Experion PKS/PMD

TPA to Experion PKS/PMD skills

transition
Design Module
Overview 1

• This presentation gives an overview of the PMD

automation system’s design module (DM).
• It describes DM’s
– Functions
– Tools and their features
– Basic engineering techniques

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Overview 2

• Design Module (DM) is a set of software tools, based on

Windows 2000 operating system and meant for
engineering and maintenance of PMD automation
system’s application and system configuration.
• DM enables to
– Create, modify, test and document application
– Load and monitor application running in the system
– Create and modify system, I/O and field network definitions
– Monitor and troubleshoot PMD system and field network
condition
– Remote control using modem or network connection

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Overview 3

• Tools
– Block Builder
• Application configuration and documentation
• Application testing in DM (off-line) in simulation mode
• Application loading to the system and monitoring
– Program builder
• Application coding using Pascal-based High-Level language
– System Builder
• I/O and system definitions
– Daxmon
• PMD system’s condition monitoring and troubleshooting
– HMIWeb Display Builder
• Displays configuration
– Fieldnet Builder
• Field network configuration
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PMD Explorer 1

• PMD Explorer is the main DM’s window to basic

functions and tools called builders.
• PMD Explorer enables to
– Test, load and monitor application
– Browse hierarchical application structure and make search
– Open DM’s builders (Block, System and Fieldnet builder)
– Monitor and troubleshoot Field controller’s condition (Daxmon)

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PMD Explorer 2

Windows Start ->

Programs/PMD
Design
Module/PMD
Design Module

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PMD Explorer 3

Application configuration:
Application/Department/
Blocks/Selected block
In this case:
HWELL\TRAIN4\BLOCKS\FC1

I/O and system definitions:

Field network configuration:
Application/Department/
Application/Department/ System/System Structure
Field_network/ Fieldnet_Builder
In this case:
or CMD
HWELL\TRAIN4\SYSTEM\SYSTE
In this case: M STRUCTURE
HWELL\TRAIN4\Field_network\Fi
eldnet_Builder
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Block Builder

PMD Explorer ->

Application/Depa
rtment/
Blocks/Selected
block -> Edit

• Application
design and
configuration is
done using
Block Builder Menu bar Tool bar

Browse
window Block window

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Application design

• In the application design it is used a hierarchical approach, which

means that a process entity or problem to be controlled is broken
down into smaller parts and correspondingly application is divided to
blocks, which form a hierarchical block structure.
• The entire process being controlled is on the highest level in the
block hierarchy.
• Further division is usually made according to process sections,
subsections and so on or in some other logical way.
• On the lowest level in the block hierarchy there are usually
measurement, control, motor etc. loops.

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Block Hierarchy (example)

Hierarchical block
Hierarchical division of a paper mill processes structure in
DM Block Builder
Paper Mill

Stock Preparation Paper Machine Couting Kitchen

Wet end Dry end

Headbox Wire Dryer 1 Dryer 2

Loop 1

Loop 2

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Block Configuration 1

• In order to achieve required control algorithm blocks can be connected

together via pins.

pins

connections blocks

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Block Configuration 2

Block configuration steps

1. Add hierarchical block to the hierarchy
– Model block can be used as a template
2. Define hierarchical block’s header
– Face plate selection and definition
– Module where block is loaded, run cycle, priority and phasing
3. Add needed basic, type or HLL blocks
4. Add pins
5. Make connections
6. Define run order
7. Test the block at Design Module (simulation)
8. Make I/O definitions in System Builder
9. Load block to the system
10. Start loaded block and test it (monitoring)

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Blocks 1

• There are 6 types of blocks

– Basic blocks
– HLL blocks
– Type blocks
– Model blocks
– Hierarchical blocks
– Loop blocks
• Basic blocks are DM’s built-in library blocks, meant for basic calculations, logic, control etc.
functions.
• HLL blocks are blocks made using DM’s Pascal-based programming High Level Language
for project specific solutions.
• Type blocks are blocks usually made using HLL, which extend basic blocks’ library for the
specific applications such as fuzzy logic, neural networks, statistical process control etc.
• Model blocks is a library of template blocks, which can be used as basis for hierarchical
blocks.
• Hierarchical blocks are blocks containing other Hierarchical, Basic, HLL or Type blocks
thus forming a hierarchy of blocks.
• Loop blocks are hierarchical blocks, which have special pre-defined operator interface
displays called Face plates for standard controls such as motors, valves, control loops etc.

