DCS EVOLUTION-CENTRALISED CONTROL

DCS EVOLUTION-DISTRIBUTED CONTROL

DCS EVOLUTION-FIELDBUS CONTROL

DCS EVOLUTION- WEB CONTROL

DCS EVOLUTION-WEB CONTROL

APPLICATION

ABB DCS ARCITECTURE

ABB DCS HARDWARE

CONTROL SYSTEMS TREND

1) PLC
2) DCS
3) PC - Based Control.
PLC : Introduced in the late 1960 to replace Relays and Hard-wired
Programming.

DCS : Introduced in the Mid-1970 to replace

pneumatic controls by using computers.
PC-Based Control : Introduced by the early 1980s to avoid the
proprietary PLC & DCS systems.

DCS EVOLUTION

LOCAL CONTROL : Initially control was performed local to the equipment control.
The ADVANTAGE was low wiring costs .DISADVANTAGES were - not much
control, monitoring, alarming & history.

CENTRALISED CONTROL: With the advent of minicomputer, sensors and actuators

were into the Central Control (Computer).
DISTRIBUTED CONTROL: With the advent of microcomputer, Distributed control
systems were installed in the plants near to the control room via proprietary digital
communications lines called as Data Hiway. First DCS was developed by
Honeywell,U.S in 1975.
The ADVANTAGES were greatly reduced wiring costs, much more limited
failure and less cost to add more points.
The DISADVANTAGES were that wiring costs were that wiring costs were still
significant and there was lack of interoperability among controllers of various
manufacturers due to the proprietary protocols. Hence the user was locked into a single
vendor.

DCS System Installations in RCF

1. Yokogawa - CS 3000
2. Yokogawa - CS 3000
3. Yokogawa - CS 3000
4. Moore - APACS
5. Fisher - Rosemant - Delta V field Bus
6. Honeywell - GUS
7. Yokogawa - Centum Excel
8. Moore - APACS
9. Yokogawa - Micro Excel
10. Yokogawa - Micro Excel
11. ABB - Freelance 2000
12. Honeywell - TDC 3000
13. Honeywell - GUS
14. Fox boro - I/A series
15. Fisher - Rosemant RS3
16. Fisher - Rosemant RS3
17. Moore - APACS

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Ammonia II
AN P
N N AP
Methyl amine
STP
Ammonia I Synthesis
Steam Generation Plant
Suphala
Methanol
S A P/C N A
AB C
Ammonia I
Ammonia/Urea - Thal
D M A C - Thal
PGR
Steam Generation - Thal
Water Treatment Plant - Thal

DCS

The importance of DCS systems to increase as global competitive dynamics in

food and beverage, specialty metals, pulp and paper, pharmaceutical and fire
chemical processing.
The DCS has networking capabilities which are useful for business
management.
The DCS has capacity for processing large number of I/O points.

TYPES OF DCS :
1) Conventional DCS .
2) PLC based DCS.
3) Hybrid DCS.
4) Open DCS System

CONVENTIONAL DCS
This is a pure Process only control system. Usually purchased from one vendor. This
DCS arranged into three categories:
Small - Less than $ 100,000.
Medium - Greater than $100,000 & Less than $500,000.
Large - Greater than $500,000.
PLC Based DCS.
This is a network of PLCs used to perform the task of conventional DCS and
programmable functionality when required.
Hybrid DCS.
Performs both process and sequential control.
Open DCS System.
This is Field-Bus Control. Advantages are lower wiring cost and less failure,
smaller expansion costs and multi vendor interoperability DCS and PLC can be more
closely and efficiently interconnected.

Honeywell TDC 3000 DCS Architecture

US#1

US#2

HM
LCN A
B

HG
AMC

Field

EC Link

AMC
Data Hiway

Field

Hiway Gateway (HG)

LCN Module. Provides a two way communication link between the Local
Control Network and data hiway.
68020 based high performance intelligence module.
Converts data and protocol between Local Control Network and data hiway.
Scans the hiway for alarm conditions.
Synchronize time keeping for hiway-based process connected boxes.
One HG is required for each data hiway that is connected to the LCN. Up to 20 data
hiway pairs can be connected to an LCN.
Connects following hiway resident boxes to LCN
1.
AMCs
2.
CPC ( critical process controller ).
3.
DHP.
4.
Hiway traffic director etc
HG Functions :
1.
Data access :- gets box data requested from LCN modules.
2.
Event processing :- sends process and box alarm to LCN modules
3.
Database configuration :- 3000 points per hg can be configured.

Data Hiway

Data hiway provides communication link between hiway gateway,

preferred access devices and process connecting box. Data hiway operates at
250 kbps.
It is redundant pair of 75 ohm coax cable connected to box. It may be
20,000 feet long.
There are 3 kinds of devices on the data hiway,
1.
Respond only devices Ex:- A-MC (Advanced Multifunction controller)
2.
Polled devices
Ex:- PIUs (Process interface unit)
3.
Preferred access devices

History Module

LCN Module. Stores process and system information that can be

displayed.
Based on microprocessors 68020.
Winchester disk for data storage.
Communicates with all Modules on the LCN.
Stores history and general information.

Universal Station
Universal station (US) communicates with all modules on the LCN, process
connected devices on the hiway via hiway gateway and UCN via network interface
module
(NIM).
The following are the features of US,
Intelligent man/machine interface in the TDC 3000 system.
Stands on the LCN. Communicates with all Modules on LCN, process connected
devices on the Hiway via Hiway Gateway.
Provides comprehensive facilities to the process operator, process engineer and
maintenance technician on the Universal Window.
US provides comprehensive facilities to the following people,
Process engineer
Process operator
Maintenance technician.

AMC

TDC 3000 controller

1.
2.

Multifunction Modulating, sequence, logic, I/O monitoring

communication and diagnostic.
Faster peer to peer communication over EC link ( 500 kbits/sec ).
Proven control techniques
1.
2.

Based on Motorola 68000 Microprocessor.

