Distributed Control System

Technology of Automatic Control

Yokogawa
Distributed Control System (DCS)
Centum CS3000 R3

Hannan Akhtar
 Objective

 Learning Industrial Automation & DCS in general

 Yokogawa DCS

 Typical Control Loop

 DCS Hardware

 DCS in FFC-MM

 DCS Software Engineering & Test Function

 Future plan of upgrade

 Industrial Automation

 Use of control systems and information technologies to

reduce the need for human work in the production of
goods and services.
 A control system is a device, or set of devices, that manages,
commands, directs or regulates the behavior of other
devices or systems. Industrial control systems are used for
controlling equipment or machines.
 Control Systems are used in various industries such as
electrical, water, oil, gas and chemical.
 Distributed Control System (DCS)

 A distributed control system (DCS) refers to a control system usually

of a manufacturing system, process or any kind of dynamic system.

 In DCS the controller elements are not central in location (like the
brain) but are distributed throughout the system with each
component sub-system controlled by one or more controllers.

 The entire system of controllers is connected by networks for

communication and monitoring.

 A DCS typically uses custom designed processors as controllers and

uses both proprietary interconnections and communications protocol
for communication.
 Distributed Control System (DCS)
 A typical DCS consists of functionally and/or geographically
distributed digital controllers capable of executing multiple
regulatory control loops in one control box.
 The input/output devices (I/O) can be integral with the controller
or located remotely via a field network.
 Today’s controllers have extensive computational capabilities
and, in addition to proportional, integral, and derivative (PID)
control, can generally perform complex algorithms.
 DCSs may employ one or more workstations and can be
configured at the workstation or by an off-line personal
computer.
 Comparison with PLC

 PLC stand for programmable logic Controllers

 Used for batch processes; fixed desired operation at fixed

input

 Sequencers and Logic based interlocking are easily

implemented

 ESD system is based on PLC(Honeywell Failsafe FSC)

 Comparison with PLC

Qualities PLC DCS

• Response Time • Fast • Slower in
comparison
• Scalability • Few hundred I/O
• Thousands of I/O

• Redundancy • Redundant • Standard/Redund

Robust Schemes ant schemes

• Complexity • Simpler and • Complex and

easier to Program proprietary
Programming
• Process Changes • Suitable for Less
Process Changes • Suitable for
online changes
 Yokogawa DCS at FFC-MM

 Yokogawa Centum CS3000 R3

 System covers Ammonia, Urea, Utilities and Water Treatment
Plants
 Seven FCS Controllers (DCS Systems) & 15 HIS Computers
(Operator Screens) are installed

# DCS System Installation / Commissioning Year

1 Utilities & TGs TA-2006

2 Ammonia & Urea Plants TA-2007

3 WTCR Year 2013/14

 Typical Control Loop

FIELD RACK ROOM CCR

INPUT
MODULE HMI
Barrier (FTA)

4-20mA 4-20mA

TRANSMITTER

CONTROL
PROCESSOR

OUTPUT
MODULE
Barrier
(FTA)
4-20mA 4-20mA

CONTROL VALVE
 Yokogawa DCS

HIS

V-NET
DATA PACKETS
FCU

RIO BUS DATA PACKETS

NIU

FCS

IOM

4 – 20 mA
4 – 20 mA

Control Valve Transmitters

DCS Control Station - FCS

FCU

NIU

IOM

Power
Supply
 REDUNDANCY OF THE SYSTEM

V net

FCU
Processor card Processor card
V net I/F V net I/F

Main CPU 1 CPU 1 Main

Memory Collator Memory
Collator
(with ECC) (with ECC)
CPU 2 CPU 2

RIO bus RIO bus

Power Supply card card Power Supply

V netBUS
RIO BUS R I/O bus
Redundant Link between control processor & HMI
I/O system
Com. Card

Com. Card
PROCESSOR
Bus type networkCARD I/O SYSTEM
CPU
Token
SpeedSPEED
Passing= 133
= 2 Mbps MHz
technology Input
Memory
Speed = 16 MBytes
Twisted pair cable
= 10 Mbps Module

640
Coaxial
Output
MaxI/Os handling
cable
distance = 750capacity
m Module
 Field Control Unit

RIO
POWER
BACKUP
BUS
RIO BATTERY
POWER
VNET
FAN
CPU DISTRIBUTION
COUPLER
UNITS
SUPPLY
COUPLER
INTERFACE
(72CARD
HOURS)
UNITS
UNITS
 Input / Output Modules

RIO INTERFACE
POWER SUPPLIES
I/O MODULE
NODENEST
I/O CARDS
 Typical DCS Inputs / Outputs Modules
Inputs
• Process Transmitters
• Process Sensing Switches
• Temperature Sensors
• Tachometers
• Limit switches
• Operator commands and push
buttons
• Inputs from MCC / Electrical
Substations
• Inputs from other systems like
Vibration Monitoring System,
Electronic Governing System,
ESD DCS and ELMS, etc.
• Communication Inputs
Outputs
• Control Valves
• MOVs (Opening & Closing)
• Solenoid Operated Valves
(SOV)
– Open / Close Shutdown Valves
– Start / Stop turbines and
machines
• Start / Stop commands to motor
starters through electrical
substations
• Indications, lamps, Hooters etc.
• Special interface signals to other
control systems like ESD,
antisurge controllers, speed
governors and Gas Turbine
• Communication Outputs
 Input / Output Modules

