Contents

Chapter 1SCADA systems hardware (and firmware)

1.1 Introduction
1.2 Comparison of the terms SCADA, DCS, PLC and smart
instrument
1.3 Considerations and benefits of SCADA system
1.4 Remote terminal units
1.5 Digital output module
1.6 PLCs used as RTUs
1,7 System reliability and availability

Chapter 2 SCADA systems software and protocols

2.1
2.2
2.3
2.4
2.5
2.6

Introduction
The components of a SCADA system
The DCS and SCADA software package
New technologies in SCADA systems
The twelve golden rules
OPC

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Chapter 3 Typical distributed control systems and SCADA systems 51

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8

Introduction
Honeywell PlantScape system
Foxboro I/A series distributed control systems
Delta V system
Citect
Wonderware
Intellution iFIX v2.5 system
Comparison of vendors

Chapter 4 The basic controller

4.1
4.2
4.3
4.4

Introduction
Identification of the controller boards
Discrete and logic control
Sequential and batch control

Chapter 5 Basic DCS controller configuration

5.1 Historical
5.2 Control modes
5.3 Tracking and initialization in control slots used for
cascade control

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5.4 Control functions

5.5 Control algorithms
5.6 Sequential programs for batch processing
5.7 Defining equipment procedures
5.8 Phase logic programming
5.9 Phase logic interface
5.10 Logic block functions in advanced controller
5.11 DCS controller configuration

Chapter 6 Introduction to communications for DCS & SCADA

systems
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11

Purpose
Basic communications principles
Balanced and unbalanced transmission lines
EIA-232 interface standard (CCITT V.24 interface standard)
The EIA-485 interface standard
Open systems
Interoperability
ModBus protocol
HART protocol
The promise of FieldBus and DeviceNet
Benefits

Chapter 7 Local area network systems

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15

Introduction
Network topologies
Bus topology
Star topology
Ring topology
Media access methods
IEEE 802.3 Ethernet
MAC frame format
High speed Ethernet system
100BaseT (100BaseTX, T4, FX, T2)
Fast Ethernet design considerations
Gigabit Ethernet 1000BaseT
Network interconnection components
TCP/IP protocols
SCADA and the Internet

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Chapter 8 ProfiBus

205

8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14

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Introduction
Architecture of the ProfiBus protocol
Application larger service specification
ProfiBus communication model
Relationship between application process and communication
Communication objects
FieldBus message specification
Network management
Fault management
Configuration management
ProfiBus FMS profiles
Performance
Diagnostics
System configuration

Chapter 9Foundation FieldBus

9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9

Introduction
Overview
Physical layer
Data link layer
Application layer
User layer block
System management
Device description
Application example

Chapter 10 Programming of DCS systems

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10.1 Development and growth of programmable controllers (PLC) - an

introduction
263
10.2 Need for standardization in programming approach
264
10.3 Drawbacks in conventional programming methodology
265
10.4 Features of IEC-1131-3 language definition
271
10.5 Summary of IEC-1131-3
272
10.6 PLC software architecture - software quality attributes
272
10.7 IEC software architecture
273
10.8 Component parts of IEC software architecture
274
10.9 Functions and function blocks
275
10.10 Local and global variables
277
10.11 Mapping software model to real life systems-Examples
278
10.12 Applications
280
10.13 Summary of PLC architecture
283
10.14 Common elements in IEC-1131-3
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10.15 Elementary data types

10.16 Generic data type
10.17 Derived data types
10.18 Variables
10.19 Variable initialization
10.20 Functions
10.21 Programs
10.22 Resource
10.23 Tasks
10.24 Summary of common elements in IEC-1131-3
10.25 Structured text
10.26 Statements used for assignments
10.27 Expressions
10.28 Evaluating an expression
10.29 Statements
10.30 Conditional statements
10.31 Iteration statements
10.32 Implementation dependence
10.33 Summary of structured text
10.34 Function block diagram
10.35 Basics
10.36 Methodology
10.37 Signal flow
10.38 Feedback path
10.39 Network layout
10.40 Function execution control
10.41 Jumps and labels
10.42 Network evaluation rules
10.43 Summary of function block diagram
10.44 Ladder diagrams
10.45 Basic concept
10.46 Graphical symbols used in ladder diagram
10.47 Boolean expressions using ladder diagrams
10.48 Integrating functions & function blocks.
10.49 Feedback paths
10.50 Jumps and labels
10.51 Network evaluation rules
10.52 Portability
10.53 Summary of ladder diagrams
10.54 Instruction List
10.55 Structure of IL programming language
10.56 Calling functions and function blocks
10.57 Portability and other issues
10.58 Summary of Instruction List
10.59 Sequential function chart (SFC)
10.60 Steps