Faster execution and control with 500 ms processing rate.

Full function algorithms.

Process oriented programming.

Configured as a box on TDC 3000 Data Hiway. Supported by

1.

LCN devices US, AM, HM.

HONEYWELL - GUS
Printer

Drives

Printer

Universal
Station

US#1

US#2

US#3

US#4

HM
History Module
A
Local Control Network

Universal Control Network

Network Interface Module

NIM
HPM
HPM
HPM

High Performance Manager

Honeywell System Description

Global User Station

History Modules
Network Interface Modules
Communication Subsystem - Local Control Network & Universal Control
Network
High Performance Process Manager

Global User Station

Overview

The TPS system provides an integrated interface between the process and the end
user. This interface is named as the Global User Station (GUS).
GUS is an important part in the Honeywell Total plant Solutions offerings. It
provides access to plant wide process network, plant or organization wide intranet or
even Internet.
The following hardware is available to enhance the functionality of the GUS:
Integrated Keyboard for Operators as well as Engineer.
Matrix printer supported by Windows NT.
8 * CD-ROM
100MB ZIP Drive
3.5 Floppy Drive
GUS has following functionality's :
The Human interface allows effective interaction of the Operator through the use of
operating displays
Engineering functions such as data point building, display building and report
building are available.
Communication with other LCN modules is accomplished.
Communication on Ethernet.

Honey well GUS Hardware:

Processor
Memory
Cache
Storage
Video
Colours
Keyboard
PIN Connection
Cursor Control

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:

Pentium Pro / 200MHZ

64MB RAM ECC
256KB ECC
2 GB hard disk drive, CD ROM, Cartridge Drive
21 high resolution screen 1280 * 1024 Pixels
256 color palette
Integrated keyboard with mouse
Built in Ethernet
QWERTY & Mouse/Touch Screen

Peripherals supported
Printer
8 * CD-ROM
1/4 Steamer Tape
3.5 Floppy Drive
100 Mb ZIP Drive
Annunciator relay on the console-based keyboard

Honeywell GUS software

Operating System
Base System
network and all GUS

:
:

Windows NT version 4.0

Provides real time data exchange
between the
functions.

History Modules
The History Modules is the bulk module that can be utilized by all module connected
to the Local Control Network. It is as the name implies the mass memory of the TPS
System. The memory components of this module are one 1.8 gigabyte Winchester discs.
It is controlled by an M68040 microprocessor. This provides the module with significant
computing power that this used to structure much of the incoming data and format it into
a form for easy retrieval.
The history in the model is provided by the History Module. Process variables are
available for hourly, shift, daily and monthly average calculation and recording.
All system event history such as process alarms, system status changes, and error
messages are stored into the History Modules.
Other modules have access to data in the History Modules for their functions.
The History Module provides two functions, storage only and data structuring and
storage. The data structuring and storage function provides much of the historical data of
the process to which the system is connected.

HM functions and Historization parameter

HM functions :
It can automatically backup the control databases in the HG, AM, CG.
HM can store,
Continuous process history.
Event journal (history).
Active system files.
Static system files.
On process analysis program (maintenance aid)
HM Historization parameters :
There can be up to 10 HMs on the LCN. There can be maximum of 150 groups per
HM. Each group can have up to 20 points. All points in the group must be in the same
unit.

Network Interface Module (NIM)

The Network Interface Module (NIM) provides the link between the local Control
Network and the Universal Control Network. As such it make the transition from the
transmission technique and protocol or the Local Control Network to the transmission
technique and the protocol of the Universal Control Network. The NIM provides access
by LCN modules data from UCN resident devices. The NIM is available in the redundant
configuration to provide continued operation in the event of the primary failure. It can
also do event processing.
There can be up to 10 redundant NIM pairs per LCN. A NIM can host upto 8000 tag
names and supports a data transfer rate of 2400 parameters per second.

Communication Subsystem
Local Control Network (LCN)

The backbone of every TPS system is a communication network, known as

Local Control Network. The LCN is a LAN through which TDC 3000 modules
communicate with each other. The LCN is a broadcast type of LAN. It is high speed
redundant communication bus that connect all the control room equipment. All information
is transferred on the network at 5 million bits per sec.,serially. It is based on the IEEE 802.4
Token passing and Bus Standard.
Each LCN device that is connected to the Local Control Network is called a
module. Up to 64 modules may be connected to the Local Control Network in a TPS
system. The Local Control Network is designated as the primary and the other as the back
up. Local Control Network provides time synchronization for all modules.

Communication Subsystem

Universal Control Network (UCN)

The Universal Control Network is a high speed, high security process
control network based on open system interconnection standards. It features a 5
megabit/second, carrier band, token bus network compatible with IEEE and ISO
standards. It is used as the real time redundant Communications backbone for
process connected devices such as the High Performance Process Manager
(HPM), Advanced Process Manager . The UCN supports peer-to-peer
communication for sharing data and allowing greater co-ordination of control
strategies among network devices. The UCN uses redundant co-axial cables and can
support up to 32 redundant devices
UCN supports 2 types of devices
- Process manager.
- Logic manager.

High Performance Process Manager (HPM)

The High Performance Process Manager is the latest in the Progression of High
Performance control products offered by Honeywell for the application to
Improve controlling of existing and new industrial processes. High Performance
Process Manager is a fully integrated member of the TPS family. It is capable
of :
performing data acquisition and control functions
fully communicating with operators and engineers at the GUSs and universal
Work stations.
Supporting higher-level strategies available on the Local Control Network
through the Application Module and Host Computers.

