PPT ON DISTRIBUTED CONTROL

SYSTEMS

SEMINAR PRESENTED BY
B.NASAR BABU, B.E
I & C ENGINEER
ENMAS O & M SERVICES
SITE: SMIORE,HOSPET
32 MW CPP

13/12/2017 I & C DEPT , ENMAS O & M SERVICES 1

A distributed control system is a computerized control system for a process or plant ,in
which autonomous controllers are distributed throughout the plant, but there is central
operator supervisory control.

MAKE/Model/Version /Type : Metso / max DNA/Release 4.3

This system consists of three components

1. Remote processing unit (Rpu)

2. Max station

3. Max network
 REROME PROCESSING UNIT

➢ The RPU is an equipment group that provides data acquasition,control and i/o processing
functions for the DCS

THIS EQUIPMENT INCLUDE

➢ controllers

➢ field i/o interface modules

➢ field terminations

➢ communication networks

➢ peripheral equipment such as communication interface & power supplies and cabinets.
 DISTRIBUTED PROCESSING UNIT
➢ DPU: The Model Pdp Dpu Which Runs Under The Windows Ce. Net Real Time Multi Tasking
Os ,Is The Hardware Processing Engine Of The Max Dna Dcs.

➢ The Dpu Also Know As Max Dpu 4f

Each dpu performs

➢ 1.Comprehensive alarming & calculations.

➢ 2.Logging of SOE data at 1ms resolution

➢ 3.Acquisation of trend information & other data

➢ 4.Contineous scanning of IOP i/o module

➢ 5.Execution of predefined algorithms, called functional blocks, for process control and data
acquisition.
 DPU PERFORMANCE
➢ A Multi Speed Processing System Is Build Into The MAX DPU 4F Which Allows Objects To
Executed In Three Different Time Classes From As Fast As 10 M Sec To ½ Sec.

➢ Up To 8500 Control Objects (Functional Blocks)c An Be Executed In The Dpu.

➢ A Function Block Can Be As Small As Atomic Block. Such As An AND (Or ) Or GATE

➢ A Data Point Management System (DPMS) Keeps Track Of The Object Size And The Total
Execution Time For Each Time Class.

Distributed Processing Unit Specifications

➢ Operating Temperature Range 0 To 60 Degrees C
➢ Storage Temperature Range (-)25 To 70 Degrees C
➢ Relative Humidity Range 5 To 90% Non condensing
➢ Power Requirements 24 V dc ±4 V dc
➢ Current: 0.9 A @ 24 V d c
 DPU HARDWARE
A DPU consists of a PRINTED CKT BOARD (PCB ) which contains
1.Control processor (CP)
2.Input/output processor( IOP) is installed in a MAX PAC chassis.

The dpu front panel contains

1. Status led’s
2.A mode switch
3.Back up connector
4.Network connectors
5.Take over button
6.Reset button
7.Serial port connector for interface to plc’s
8.BNC connector for interface to an IRIG-B time source
 CONTROL PROCESSOR
➢ The DPU comprised of a single PRINTED CKT BOARD that contain Pentium-class control
processor and dedicated MICROPROCESSOR for scanning I/O’S. These are also sockets on
the board for 64 M BYTES of compact flash and 128 M BYTES of DRAM.
 I/O BUS INTERFACE
➢ A MOTOROLA 68332(68K) 32 BIT I/O PROCESSOR And FIELD PROGRAMBLE GATE
ARRAY(FPGA) Are Used To Interface To The Both Model IOP I/O Bus And To The I/O Bus
Expander Module For Remote I/O Applications.