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10.61 Transitions
10.62 Actions
10.63 Action qualifiers
10.64 Action control function block
10.65 Execution rules
10.66 Design safety issues
10.67 Top down design
10.68 Summary of sequential function charts

Chapter 11 Alarm system management

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351

11.1 An alarm system

351
11.2 Functions of the plant or process operator
352
11.3 Functions of an alarm system
355
11.4 An effective alarm system
355
11.5 Design overview
358
11.6 Human and ergonomic factors
359
11.7 Structure of a good alarm system
361
11.8 Safety integrity level (SIL)
370
11.9 Definition of strategy
371
11.10 Strategy for alarm system design
371
11.11 Strategy for alarm system maintenance and management at the
site/plant
372
11.12 Generation of minimum design documentation for each alarm 372
11.13 Measurement of the alarms
376
11.14 Field measurements for deriving alarms
377
11.15 Hardware for alarm processing
377
11.16 Alarm displays
378
11.17 Testing of alarms
380
11.18 Generation of various types of alarms
380
11.19 Selection of alarm settings
387
11.20 Setting alarm priority
389
11.21 Design of field sensors for generating alarms
395
11.22 Logical processing of alarms
400
11.23 Design of alarm list displays
406
11.24 Measurement of performance
411
11.25 Usefulness of alarms
414
11.26 Measurement of number of alarms and average rate of alarms 417
11.27 Measuring operator response
423
11.28 Management of improvement program
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11.29 Alarm review
425
11.30 Elimination of spurious alarms
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11.31 Intermittent and fleeting alarms
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11.32 Processing alarms
427
11.33 Control of modifications
433
11.34 Hazard and operability studies (HAZOP)
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11.35 Hazard assessment

11.36 Hazard and operability studies (HAZOP)

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Chapter 12Distributed control system reporting

439

12.1 Introduction
12.2 Operation of advanced DCS using multi-screen displays,
cross screen invocation and linking
12.3 Alarm reporting, generation and acceptance
12.4 Alarm reporting
12.5 Generation of alarms
12.6 Different types of logs and reports configurable on a DCS

Chapter 13Distributed control system (DCS) configuration

13.1 Introduction
13.2 An engineering station
13.3 System/project tree structure
13.4 DCS system database
13.5 Configuration of control functions
13.6 Configuration of operator/monitoring functions
13.7 Configuration of system hardware structure
13.8 Configuration of system software
13.9 Documentation
13.10 Commissioning

Chapter 14Maintenance consideration

14.1
14.2
14.3
14.4
14.5

Introduction
Maintenance requirements of system and system elements
Requirements for in-built diagnostic and maintenance routines
Requirement for installation of UPS system
Recovery of a DCS following power outage

Chapter 15Distributed control system applications

15.1
15.2
15.3
15.4

Introduction
Use of DCS in pulp and paper environment
Use of DCS in petroleum-refining environment
Use of DCS in oil and gas processing environment

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Chapter 16Distributed control systems implementation

16.1
16.2
16.3
16.4
16.5
16.6

523

Introduction
System strategy
Automation plan
Project implementation
Installation and commissioning
Change management

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Chapter 17The future of distributed control systems

539

17.1 Introduction
17.2 Creation of E-commerce solution

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Appendix AFundamentals of control systems

457

Appendix BIntegration of the complete FieldBus system

469

Appendix CAdaptive and predictive control

483

Appendix DCentral site computer facilities

497

Appendix EFuzzy logic control

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Appendix FStability and control modes of closed loop

515

Appendix GDCS and process control exercises

529

Glossary

541