High Performance Process Manager Overview

The High Performance Process Manager uses a powerful multi-processor architecture
with separate microprocessors dedicated to perform specific tasks. The HPM consists
of two modules Communication and Control Module (CCM) and the I/O subsystem
the I/O subsystem consist of up to 40 Smart I/O Modules (SIOM). All control
operation are performed within the communication and control module. The process
engineer has complete flexibility of choice within the maximum HPM design limits.
These selections are implemented using the interactive tools provided by both the
GUS and Universal Work Station. The I/O processors, for example, provide such
functions as engineering unit conversion and alarm limit checking independent of the
communication and control modules.
The communication process is optimized to provide high performance network
communications. The control processor is HPM resource dedicated to executing
regulatory,logic and sequence functions, including a powerful user programming
facility. Since communication and I/O processing are provided by separate dedicated
hardware.

YOKOGAWA CENTUM EXCEL ARCHITECTURE

EOPS
/1

EOPS
/2

ENGG.
STATION

Micro-XL

A
B
HF BUS
(1 Mbps)
EFCD

EFMS

EFGW

I/O #1
ncst
Closed loop
control signal
Through I/O NEST

I/O #2
ncst

Monitoring signals
Through I/O NEST

Third party system with PLC,

Gas Analyser etc. thr RS 232C port
At the rate of 9600 bps

I/O #3
I/O #5
ncst
I/O #4
A B
NIO Bus

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.

Windows NT Based Centum CS Configuration

INTERPLANT
NETWORK PC
(OPTIONAL)

Ethernet Connectivity (optional)

OPERATOR/ENGINEERING
STATION

OPERATOR STATION SUB-SYSTEM

HIS

DM
Printer

PRT

HIS

HIS

PRT

Inkjet
Printer

DUAL V NET
10 Mbps

FCS

RIO BUS
NIU

NIU

HIS Human Interface Station.

FCS Field Control Station.
NIU Node Interface Unit.
RIO Bus Remote I/O Bus.

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 Yokogawas experience
and specialist know-how.
Centum CS 3000 system features :
Synthesis of DCS with Personal computers.
Online Documentation.
Powerful Operation and Monitoring Functions.
Two Types of Control Station.
Compact I/O Modules.
Powerful Control and Communication Functions.
Efficient Engineering.
Virtual Test functions dont require Control Station hardware.
Full-Featured Batch Package.
CENTUM CS micro-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 Yokogawas 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 CPUs.
Powerful Control Tools and Communication Functions.
Virtual Test functions dont require Control Station hardware.
Full-Featured Batch Package.
Built in security features to prevent mal-operations.
CENTUM CS micro-XL Integration ( to be released ).

CS3000 System Configuration

INTERPLANT
NETWORK PC
(OPTIONAL)

Ethernet Connectivity (optional)

OPERATOR/ENGINEERING
STATION

OPERATOR STATION SUB-SYSTEM

Remote Domain System

HIS

DM
Printer

PRT

HIS

HIS

PRT

CGW

Inkjet
Printer

V NET
10 Mbps
FCS

BCV
RIO BUS

NIU

NIU

CS, CS 1000
Centum XL, -V, -MXL
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

CENTUM CS 3000 NETWORK

HIS

HIS

HIS

V net

FCS

FCS

FCS

CENTUM CS3000 SYSTEM SPECIFICATION

NO. OF TAGS MONITORED

TOTAL NO. OF STATION
NO. OF DOMAINS
NO. OF STATIONS IN A DOMAIN
NO. OF HIS / DOMAIN

1,00,000
256
16
64
16 NOS

CENTUM CS3000 SYSTEM SPECIFICATION

Max. no. of stations

Max. no. of Domains
Numbering of Domains
Domain No. CS3000 Domain
(V net Domain)
Max. no. of stations/Domain
Domain No.Virtual Domain
(Non V net Domain)
Station NO. HIS
Station NO. FCS
Max. No. of ICS / Domain
Max. No. of NIU / FCS
Max. No. of IOU / FCS
Max. length of Vnet
Max. length of RIO bus

:
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:

256 / system
16 / system
1 to 64

:
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1 to 16
64

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17 to 64
1 to 64 in descending order
1 to 64 in ascending order
16
8
40
( Max. 5/ IOU)
20 Km
20 Km (750m ~ 20Km)

Centum CS-3000 Communication

V net
V net is 10 mbps real time control bus which links station such as FCS , HIS , BCV and
CGW. It can be dual redundant. It can be up to 500m using coaxial cable alone, or up to 20
Km when repeater are used or optical fiber is used.

10BASE2 cable
used by HIS, maximum segment length = 185 m
10BASE5 cable
used by stations other than HIS(FCS,CGW etc.) maximum segment length = 500 m

V net Communication

HIS

HIS

V net
Protocol
: IEEE802.4
Access Control : Token Passing
Trans. Speed : 10 Mbps
Trans. Distance: 500m to 20Km
Media
: Coaxial/optical fiber
FCS

FCS

V net specification
ITEM

SPECIFICATION

Transmission route

Coaxial or fiber optical cable

Type

Bus type or Multi-drop type

Communication rate

10 Mbps

Transmission Distance

500M 20Km Max

Redundancy

Dual-redundant

Proto type

Token passing

V- net Features

Real time control bus. ( Dual redundant possible )

Cable : 50 ohm coax. cable with BNC connector ( 10Base2 comp. )
Communication speed : 10 Mbps.
High reliable token passing communication
( performance guaranteed )
Std. max. length : 185 m.
BNC Connector
Max. length : 20 Km ( with optical fiber )
1.6 Km ( with coax. Repeater )
VL net
cable

VL net I/F card ( PCI )

Ethernet
HIS and ENG, HIS and supervisory systems can be connected by an
Ethernet LAN; supervisory computers and personal computers on the Ethernet
LAN can access messages and trend data in the CS 3000 system. The Ethernet
can also be used for sending trend data files from the HIS to supervisory
computers, or for equalizing the data in the two HIS station ( rather than using
the V net control bus to do this ). A system with only one HIS with engineering
functions installed, does not need Ethernet but in general Ethernet ( and
corresponding network engineering ) is required.

Ethernet Specification
ITEM

SPECIFICATION

Transmission Route

Coaxial or Fiber optical cable

Type

Bus type or Multidrop type

Communication Rate

10 Mbps

Transmission Distance

500m 2.5 Km max.