➢ Up to 60 IOP I/O Modules Can Reside Of Each Electrical Bus

➢ The Maximum Length Of The 564 Model I/O Bus Is 30 Feet

➢ The Length Of The Remote I/O Link With Fiber Optic Extender Is Up to 2000 m

Fully Software Back Plane Compliant

➢ With The S/W Backplane Installed, the DPU Can Access Any Exposed Data Stored Any ware In A
Connected System As Long As The Connected System Also Uses The SPB Protocol

➢ The S/W Back Plane Uses Subscription Services Where Data Is Only Transmitted When Changes
Are Detected
DPU Front Panel Controls and Features
All DPU Controls, Indicator Leds, And Push Button Switches Are Accessible From
The DPU’S Front Panel. Use This Front Panel To Monitor Or Control Different
Aspects Of The DPU. There Are No Internal Switches Or Jumpers To Be Set During
Installation.
Mode Switch
The Mode Switch Is A 16 Position Rotary Switch. It Is Read After A Reset Or Power
Up Cycle Of The DPU To Determine Its Operational Mode. The Switch Is Also Read
During Online Operation To Allow Setting Of The Mode To “Running”, “Locked”,
Or “Offline”.
MAXNET Interface Ports
Dual ETHERNET 10/100BASE-T Ports Are Provided To Interface With The
MAXNET Communication Network. The DPU Communications Is Configured To
Be 10M BIT Full Duplex, 100 MBIT Full Duplex.
DPU Front Panel Controls and Features
Network status led’s
These led’s report the status of MAX NET network A and B links.
Backup port
A 100 MB Ethernet interface is provided to pass database information to a hot
standby DPU. A custom category 5 Ethernet cable used to connect both DPU’S via
this port. A status signals are also passed between DPU’S through this port to
indicate which DPU is in control.
Backup led
This led shows the status of redundancy for DPU’S configured as a backup Pair.
Specifications of back up cable from controller -controller
Utp cat 5 e /350 MHz
Verified for gigabit Ethernet
TIA/EIA 568-B
IEC 11801 standard
Vertical cable E 312655 (UL) CMR FT4 UTP 4PR 24 AWG
Serial Port (Optional)
The optional Serial port is an eight-pin RJ45 connector that supports RS232 signal levels. This port
can be used by the DPU to interface with external PLC type equipment.
IRIG-B Port (Optional)
The IRIG port is a BNC connector that supports an interface to a GPS receiver. This option allows
time synchronization to global time.
Reset Button
Pressing this button will cause the DPU to stop controlling and go through a reset cycle. This should
not be done casually as it can cause a severe disruption to your process.
Takeover Button
Pressing the Takeover button can force a previously inactive DPU to go active. This should not be
done casually as a manually forced takeover occurs regardless of the inactive DPU’s ability to
control. This can have severe consequences to your process.
 STATUS LED’S
IOM Status LED
The IOM LED shows the operational state of the IOM Processor.
I/O Status LED
This LED shows the status of I/O BUS transactions.
CP Status LED
The CP Status LED reports the health of the CONTROL PROCESSOR.
State LED
The State LED reports the current control state of this DPU.
The status led’s are divided into the following sections:
NETWORK STATUS LEDS
MAXNET network A health – 1 green and 1 yellow
MAXNET network B health – 1 green and 1 yellow
BACKUP LINK health – 1 multi colour green/red/yellow
operational status led’s
IOM health – 1 multi colour green/red/yellow
I/O status health – 1 multi colour green/red/yellow
CP health – 1 multi colour green/red/yellow
state health – 1 multi colour green/red/yellow
 Icon colours appearing in max DPU annunciator
objects represent the following conditions

CP defines the status of the max DPU computer

➢ Off-red: SBP communications bad

➢ Red: DPU Status bad (Dark Red, if DPU Fan and/or Battery bad)

➢ Yellow: DPU Status marginal

➢ (Dark Yellow, if DPU Fan and/or Battery bad)