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Blocks 2

Menu Bar -> Block/Header

Every hierarchical block has

a header containing
additional data about the
block, which can be viewed
and defined in block
“Header” and “Execution
data” windows and in case
of loop block also in a
“Setting initial Face Plate
values:” window.

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Blocks 3

• Ids – Id1 is a block name given in the hierarchy and also displayed in Face plate. Id2
and Id3 are additional Ids, which can be used as loop’s electrical and instrument Ids.
• Name – block name seen in a block window header.
• Name2 – additional name, which can be given to the block.
• Description – if the block has description text, then this field is checked.
• Tag – if checked, the block’s Id1 and Name is attached to the description of alarm
generated by the block.
• Ready – if checked, a code file downloadable to PMD system is compiled for the block.
• Face plate – type of Face plate defined for the loop block (chosen from a list on the
right).
• Extension – should be checked, if one wants to view or define Face plate’s initial
values.
• Version – current version of the block (displayed automatically).
• Author – block author’s ID entered at PMD explorer start-up (displayed automatically)
• Date – date, when block was last time changed (displayed automatically).
• Associated pages – At the moment, can be used to define a display to associate with
the block in alarm display.

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Blocks 4

Header window -> OK

• Block’s execution data is needed for

controller’s operating system, which executes
all the blocks loaded to controller according to
these parameters.
• Module – Controller’s name, defined in
system builder to which application block is
loaded. In case redundant controller,
secondary controller name is also defined.
• Cycle – Block’s execution cycle length.
• Phase – Usually, fixed phase is used for hierarchical sub-blocks of loop blocks. Auto is
used for all other blocks. 0,1,2 etc. is not used.
• Priority – Block’s execution priority. High priority is used for the blocks with fast cycle
(<0.1s). Low priority is used for the blocks with slower execution cycle (>5s). Normal is
used for all the other blocks.

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Blocks 5

Header window -> Extension

(Checked) -> OK ->
Execution data window ->
OK/Cancel

• Process area is a part or

section of a process
•Every block belongs to a
Process area and different
users rights can be given to
the block according to
process areas.
• Face plate parameters’
initial values depend on the
type of Face plate. • There are Face plates for Measurement and Control loops,
different types of Motor and Valve controls, Sequence
• Trend collection pin’s are control etc.
also defined

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Basic Blocks 1

• Process Interface Blocks

– Data from interface card (I/O card)
– Standard data
• Analog or binary data
• AILI, AOLI, AISQ, PTIN, BI4 and BO4 blocks
– Measurement target specific data
• channel data type and value range varies from case to case and
are determined when application is defined
• EXTRI and EXTRO blocks
• Filtering, limit monitoring and limit blocks
– used to influence the functioning of the process real number variable or
signal.
• Selectors and switches
– used to select or branch out data according to control data

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Basic Blocks 2

• Vector blocks
– handling/forming of vector formed data
• Basic calculations
– basic calculations (add, divide, etc.)
– substitutions (put, etc.)
– comparisons (greater than, etc.)
– chancing of data type (move etc.)
• Primary functions
– Most common mathematical primary functions (sin, cos, etc.)
• Special functions
– Blocks: Clock, Date and CycTime (time and date monitoring)
– compensating blocks
– calculation and monitoring blocks

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Basic Blocks 3

• Control blocks
– control algorithms (P, PI, PID,PIDEL)
• Logic Blocks
– processing and controlling of binary data (and, or, etc.)