Redundancy

Not available

Proto type

CSMA/CD Type

TYPES OF HIS
Console type HIS
Desk top type HIS
PHIS Yokogawa brand OPS

HIS Hardware

CPU
Main memory
Hard disk
Display

Serial port
Parallel port
OS
Operator stations

Pentium 166
96MB or larger(for op & monitoring only)
1 GB or larger
256Colors min. resolution 800*600
1024*768 recommend(1280*1024 best)
RS232C*1 or more (for operation keyboard)
1 port for printer or more
Windows NT 4.0 Workstation
Max. 8 stations

Field Control Station Configuration

Ethernet

HIS

HIS

HIS
V net

I/O Unit
RIO Bus

Sub system

Node

Node
Interface
Unit
I/O Unit

Sub system

Compact FCS

Standard FCS

Connection to Centum CS 3000 System

Exapilot client
(engineering, operation)

Ethernet
Exapilot client
(engineering,
operation)

HIS

ENG

Exaopc
Exapilot server
(engineering, operation)

V-net

Exapilot communication data

Process data read/write
FCS

FCS

Features of Exapilot

Standardize and Automate Manual Procedures

Improve Plant Operating Efficiency
Improve safety of Plant Operation

Features of Event Analysis Package

Analysis DCS Event History to Help You Enhance Efficiency.

Enhance Process Stability: Balance Process Events and Operator Actions.
When, Where, What (3W) Filters Help You Narrow Focus of Analysis.

OPEN DCS SYSTEM

Ethernet
Field Bus Power Supply

Flow Trans.
Terminator

HMI

Control Valve

Safety Barrier

Pressure TX.

Field bus
It is a standardized digital communication protocol between a process Control field
devices
and the Control room. It is a simple pair of wires to power and carry the communication
signal between the field devices and the Control room.
FEATURES :
Drastic reduction in cable, conduits cable trays, marshallive racks, and connectors etc.
Drastic reduction in installation cost.
Fewer non field devices.
More reliability due to the smaller number of devices.
More efficient operation due to better accuracy (no A/D and D/A conversion).
Easy integration into plant management system.
Flexibility for different suppliers are interoperable and interchangeable.
Major reduction in maintenance cost.

Field-bus Benefits
Wiring

Wire
(pair)

Screw
Terms

I/O
Cards

IS
Barriers

Traditional

3500

168

Field bus

640

64

Savings

2860

104

Savings %

82%

63%

$ 3000 Material
$ 2000 Labor
$ 5000 Total
Typically comments from a plant personal :

Savings $

Easy to identify whats out there.

Consistent calibration procedure.
Two days versus four days to commission system.
Familiar with twisted pair wiring comfortable.

50%

50%

FOUNDATION fieldbus Vocabulary

Blocks
Basic Components
Valve
Resource
Resource
Block
Block

Transducer
(Servo)
Block

Function
Function
Block(s)
Block(s)

FOUNDATION
fieldbus

FOUNDATION fieldbus Vocabulary

Blocks
Basic Components
Resource
Resource
Block
Block

Transducer
Block

Temperature
Transmitter

Function
Function
Block(s)
Block(s)

FOUNDATION
fieldbus

FOUNDATION fieldbus Vocabulary

H1 and H2
H1 Segment

Moderate speed
Use existing wiring
Bus powered
Can be intrinsically
safe
Low power 2 wire
devices
4 wire devices
Replace analog &
proprietary digital

H2 Segment
High speed
Link multiple H1
Segments
I/O subsystem bus
Replace proprietary
networks
New wiring

FOUNDATION fieldbus Vocabulary

New Approach for H2
100 Meg Ethernet technology with extensions

Improve time to market

High speed
Mandatory redundancy
Widely available technology and silicon
Widely available tools
Limited incremental development
Many suppliers
High volume for low cost
Works with installed equipment
Evergreen technology

Better than ANY other solution!

FOUNDATION fieldbus Vocabulary

H1/H2 Bridges
Server

H1/H2
H1/H2Bridge
Bridge
Replaces
Replaces
Traditional
TraditionalI/O
I/O

H1/H2
Bridge

H2 Segment 100 Meg Ethernet

Control
Module

PLC

H1 Segment

H1 Segment

H1 Segment

FOUNDATION fieldbus Standards

Organizations
IEC
International Electro-technical Commission

ISA
International Society for Measurement and Control
(formerly: Instrument Society of America)
SP50

CENELEC
European standards body
Parallel (competitive?) Working Groups to IEC

FOUNDATION fieldbus Topography

H1 Fieldbus Installations
Controller
Similar
SimilarI/O
I/OCards
Cards

Reduced
H1 I/O
ReducedWiring
Wiring
Interface

Junction
Box

H1 I/O
Terminations

FewerTerminations
FewerTerminations

H1 Fieldbus
all-digital
Marshaling

Fewer
FewerTerminations
Terminations
Fewer
FewerIS
ISbarriers
barriers

IS (Ex i)
Barriers

Cost
Costsavings:
savings:
wiring
wiring
I/O
I/Ocards
cards&&
cables
cables
terminations
terminations
IS
ISbarriers
barriers
marshaling
marshaling

H1 Fieldbus
all-digital

FOUNDATION fieldbus Topography

Intrinsic Safety

Barriers

DeltaV System Architecture

Engineering station
Printer

Operator station
Printer

8 port Hub
primary

8 port Hub
Redundant
1

Serial

P
S

Contr.

Contr.