➢ Green: DPU Status good (Dark Green, if DPU Fan and/or Battery bad)
 BK defines the status of backup
 Off-red: SBP communications bad
 Red: Backup Status bad
 Yellow: Backup Status marginal
 Green: Backup Status good
I/O defines the I/O card and Key-lock status
 Off-red SBP communications bad
 Red: Critical I/O card bad
 Yellow: Normal or Non-Critical I/O card bad
 Yellow Key In Between or Key Off Line
 Green: Normal and Critical cards good
 Compact Flash
The DPU utilizes a compact flash for storing and retrieving all software and

Configuration information for the DPU. The compact flash is non-volatile

And can be removed to allow updating or moving a configuration from one

DPU4F to another. The compact flash is a minimum of 64 megabytes and is

Industrial grade to allow for operation in harsh environments, as well as,

Supporting a very large number of write cycles.

 Compact flash

The Compact Flash contains the following files:

➢ • Core Processor’s CE Windows operating system and application firmware

➢ • Input Output Manager (IOM) Flash Firmware

➢ • Configuration File for Shared Memory FPGA

➢ • Configuration File for IO FPGA

➢ • IOM Diagnostic Code Firmware

➢ • BIOS – Embedded BIOS code

➢ • Initialization file containing DPU Name, IP Address, and general

➢ configuration information
 I/O Module Types
 Because of the variety of input and output ranges needed in distributed
control applications, the Model IOP I/O offers many types of easily
configurable discrete and analog I/O modules. For a list of modules,
along with their ranges and number of points per module.

Digital Input
 module number : 69230 I330A
 TYPE: IOP330 (24 V dc digital input module;16 channels)

Digital out puts

 module number : 692 30 I351A

 TYPE: IOP 351 (24 V dc relay output module;16 channels)
 Analog Input
 module number : 692 30 I301A
 TYPE: IOP301(isolated analog input module)
Analog Output
 module number : 69230 I320A
 TYPE: IOP320 ( analog output module)
RTD input module
 module number : 69230 I303A
 TYPE: IOP303 (8 channel)
TC /MV input module
 module number : 69230 I304A
 TYPE: IOP304 (8 channel)
 MAX STATION
➢ Provides interface between operators, engineers & other users & systems .

➢ It functions include providing graphical user interface to the process. Creations and maintain
configurations and process control documentations

➢ Collection & management of process & event history

➢ As an operator, you may view and manage your process control environment

Through a max station, the interface between you and the max DNA Distributed control system. A
max station may be set up as an operator's Workstation or an engineer's workstation. The operator’s
workstation uses max VUE graphical interface software to Provide a graphical view of the process.
The software uses both standard and Custom displays.
The Engineer’s Workstation Is Used For Creating And Maintaining Configurations And
Process Control Documentation Using The Max DPU Tools And MAX VUE Graphical
Configuration Software. It Is Also Used To Create And Maintain Custom Graphic Displays
Using The Graphics Editor Software.

In Addition To These Functions, The Max Station Collects And Manages Process And Event
History, Reporting, And Archiving Using The Max Storian History And Archiving Software.

These Software Functions Can Be Distributed Among Multiple Workstation Processors In A

Large System Segmented By Domains Or Combined Into One Max station In A Very Small
System.
 MAX NET

➢ Max DNA Uses A Client / Server Architecture. The Max DPU, Acting As A Server , collects
Information, Stores It, And Ultimately Transfers The Information To The Appropriate Max station
Clients. The Collected Data Is Comprised Of Alarm, event, Trend, Historical, And General Point
Information.

➢ Max stations And Max Dpu’s Communicate With One Another Via Max net.

➢ The Max net Network Is A Fully Redundant 10/100 Mb Per Second Ethernet

➢ Network Using Industry Standard TCP /IP Protocol

➢ Make :D-link

➢ Des 3000-series
Gigabit media converter fulfills the
conversion between10/100/1000base-
t&1000base fx or vice-versa, extending the
transmission distance of Ethernet .
 Operating
station
Field Instruments

Engineering
station

System Network
Marshalling
Local JB Cabinets station
cabinets

Sequence Of
Event station

Printer
server
THANK YOU