(%* !net coupler 81%BASE !net cable is used:9
Detacablbottom uni
,,CS ;ard7are !ie7
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0ardware Configuration. 4ocal )ode
,43< Ma=: )
LocalnodeMa=: $
ESB busESB busUp to >Modules
Up to )Modules
C P $ % & C P $ % &
P ' $ ( ) P ' $ ( )
! net! net
,,C,,C
SS
C P $ % & C P $ % &
P ' $ ( ) P ' $ ( )
E C $ % &
E C $ % &
* + $ %
& P ' $ (
) P ' $ (
) * + $ %
&
* + $ % &
P ' $ ( ) P ' $ ( )
* + $ % &
* + $ % &
P ' $ ( ) P ' $ ( )
* + $ % &
,,C,,C
SS
MinimumMinimum
Con?gurationCon?guration
Ma=imumMa=imum
Con?gurationCon?guration
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0ardware Configuration5"emote )ode! net! net
,,C,,CSS
2emote node2emote node
E=panded 2emote node upto $
E2 busE2 bus
E + $ % & E + $ % &
E + $ % & E + $ % & E + $ % & E + $ % & E + $ % & C P $ % & C P $ % &
P ' $ ( ) P ' $ ( )
E + , % &
P ' $ ( )
P ' $ ( )
E + , % &
2emote node2emote node
E + , % &
P ' $ ( )
P ' $ ( )
E + , % &
E + , % &
P ' $ ( )
P ' $ ( )
E + , % &
2emote node2emote node
3ptical 2epeater can be used3ptical 2epeater can be used
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$IO System Secification for $$CS
/he bus among %%CS and local nodes. &5S! bus'
Dedicated Internal !us
S"eed ;
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-air @ Spare C-UConcept
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$$CS Secification
CPU "67,8 %"ISC&
+emory Size ,8+'
Power suly 9--88-3 AC; 873 DC
)o! of IO slot <
)o! of IO nodetotal 7 including CPU
node
(S' bus I$ (C7-9S'7-9
4ocal node for (S' bus U to 7
"emote node for (" bus U to ,
(" bus I$ ('7-9('6-9
AP caacity
AIAO 7
Common S2 7---
?A)) 9---
?P" 9---
?OP 6--
?"@ 8--
)o! of control drawing sheet 8--
)o! of function block %total with
?A))&86--
"ealtime trend 86>
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Inut Outut +odules
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Analog +odules
$nalog +odules )on.isolated tyeB$$I
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Analog +odules with 0A"*
%IO ($R/ +odule ineu"s
$$I
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0A"* +odule data
$nalog Data 9 to 23 m$ from Device
($R/ 6ariable Data
($R/ device su""orts +a* 9 ($R/ 6ariableP6 Primary 6alueS6 Secondary 6alue/6 /hird 6alue%6&96' %ourth 6alue
($R/ +odule su""orts +a* :2 ($R/ 6ariable data
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Digital IO +odules
1eneric tyeB
$D6
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Communication +odules
Serial Communication +odule $R
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Subsystem Packages 4ist
RS Communication &$R
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$oundation $ieldbus +odule %A4$999&
%%-(< interface card
Redundancy
Installable both on ocal and Remote nodes
6CR &6irtual Communications Relationshi"';
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"edundant $ieldbus +odule %A4$999&
4 3 M
4 3 M
4 3 M
4 3 M
4 3 M
4 3 M
C o m :
C a r d
C o m :
C a r d
- S U
- S U
,ield De5ices
AL,1114mage o6 2edundant Card
%=1* %=1(
E=ternal-o7erSupply
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/he Station for Real time Plant +onitoringO"eration
0IS %0uman Interface Station&
%asy )peration by a mouse a 2eyboard etc.
!eal time display o$ Plant Abnormalities.
Plant )peration by t#ousands o$ Grap#ics
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*yes of 0IS
'&STP IS A IB/ PC@A compatible mac#ine is generally used. Apart $rom t#e general PC t#e
5o2oga"a PC is also supported. Speci$ications o$ t#e PC 3IS Des2top are as $ollo"s CP Pentium I+ Processor /ain /emory ;< /B &/inimum' 3ard Dis2 6 GB or more +ideo Display 96 ? or more ;< colours C! /onitor /ulti Scan 9? monitor or larger Serial Port !S,C one port or more Parallel Port )ne port or more %tension Slot PCI slot $or +@+L net card ISA slot $or %t#ernet card Po"er Supply 66-6+ AC Basic So$t"are 7indo"s 0 "it# Ser(ice Pac2 7indo"s 666 or
7indo"s 4P
C3S& IS #e $loor mounted console type 3IS comes "it# 9 monitor "#ic# #as a touc# panel
operation. It #as an operation 2eyboard and an engineering 2eyboard.