2 wide carrier for

Power/Controller P

A AA DDD
I I O I I O

Power supply
Controller

8 wide carrier for

I/O subsystem

H1
Connector

I/O extension cable

RS232 Modbus
D
O

Blank
Blank
Blank
Blank
Blank
Blank

PLC For
8 DI &
8 DO

H
I

Fieldbus Power

Fieldbus Transmitter
3244MVF1NAB4

Pressure Transmitter
3051TG2A2B21AB4M5FF
Smart valve positioner
FSDVC0400-201

DCS communication system Hierarchy

Level 5
Management
Low data rates
Superior responsibility

MIS
High

Level 4
Scheduling

SCHED.
Low

Level 3
Supervisory control

Level 2
Direct digital
Control (DDC)
Level 1
Sensors (S)
& Actuators (A)
High data rates
Low responsibility

SUP.

SUP.

DDC

DDC

DDC

PLANT

DDC

History of Process Control Signal

Around 50 years ago, most plant used 3-15psi pneumatic signal to control their
process.
The last change change in signal standard was the open protocol HART digital communications
format. The HART protocol provides simultaneous digital communications with the 4-20 mA
output.
The next protocol change will be fieldbus. Fieldbus is entirely digital-there is no
analog
Signal. Fieldbus also allows migration of control functions to field devices.
Process control Timeline The Evolution of Signal Standard
Signal standards have evolved over the years, starting with the 3-15 psi standard.
There are also other communication methods, but they have not gained widespread acceptance.
With many standard there is typically a slow transition period as plant engineers and
managers test period does gain widespread acceptance. However, once the benefits
of the
Digital: Fieldbus
Fieldbus become tested and proven, more plant will install Fieldbus because of its benefit and
Digital plus Analog: HART with 4-20mA
economic cost.
Analog: 4-20mA

Pneumatic: 3-15 psi

1940

1950

1960

1970

1980

1990

2000

2010

I/O Bus Network Protocol

I/O Bus Network
Device bus network

Discrete

Byte-wide
Data

Process bus network

Analog

Bit-wide
data

Several Hundred
Data Bytes

Protocol Standard
Field Bus Foundation
(Field Bus std.)

Process bus network

Profibus Trade Organization

(Profibus std.)

Byte-Wide
Data

CAN Bus

Device net
SDS

Inter Bus-S

Device bus network

Bit-Wide
Data

Seriplex
ASI
Inter Bus Loop

Fieldbus Architecture
Fieldbus is more than just a new signal communications protocol, but a whole new way to
control the process. With the release of the low fieldbus (H1), the entire fieldbus will be
defined. Most of the recent published literature has focused on the intricate details of the
fieldbus architecture, especially those layers that have not been released. However, except
physical layer and the user layer, these layer are transparent to the engineers and the manager.
Maintenance
information
system

Workstation

Data Layer

Physical Layer

Multivariable Valve
Transmitter

Level
Pump
Transmitter

stack

System management

Application Layer

Network Management

User Layer

Open System Interconnected Reference Model

Application
Presentation
Session
Transport
Network
Data link
Physical

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.
TCP, SPX, UDP
Transport Establishes a dependable end-to-end
IP, IPX, NetBeui
connection between two host.
HDLC, ETHERNET, ANSI/ISA S50.02 Session provides Management and Synchronization
of complex data transaction.
EIA-485, ETHERNET,ANSI/ISA S50.02 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.
MBAP, SMB, FTP, SMTP, FMS,
IEC 61158, ANSI/ISA S50.2,IEEE 1451

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 Bus
Field Bus is a bi-directional digital communication that interconnects smart field devices to
control system or to instrument located in the control room.
Field Bus is based on the OSI (Open System Interconnect), which was developed by the ISO
(International Standard Organization) to represent the various functions required in any
Communication network.
Layer

Function

Application

Provides formatted data

Presentation

Converts data

Session

Handles the dialogue

Transport

Secures the transport

connection

Network

Establishes network
connections

Link

Establishes the data link

connection

Physical

Connects the equipment

Field Bus

The OSI model consists of seven layers. However for real time application layers 3 to 6 are
not considered since they deal with transference of data among networks. For such
application following layers are used:
LAYER 1 - PHYSICAL LAYER
Defines the type of signal, transmitting medium, data transmission speed, etc.
LAYER 2 DATALINK LAYER
Define the interface between the physical layer and the application layer. It establishes
how the messages shall be structured and normalizes the use of multiple masters.
LAYER 3 APPLICATION LAYER
Defines how data is specified, its addresses and its representation.

The Fieldbus was invented by an Indian engineer Mr. Ram Ramchandran

( M.S in Comp. Tech , Texas)

PHYSICAL LAYER
The Physical layer defines the medium that transport the messages frames, the signal shape and
amplitude limits, data transfer rate, and power distribution.
Technical Characteristics:
Physical Medium
Three types are defined: wires, optic fiber, and radio signals. The specification for
wire has been already approved.
Bit rate for wire media
31.25 Kbps (H1)
1 megabits and 2.5 megabits (H2).
H1 and H2 are classification of the two hanks of Field Bus target applications. H1 has
low speed and utilizes existing wires. H2 has high speed and may require independent
wires to power up field devices.
Number of devices per link (31.25Kbps)
2 to 32 devices, without power and no IS (intrinsic safety).
2 to 6 with power and IS.
Maximum distance
Up to 1900 meters for 31.25Kbps, without repeaters. Up to 750 meters for 1
megabits. Up to 500 meter for 2.5 megabits.

PHYSICAL LAYER
Signal Modulation
Manchester bi phase L synchronous.
Physical layer preamble
on transmissions, the physical layer will add to the data sent by the layer above a
preamble and one start delimiter in the beginning of the frame and one end delimiter
at the end delimiter at the end of the of the frame.

DATA LINK LAYER

The Data Link Layer will assure the integrity of the message by using the frame check sequence:
Two bytes added to the frames and a polynomial calculation of all frame data.
The Data Link Layer also checks to see that the data reaches the devices correctly.
Technical characteristics
Medium Access: There are three forms to access the network:
Token passing:
Token is the right to initiate a transaction on the bus. A device must have the token to
initiate a conversation. As soon it finishes it will return the token to the LAS (Link
Active Scheduler). The LAS send the token to the unit that requested in either in a
pre-configured way or via scheduling.
Immediate response:
A master station will give an opportunity to the station to reply with one frame.
Requested token:
a device request a token by using a code in any of the response sent to the bus. The
LAS will hear this request and will then send a token to the device when there is time
available in the aperiodic traffic scheduling phase.