 I/O modules transfer field signal to field control stations and vice versa
 I/O modules can be categorized into the following main types:
Types Model Name
Current/Voltage Input Module (Single
AAM10
Channel)
AAM11 Current/voltage Input module

AAM21 mV, Thermocouple, RTD Input Module

Analog
APM11 Pulse Input Module (Frequency)

AAM50 Current Output Module (Single Channel)

AAM51 Current/Voltage Output Module

ADM12T Contact Input Module (32-Point)

Digital
ADM52T Contact Output Module (32-Point)

Communication ACM12 RS-422/RS-485 Communication Module

 DCS Architecture

• In Yokogawa DCS, there are two networks:

– Control Network (Vnet)
• Real time data from field devices etc
– Data Network (Enet)
• Data Equalization.
• There is no central server station, every computer on
Vnet directly communicates with FCS.
• Following different O&M groups are configured:
• Urea
• Ammonia Front-End
• Ammonia Back-End Boardman
• Utilities
• Power Generation
• WTCR (Not linked with main CCR)
• HMI/EWS : OS Windows XP SP-2
 Human Interface Station (HIS)

HIS is a computer where operating & monitoring software is

used by plant operators

These are standard computers with special communication

cards used for interfacing with FCS (DCS Controllers).

Yokogawa supply standard license for operation and

monitoring software.

Engineering Station computers have additional license of DCS

configuration software
 FFC – MM Main DCS Architecture

TGs AMMONIA
UTILITIES COORD
GCR CONTROL UREA
E-NET

300 Meters V NET

ENGINEERING FRONT END

Power Generation 01 FCS Unit BACK END 01 FCS Unit
STATIONS
02 FCS Units 02 FCS Unit

Note: WTCR DCS is equivalent to Utilities DCS System

Control Room
DCS Network Architecture
 Types of Networks

• Vnet
– All stations are connected to each other through Vnet
– Used to fetch process data from FCS to HIS
– Used to send operator commands/action from HIS to FCS
– Used to exchange process data between FCSes
– Redundant
• Ethernet
– All HIS PCs (including EWS) are connected to each other
through Ethernet
– Based on standard LAN adapter
– No connection with DCS controller (FCS)
– Used to equalize/synchronize engineering data from EWS
to HIS
– Used to exchange trend data between HIS
– Non-redundant
 Functional Distribution
06 Field Control Stations (FCS)
FCS0101 TG-701A
FCS0102 TG-701B
FCS0103 Utilities
FCS0104 Ammonia Front-End
FCS0105 Ammonia Back-End
FCS0106 Urea
13 Human Interface Stations (HIS)
HIS0131, HIS0132, HIS0133 Urea
HIS0141, HIS0142 Ammonia Front-End
HIS0143, HIS0144 Ammonia Back-End
HIS0161, HIS0162 Utilities
HIS0160 Coordination Engineer
HIS0159*, HIS0163 Power Generation (read-only)
HIS0145 Engineering Workstation
*HIS0159 is read-only HIS placed in G
 HIS – Operation and Monitoring

 Number of Tags = 100000

 Operation and monitoring windows
 Graphic Window
 Control Loop Face-Plate
 8 – Control Loop Display
 16 – Control Loop Display
 Trend Window
 Tuning Window
 Process Alarm Window
 HIS – Operation and Monitoring

 System Maintenance Functions

 System Alarm Window
 System Status Overview Display
 FCS Status Display
 NIU Status display

 Electronic Sounds for annunciation

 Seven different sounds are produced

 Reporting Package
 Generate reports periodically and on demand
 Graphic Window

Graphical Window
400 Data points per window
200 Data Modifiers
(Flashing, Color change)
Graphic Window
 LOOP LOOP TAG
IMPORTANCE

PROCESS LOOP
CONDITIONS OF DESCRIPTION
LOOP

LOOP OUTPUT MODE OF

OPERATION

PROCESS
VARIABLE

SET POINT
 Distributed Control System
Technology of Automatic Control
SYSTEM ALARMING

ALARM STATE
NORMAL STATE
8- Loop Display
16 – Loop Display
 Trend Window

06-TIC-101

Trend Window
6400 trends can be archived
Minimum time resolution = 1 sec
Trend point window
 Sample Time of Trends

Following sampling times are available:

– 1 second
– 10 second
– 1 minute
– 2 minute
– 5 minute
– 10 minute
• Sample time is assigned at Trend Block level
• High-speed trends (1s, 10s) generate more
network traffic and require more storage space
• Maximum of 02 high-speed trends can be
configured per HIS
 Trend Data Storage
• Trend data is stored in files
• One file stores 2880 process samples.
– For 1 second trend: 2880 seconds = 48 minutes
– For 1 minute trend, 2880 minutes = 2 days
• By default, HIS saves only current file and discards older
ones
• If the HIS has “Long-Term Data Archive Package”, it
does not discard older files and stores trend data for
extended periods.
• Space requirement for storing trend data:
– 1 second trend block: 2.5 GB/month (approx.)
– 1 minute trend block: 42 MB/month (approx.)
• Long-Term storage is available on HIS0131, HIS0141,
HIS0144 and HIS0163.
• We are retaining 3 months of trend data in these HISes
 Tuning Window

Tuning Window
Set point, PV, MV limits
Alarms Settings
Vary PID control tuning parameters
Add / Remove Operation Mark
Monitor real time trend (SP, PV, MV)
 Process Alarm Window

Process Alarm
Alarm will be logged in chronological order
 System Alarm Window

System Alarm
Alarm will be logged in chronological order
FCS Status Window

FCS STATUS

NIU STATUS
 System Status Overview
VNET STATUS

FCS STATUS

HIS STATUS
 Distributed Control System
Technology of Automatic Control

NIU STATUS

POWER
COMM. SUPPLY
MODULE STATUS
STATUS

I/O MODULE
Operator Keyboard
 System Message Window
1. Main Toolbar

2. Message Display Area: Display alarms and system messages

3. Date/Time Display: Displays Current Date and Time

4. Icon Display Area: Indicates various states of the HIS

Database Equalization Required

Extended Toolbox
Window Call Menu
Preset Window Menu
 Engineering and Configuration
• All engineering and configuration functions are performed from the
engineering work station machine.
• Steps are involved in engineering of the system.
– Defining System Architecture
• FCS Controllers
• I/O Cards & Channels
• HIS Stations
• Project Common (Alarm Processing etc)
– I/O & Loop Configuration
• Defining all tag names and data points which will be
exchanged between field and system
• Configuring loops using function block library
– Developing Graphics
• Developing graphics of plant data
• Linking live data (tag names and data points) with effects on
graphics
 Engineering and Configuration

• Operation & Monitoring is managed through security

level, configuring access level and alarm priorities.

• HIS Security:
– Off User – Operation & Monitoring of plant (If Privileged)
– On User – O&M with configuring tuning & other settings
– Eng User – O&M, additional functions for managing
specific functions of HIS settings

• Access level is configured through HIS configuration

from EWS
 Alarm Management

• Common Alarms of Process Indicator

– PLL, PL, PH, PHH, VH, IOP
• Configuration of individual type of alarm is
done through two tables:
– Alarm Priority Table
• Define priorities High, Low, Medium & Logging.
– Alarm Processing Table
• Different User Levels (1-8), these user definer the alarm
priority & color alarm state for each type of alarm.
• Individual loops are tagged with user level for
alarm processing.
 Alarm Management

• Alarm Priority Table

Priority HMI Printer History Action
High Y Y Y Lock Type
Medium Y Y Y Lock Type
Low Y Y Y Non Lock Type
Logging N Y Y Self Ack. Type

• Alarm Processing Table

User PLL PL
S5 L Yellow L Yellow
S6 M Orange M Orange
S7 H Red M Orange
 Communication with Sub-Systems

• Data is fetched from various devices through

communication link and displayed on DCS HMI.
• DCS initiates all data transactions, therefore, DCS
is called Master and the devices are called Slaves
or “Sub-Systems”
• Sub-System communication allows transfer of
process parameters from various systems to DCS
with minimum hardware wiring
• Over 20 devices are communicating with DCS
currently.
– Communication Interface: RS-485
– Communication Protocol: Modbus RTU
 Sub-Systems connected with DCS

Sub-System Description Related Equipment

Bently Nevada 3500 Systems TK-421 / TK-431 / TK-441 / MK-212
TK-101 / P-102 / TG-701A / TG-701B
Woodward Governors TK-601 / TK-101 / TG-701A
CCC Vanguard / Guardian System TK-421 / TK-441
GE Antisurge Controllers (CMS) TK-431 / TK-101
Honeywell FailSafe Control (FSC) F-202 BMS
TurboMach Gas Turbine GT-703
GE PAC 8000 B-603 (HRSG) BMS
GE-Fanuc PLC F-501 BMS
Red Lion PLC MK-800A-H (Fan Vibration)
GE-Fanuc PLC Urea Cooling Tower (Wireless)
 Future Plans

• Existing HIS computers are based on Windows XP,

running on old machines (about 8 years old), which are
no more available for purchasing.

• Its software and PC up gradation with Windows 10 will

be proposed in CAPEX-2017.

• Architecture of the new system will be similar to the

existing system except the Control network. New
network will be Vnet/IP.

• With this upgrade, we can also add PIMs (Plant

Information Management System).
Thank you