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Alication Caacity of 0IS
+aimum number of tags that canbe monitored from 0IS : One+illion!
+aimum number of windows thatcan be created er 0IS : 7---!
+aimum number of *rend"ecording Points er 0IS : ,,8
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! net Communication
Protocol I%%% >6.
Access Control o2en Passing
rans. Speed 96 /bps
rans. Distance ;66m to 62m
/edia Coaial@)ptical FibreStd. ma. lengt# 9>; m
/a. lengt# 6 =m &"it# optical repeater' 9.<
=m &"it# coa. repeater'
V net
;4S
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! net < E=tension Details
Optical
FibreR
R R
RT
T
Optical
FibreR
R R
R T
T
Max. 500m Max. 500mMax. 500mMax.
15 km
Max.
15 km
Overall Max. 20 km
Co-axial CableV net
;4S ;4S;4S
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Domains a#e %#o&' o( stations )onne)te* on t"e V-net+
B&s Cone#to# is &se* to in. t/o *omains+
BCV is &se* to )onne)t CS, CS 1000, CENTUM-XL,CENTUM-V ND MXL to CS000
system
'us Con#ertor
H! BUS
E!CD !CS
HIS
ooo
BCV
ooo ooo
Domain
)onne)tion
E2S
V-NET
ETHERNET
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Oeration 2indows
Information regarding the rocess is gatheredas well as monitored by the following StandardOeration windows on the 0IS!
/uning 0indow
Control )rou" 0indow /rend 0indow Process $larm 0indow O"erator guide +essage 0indow )ra"hic 0indow Overview 0indow Process Re"ort 0indow (istorical Re"ort 0indow
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System +essage 0indow
T,ese uttons are #rovie )orcalling various )unctional 5ino5s
on t,e IS
T+#e t,e TA63AM& to call t,einstrument )ace#late 5ino5
System Message +indo7
S t + A
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+arious "indo"s can be
accessed by selecting t#e respecti(e icons in t#e
System /essage Area
#ese "indo"s can also be accessed by t#e 2eyson t#e )perator =eyboard
S7ST&M M&SSA6& A8&A IC3S
System +essage Area
3peration eyboard
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O"eration eyboard#eration e+oarP&8ATI3 &79A8'
All t#e operations can be per$ormed "it# t#e #elp
o$ t#e )peration =eyboard. #e sameoperations can also
be per$ormed by touc# $unctions a(ailable
on t#e System /essage Area Icons.
3peration eyboard
O i 2i d
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%rom t,is 5ino5 +ou can o#en t,e
)ollo5ing 5ino5s.
1. vervie5 :ino5
2. Control :ino5
!. Tuning :ino5
4. Tren :ino5
". 6ra#,ic :ino5
;. Alerm :ino5
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Instrument $acelate 2indow
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*uning 2indow
Select t,is icon to is#la+ t,eTool o=
Select t,is icon to is#la+ t,e
Tuning :ino5
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*uning 2indow
TUNING WIND2W displays all the
T!i!" parameters o# the i!strme!t.
The T!i!" $i!do% is sed to set p the
alarm setti!" as %ell as the loop t!i!"
parameters.
2ny t"e items in*i)ate* /it" a 34 3 )an
5e )"an%e*+
Dis'ayin% a 3T&nin% Win*o/6
1+Do&5e )i). on a Ta%7s name o! a
3Cont#o Win*o/6 a!d a #aceplate %i!do%
%ill appear. See)t t"e 3T&nin% 3
/in*o/ i)on (#om t"e to 5o8+
9+ &elect 3NME i)on i! the System Messa%e
#ea6 the! e!ter the 3TGNME6+
Tuning +indo7
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Tuning +indo7
Control Dra7ing Display
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Control Drawing Dis"lay
Select t,is icon to
call t,e Control
'ra5ing is#la+
Cont#o *#a/in% *is'ay
Control Dra7ing Display
C l 1 2i d
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Control 1rou 2indow
Select t,is icon to is#la+
t,e Tool o=
Select t,is icon to is#la+
t,e Control 6rou# :ino5
C t l 1 2i d < I t t
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Control 1rou 2indow5< Instruments
Cont#o %#o&' /in*o/s are sed to
display mltiple i!strme!t #aceplates.