APPLICATION LAYER AND MANAGEMENT

The Application Layer provides a simple interface to the end users application. Basically , it
defines how to read, write , interpret and execute a message or command. A big part of this job
is to define the message syntax. The contents include the requested message, action taken, and
the response message.
The management defines how to initialize the network : tag assignment, address assignment,
clock assignment, clock synchronization, distributed application scheduling across the network
or association of the input and output parameters of the function blocks. It also controls the
operation of the network with statistic of faults and detection of the addition of the new element
or the absence of a station. The system always look for the new stations on the bus by polling
the possible station addresses.

Digital Communication Protocol

ISO

IEEE
SP72
SP50
F.I.P
Profibus
WorldFIP
ISP

- International Standard Organization. Responsible for developing the

model that the communication specification are based upon as well as
standards for each layer of communication specification.
- Institute of Electrical and Electronics Engineers. Formed the IEEE 802
project for defining standards for network media and access methods.
- Institute Society of America, Standards and Practice committee Number 72
Developing EIA1393 companion standard for process control messaging.
- Institute Society of America, Standards and Practice committee Number 50
Developing standards for digital communication between field devices.
- Factory Information Protocol, approved French National Standard.
- Process Fieldbus, approved German National Standard.
- A U.S./French conglomerate of instrument manufacturers.
- Interoperable Systems Project, a multinational group of some 80
manufacturers spanning U.S/Europe and Japan.

HART COMMUNICATION PROTOCOL

Why HART protocol ?
4-20 ma is tried, tested and widely used standard but only limited amount of information
is sent by a 4-20 ma signal.
HART (Hiway Addressable Remote Transducer) protocol enhances these operations by
transmitting digital data along with the 4-20 ma signal without interfering with it !
HART permits two-way communications. It also has all digital mode that allows
instrument to be connected to a single cable, cutting installation costs dramatically.
Features :
1.
Field proven concept that is easy to understand and use.
2.
Compatible with existing 4-20 ma systems.
3.
Simultaneous point-to-point 4-20 ma and digital communication.
4.
Alternative multi-drop mode.
5.
Measured variables, tag no. , range and span settings, device information,
diagnostics and simple messages transmitted.
6.
Digital response time of 500 msec; burst mode response of 300 msec.
7.
Open architecture; freely available to any vendor and every user.

HART COMMUNICATION PROTOCOL

Method of Operation :
The Hart protocol operates using the FSK principal. The digital data is made up from two
frequencies 1200 Hz and 2200 Hz representing bits 1 and 0 respectively. Sinusoidal
waves of these frequencies are superimposed on the DC analog signal cables to give
simultaneous analog and digital communications

HART Protocol Structure :

HART follows the basic Open Systems Interconnection (OSI) reference model, developed
by the International Organization for Standard (ISO). The HART protocol uses a reduced
OSI model, implementing only layers 1,2 and 7

HART COMMUNICATION PROTOCOL

OSI reference model
Open Systems Interconnections

LAYER

FUNCTIONS

HART

Application

Provides formatted
data

Presentation

Converts data

Session

Handles the
dialogue

Transport

Secures the transport

connection

Network

Establishes network
connections

Link

Establishes the data

link connection

HART protocol
regulations

Physical

Connects the
equipment

Bell 202

HART instructions

HART PROTOCOL LAYERS

Layer 1, the physical layer, operates on the FSK principle
Data transfer rate: 1200 bit/s
Logic 0 frequency: 2200 Hz
Logic 1 frequency: 1200 Hz
the vast majority of existing wiring is used for this type of digital communication.
Layer 2, the link layer establishes the format for a hart message. HART is a master/slave
protocol.
the structure of these messages is given below:
Preamble SD

AD

CD

BC

Status

Data Parity

SD start character.
AD display terminal and field addresses.
CD HART instruction.
BC Byte count.
Status Field device and communication status (only from field device to master)
The individual characters are : 1 start bit, 8 data bits, 1 bit for odd parity and 1 stop bit.

HART PROTOCOL LAYERS

Layer 7, the application layer, brings the HART instruction into play. The master sends
messages with requests for specified values, actual values and any other data or
parameters
available from the device. The field device interprets these instruction as defined in the
HART protocol. The response message provides the master with the status information
and data from the slave.
For slave devices, logical uniform communication is provided by the following command
sets:
Universal commands understood by all field devices.
Common practice commands provide functions which can be carried out by many,
though not all, field devices.
Drive-specific commands provide functions which are restricted to an individual
device.

HART PROTOCOL TECHNICAL DATA

DATA TRANSMISSION
Types of data transmission
Transfer rate
0 bit information frequency
1 bit information frequency
Signal structure
Transfer rate for simple variables

:
:
:
:
:
:

Frequency shift keying (FSK)

1200 bit/s.
2200 Hz
1200 Hz
1 start bit, 8 data bits, 1 bit for odd parity, 1 stop bit.
Approximately 2/s (poll/response)

DATA INTEGRITY
Physical layer
: Error rate destination circuit : 1/(10^5)
Link layer
: Recognizes : all groups up to 3 corrupt bits and practically all longer
and multiple groups.
Application layer : Communication status terminated in a response message.

MODBUS
The MODBUS protocol describes an industrial communication and distributed
control system developed by Gould-Modicon. MODBUS is a Master/Slave
communications protocol, whereby one device (Master), controls all serial activities by
selectively polling one or more slave devices. The protocol provides for one master device
and up to 247 slave devices on a common line. Each device is assigned an address to
distinguish it from all other connected device.
Only a master initiates a transaction. Transactions are either a query/response type,
or a broadcast/no-response type. A transaction comprises a single query and single
response frame or a single broadcast frame.
Certain characteristic of a MODBUS protocol are fixed such as frame format,
frame
sequences, handling of communication errors and exception conditions, and the functions
performed.
Other characteristics are user selectable. These include a choice of transmission
media, baud rate, character parity, no. of stop bits and the transmission modes. The user
selected parameter are set at each station. These parameter cannot be changed while the
system is running

RS-232 Communication

RS-232 is an asynchronous communication network. Normally, a binary system is

used to transmit data in ASCII (American Standard Code for Information Interchange)
format. This code translates human readable code (letter/numbers) into computer readable
code(1s and 0s).
There are 2 types of RS-232 devices. The first is called a DTE (Data Terminal
Equipment) device and a common example is a computer. The other type of device is called
DCE (Data Communication Equipment) device and a common example is a modem.
In RS-232 the first thing a terminal send is start bit. This start bit is a synchronizing
bit added just before each character being send. The last thing send is a stop bit. This stop bit
informs to the receiving terminal that the last character has just being send.

RS-232 Communication
RS-232 communication is done through Serial port which usually has a 9-pin
configuration. The pin and their purposes are shown below.

9-PIN

PURPOSE

Frame ground

Receive data (RD)

Transmit data (TD)

Data terminal ready (DTR)

Signal ground (GND)

Data set ready (DSR)

Request to send (RTS)

Clear to Send (CTS)

Ring indicator (RI) *only for modems*

PC-to-PC Communication through Serial Port

CD 10

01

CD

RXD 20

02

RXD

TXD 30

03 TXD

DTR 40

04

DTR

GND 50

05

GND

DSR 60

06

DSR

RTS 70

07

RTS

CTS 80

08 CTS
09 RI

RI 90

9-Pin D Connector

PC-to-PC Communication through LPT1 Port

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

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

Flavours of Internet Telephony

PC-to-PC
The
Internet
PC

PC
Dial-up or Local ISP
Leased Line

Local ISP

PC-to-Phone
The
Internet
PC

Phone
Local ISP
Voice Gateway

Local ISP

Phone-to-Phone

Access
Code
The
Internet

Phone

Phone
Local ISP
Voice Gateway

Local ISP
Voice Gateway

APACS - Operation Platform

Database Ownership

Operator Console

Engineer Console

Operator Console

Controller Level

Controller Module

I/O Level

I/O Modules
Transmitter

Interlock

Console Level

I/P Valve

TAGS
Range
Engineering Unit
Diagnostics

TODAYS INDUSTRIAL SYSTEMS

Application

Drivers

-----------------------

HMI
1

Planning
HMI
4

Devices
PLC

DCS

I/O

PC Based Industrial Systems

OPC Client
Application
OPC
Server

HMI

----------------------------------

Planning
HMI

Devices
PLC

DCS

I/O

Enterprise Automation Schemes

Windows NT

Corporate
IT Network
Windows NT
Server

Control
network

Embedded
Real System

Windows NT (New technology)

FEATURES:
A true 32 bit processing.
A very reliable operating system.
Real operating system.
TECHNICAL ASPECT:
Multiprocessing, Multithreading and partitioned memory space.
Security - C2 compliance.
In-built networking.
Internationalization .
Human interface as Windows 95.
Object - based : DCOM/OLE - ActiveX.
for special need of the process industries. DCOM and OLE are not robust,
deterministic and secure.
Client - Server architecture.

Windows NT Interconnectivity
Transparent inter-connectivity to typical business systems in plants:
1) ODBC : It provides access to most SQL databases.
2) ActiveX/OLE : Supports data access between application and embedding of
one applications function within another.
3) DDE : Dynamic Data Exchange supports simple data exchange between
applications such as plant data populating an Excel spread sheets.

Windows NT features
Windows NT is gaining ground in open control because of the following advantages :
User acceptance.
Corporate interoperability
Ease of use.
Connectivity.
Scalability for small and large application.

However, Windows NT has the following disadvantages :

Needs a lot memory and processing power.
Optimized for office, not control, requirements.
Requires a disk drive which may fail.
Depends on single vendor.
Reboots at unexpected times
Unstable operating system.

Embedded control Operating System - QNX

QNX real-time operating system, has evolved from the first-ever micro-kernel operating
system for PCs into one of the best selling and most trusted operating systems for mission
critical application. Today, QNX is the real time operating system in industrial automation,
hand held devices, controllers and soft PLCs
QNX is recognized as :
The fastest and most dependable real time operating system.
The most proven high speed, deterministic real time kernel.
Having a hard real time engine that gives PLC-style control.
Enabling data acquisition with milliseconds resolution.
Providing a fault-tolerant architecture on which you can run control, events, alarms in a
virtually crash-proof environment.

Windows NT - for Process control

Windows NT features :
A true 32 bit processing.
A very reliable operating system.
Real operating system.
Multiprocessing, Multithreading and partitioned memory space.
Security - C2 compliance.
In-built networking.
Internationalization.
Human interface.
Object-based DCOM/OLE :
The sending object is shown as client and receiving object is known as server. The
MS technology allows any developer to produce small, self contain objects that have
packaged visual component and specific action. These components are called
ActiveX objects. NTs OLE technology is part of Microsofts Distributed
Component Object Model (DCOM) operating across networks. Anyone can develop
ActiveX Object using VC++ or even VB on a PC. For special needs of the process
control industries DCOM and OLE are not secure, deterministic and robust enough.
OPC is a process industry consortium that is working to make extension to
DCOM\OLE

Ethernet
Ethernet was originally designed by Digital, Intel and Xerox (DIX) in the early 1970s
and has been designed as a broadcast system. The original format for Ethernet was developed
in Xerox Palo Alto Research center (PARC), California in 1972. The two inventors were
Robert Metcalf and David Boggs.
Ethernet version 1.0 and 2.0 followed until the IEEE 802.3 committee re-jigged the
Ethernet II packet to form the Ethernet 802.3 packet. Nowadays you will see either
Ethernet II (DIX) format or Ethernet 802.3 format being used.
The Ether part of Ethernet denotes that the system is not meant to be restricted only to
one medium type, copper cables, fiber cables and even radio waves can be used.
Briefly, stated Ethernet what is referred to as the Physical layer and the Data-link layers
protocols. The physical layer defines the cable types, connectors and electrical
characteristics.
The Data link layer defines the format an Ethernet frames, the error checking method and the
physical addressing method. As Ethernet is only a Physical/Data link layer other protocols
need to be added on top of it to address the issues of routing, end-to-end data integrity and
house specific network task are carried out.