Ma8im&m : o# 1; inst#&ment (a)e'ates
ca! be displayed i! o!e Co!trol 'rop
$i!do%
(ormally the i!strme!ts are mo!itored a!d
operated #rom this %i!do%.
Do&5e )i). o! the i!strme!t TGNME to
*is'ay t"e T&nin% Win*o/ o# the i!strme!t.
&elect the U''e# Win*o/
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Control .roup +indo7 1> 4nstruments
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*rend 2indow
Select t,is icon to is#la+ t,eTool o=
Select t,is icon to is#la+
t,e Tren :ino5
* d 2i d
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*rend 2indow
TREND WIND2W records the )*+ &* a!d
M* o# varios i!strme!ts.
T#en* )an 5e *is'aye* i! T#en* G#o&'
Format or i! T#en* oint Format.
Ma8im&m : 'ens ca! be assi"!ed i! one
T#en* G#o&' Win*o/
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*rend 1rou 2indow
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*rend Point 2indow
'oule clic> ,ere
to call t,e Tren
Point :ino5
Tren Point
:ino5
Calling Instrument from *rend 2indow
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Calling Instrument from *rend 2indow
'oule clic> ,ere
to call t,e
Instrument
)ace#late :ino5
Instrument
%ace#late
:ino5.
Instrument can eo#erate )rom t,is
5ino5.
l i d
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Process Alarm 2indow
R2CESS LRM WIND2W displays the
latest 200 process alarms.
,larms ca! be ack!o%led"ed either as a
G#o&' or as In*ii*&a alarm.
Select t,is icon to call t,e Process
Alarm :ino5
Process Alarm 2indow
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Process Alarm 2indow
R2CESS LRM WIND2W displays the
latest 200 process alarms.
,larms ca! be ack!o%led"ed either as a
G#o&' or as In*ii*&a alarm.
T,is icon is#la+s t,e current PV
Values o) t,e instruments t,at arein alarm
T,is icon is#la+s t,e im#ortant
tags (ig, Priorit+ Alarms$ t,at
are in alarm.
T,is icon is use to ac>no5lege
t,e #rocess alarms.
Oerator 1uide +essage 2indow
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Oerator 1uide +essage 2indow
Select t,is icon to call t,e #erator
6uie Message :ino5
2ERT2R GUIDE MESSGE WIND2W
displays the prede#i!ed messa"es to "idethe operator re"ardi!" the crre!t process
stats a!d or the actio!s to be take!.
O' messa"es ca! be ack!o%led"ed either
as a G#o&' or as In*ii*&a messa"e.
.rapic +indo7
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.rapic +indo7
O i 2i d
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O#er#iew 2indow
Select t,is icon to is#la+ t,e
Tool o=
Select t,is icon to is#la+
t,e vervie5 :ino5
O i 2i d
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O#er#iew 2indow
2e#ie/ Win*o/ *is'ays t"e oe#ie/ o( t"e
)#ent '#o)ess stat&s+
In(o#mation #e%a#*in% t"e '#o)ess is *ist#i5&te*
amon% t"e a#io&s *is'ay 5o).s+
9 Dis'ay Bo). s 'e# 2e#ie/ Win*o/+
ach block "ives dy!amic i!#ormatio! re"ardi!" theprocess.
Do&5e )i). o! the display block to more details.
Ty'es o( Dis'ay Bo).s
/Sin%e Ta% Bo)./Win*o/ Dis'ay Bo)./Comment Bo).
35er5ie7 +indo7
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35er5ie7 +indo7
-rocess 2eport +indo7
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-rocess 2eport +indo7
;istorical Message 2eport +indo7
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g p
Seuence *ables
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Seuence *ables
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4ogic Charts
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g
4ogic Charts
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g
System Status +indo7
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y
System Alarm +indo7
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y
S=STEM LRM WIND2W displays the
latest 200 system alarms.
,larms ca! be ack!o%led"ed either as aG#o&' or as In*ii*&a alarm.
Na5igator +indo7
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!irtual test ,unction
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*MA3 I3T&8%AC& STATI3*MA3 I3T&8%AC& STATI3
S7ST&M 6&3&8ATI3
%*3CTI3
P&8ATI3
?
M3IT8I36
%*3CTI3
C3T8 %*3CTI3
T&ST
%*3CTI3
S%CS
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Tan you