Ethernet
10Base5
Traditionally, Ethernet is used over thick coaxial cable called 10Base5 ( the 10
denotes 10 Mbps, base means that the signal is baseband i.e, takes the whole
bandwidth
of the cable, 5 denotes 500m maximum length ). The minimum length between stations
is 2.5m.
The cable is run in one long length forming a Bus Topology. The segments are
terminated by 50 ohm resistor and the shield should be grounded at one end only.

10Base2

Thin Ethernet (Thinnet) uses RG-58 cable and is called 10Base2 (the 2 denotes
200 mtr maximum length cable). Each station connects to the Thinnet by way of
Network Interface Card (NIC). At each station the Thinnet terminates at a T-piece and
at each end of the Thinnet run a 50 ohm terminator is required to absorb stray signals
thereby preventing signal bounce.

Ethernet

10BaseT
Nowadays, it is becoming increasingly important to use Ethernet across Unshielded
Twisted Pair (UTP) or Shielded Twisted Pair (STP), this being called 10BaseT (the T
denotes twisted pair). UTP is installed in star wire format and Ethernet Hubs with UTP ports
(RJ45) centrally located. Also there should be no more than a 11.5db signal loss and the
minimum distance between devices is 2.5 meters.
The advantages of the UTP/STP technology are gained from the flexibility of the
system, with respect to moves, changes, fault finding, reliability and security.
10BaseF
10BaseF standard developed by IEEE 802.3 committee defines the use of Fiber for
Ethernet. 10BaseFB allows up to 2 Km per segment and is defined for Backbone application
such as cascading repeaters. 10BaseFL describes the standards for the Fiber optic links
between stations and repeaters allowing up to 2 Km per segment on multimode Fiber.

Ethernet
The following table shows the RJ45 pin outs for 10BaseT :

RJ45 Pin

Function

Colour

Transmit

White/Orange

Transmit

Orange/White

Receive

White/Green

Blue/White

White/Blue

Receive

Green/White

White/Brown

Brown/White

PC-to-PC Communication through Ethernet

RJ45

RJ45

Ethernet Topology
Segmented (star) topology

Workstation

Workstation

Bus topology

Workstation

Workstation

Switched Hub

Controller
Controller

Controller

Controller

Wireless LAN
Wireless LAN is based on standard IEEE 802.11b which throughput of up to 11Mbps in the
2.4 Ghz band. Similar Wireless Personal Area Network (WPAN) are Bluetooth and Infrared.
Ethernet works on the CSMA/CD technology but wireless LAN has difficulty of detecting
collision in Radio frequency. Therefore they are using CSMA/CA (Collision Sense Multiple
Access / Collision Avoidance) technology to transmit data. Physical Layer is either Photonic or
Radio frequency.

Process control Software characteristics

The most important feature of process control system is that it needs to be reliable. The
process control system used has to be completely crash-proof and any changes in the
system need to be made on-line.
The process control needs to be made real time, which means that it can update the I/O
data table and process the control program in the time required by the process.
A process control system that is deterministic refers to whether the operating system
allows the highest priority task to work without interruption from task with lower priority.
Software offerings in the automation and the process control fields must be versatile and
open enough to address the needs of different applications.
Finally the chosen solution must deliver tangible, quantifiable values such as :
1.
Reducing project implementation time and cost.
2.
Improving time-to-market.
3.
Achieving higher production and quality.
4.
Cutting maintenance and training cost.
5.
Increasing profits.

PC-based control system features

Unlike the other systems, PCs provide a more open architecture making them ideal for
improving, optimizing and integrating the overall automation process, as well as conducting
control task.
In addition PCs offer the following features :
Lower cost.
Ease of use.
Graphical user interface.
Easy integration of logic, motion and process control.
Simplified application development.
Software portability
Independence from proprietary control system.
Using PCs enable the following functions,
Millisecond time stamping which is essential to utilities.
Real time control.
Sequence of events.
Alarming.
Data collection.

PLC conceptual overview

Process
Graphics

History &
Trend

Alarm &
Events

SCADA
configuration
editor

Other Aspect
system

SCADA Control
Aspect

OP Client

OPC server
SCADA
server

Real-time
database

opc

Modbus

comli

Protocol Protocol
xx
yy

ABB

Siemens

Allen
Bradley

GE
Fanuc

PLC Programming Standards

The open, manufacturer-independent programming standard for automation is

IEC 61131-3. You can thus choose what configuration interface you wish to use when
writing your application :

Ladder Diagram
Instruction List
Function Block Diagram
Sequential Function Chart
Structured Text
All users, be they plant electrician or computer scientists, thus have a
configuration interface in which they can feel at home.

Industrial IT Trends
The availability of information is becoming increasingly crucial in the view of growing global
competition. In future, a decisive competitive edge can only be achieved by providing the
right information at the right time, in the right place and in the right form for the right person.
these leading- edge application are continuously optimized and repositioned.
Industrial IT consists of five components:
1.
2.
3.
4.
5.

Engineering IT
Operation IT
Production IT
Optimization IT
Evolution / Information

Industrial IT Trend

Business
Systems

Sales &
Marketing

Operation &
Maintenance

ASSET

Y
CTIVIT

Plant &
Process Eng.

Real-time
Automation &
Information

U
e-PROD

Planning &
Scheduling

ION
OPTIMIZAT

Distribution

Plant