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Basic Blocks 4

• Logic packages
– logic controlled actuators
– motors, valves and switches
– Functions:
• Prioritization of controls
• Control modes (man, auto, local)
• Inhibition/protection
• Control state
• Status code and alarm evaluation

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Basic Blocks 5

• Sequence blocks
– control sequences
– STEPX consists of step blocks executed conditionally
accordance with step number
• Alarm blocks
– configuration of application alarms
– Features:
• alarm filtering and inhibit
• priority
• alarm area (not applicaple in PMD)
• output text
• manner of output (not applicaple inPMD)

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Pins 1

Menu bar -> Pins/Insert

• Pins are block interface

variables, which can
have different properties.

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Pins 2

• Name = Pin name 1 - 3 characters (alphabets A-Z and numerals 0-9).

• Input/Output = Defines which frame pin is added: input is left and output is right.
• Vector = vector pins (used with vector blocks and when necessary with High Level
language).
• Type:
– Signal = bit data “all alphabet characters lower case”
– Real = real number (3.4128237E38 ... 3.4128237E-38) “all alphabet
characters upper case”
– Word = integer (0...65535) “first alphabet character upper case, rest lower
case”
– LongReal = large real numbers “first alphabet character upper case, rest lower
case”
– Char = character (e.g. date) “first alphabet character upper case, rest lower
case”
• Description = Description printed onto documents, does not affect functioning.

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Pins 3

• Badge = Additional description for I/O pin, which is output onto document.
• Visible on higher level = Can be linked on higher hierarchical level into other
blocks.
• Public = Enables connection to other block or diagram. All Face plate related pins
are public!
• Activates task = Not available!
• Trend record = Not available!
• Bin/Analog. I/O = I/O pins (I/O connections can be made only to these type of the
pins). I/O pins are signal or Analog. Pin type is word.
• Register I/O = Used with register-connected I/O cards (e.g. PFI).
• Creates/target of interlocking = Motor and valve loop interlocking data used in
input/output pins. Texts for motor, valve and switch loop extensions come via
these definitions.
• Block able to write to its input = Used when necessary in HLL block pins and
sequence time counter pins.
• Pin to be copied in testing = An input pin can be allocated the name of that output
pin whose value is intended to be transferred to the input pin. (Testing function
can be set On/Off in Monitor.)
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Connections 1

• Connection between block pins can be made in 3 different ways.

– By link
– With flags
– With name
• Connection by link can be made between two visible and connectable pins
of the same type within the same block window
– If DM cannot draw link (line) it is automatically changed to connection
with flags. Connected pins are indicated with small yellow flags with
same uppercase letter in them.
• Connection with flags can be made between two visible and connectable
pins of the same type within the same block window
– Connection is shown with yellow flags with the same lowercase letter
next to the connected pins.
• Connection with name can be made between blocks:
– Connection with name can be made within the same block, other block,
a block located at the other module or even department.

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Connections 2

Connection with link:

- REAL (and other types except signal)
- signal
Connection with flag:
- a and a are connected

Connection with link:

- Vector

Connection by name:

Department,block,pin

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HLL

• HLL is needful in cases when application configuration using basic blocks is

complicated or inapplicable.
• HLL is based on Pascal language using its syntax, structure, operators,
statements, functions and procedures etc.
• There are two versions of HLL
– Cyclic
– Event-based
• Cyclic HLL is usually used in applications demanding plenty of
mathematical calculations and data processing.
– Cyclic HLL can be used for creating Type Blocks, which in turn can be
used along with Basic Blocks in application configuration.
• Event-Driven HLL is an extension of Cyclic HLL and usually used for
specific system applications (e.g. communication links to other systems).

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Program Builder

Block Builder’s
Menu Bar ->
Tools/Pascal or
Toolbar -> Pascal

• Program
editor is used
as program
code editor and
compiler.

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Run order

Menu bar ->

Execution/Change/Orde
r

• Execution (run)
order of the blocks
need to be defined
for planned
functioning of the
hierarchical block in
question.

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Block Simulation

Tool bar ->

Simulate
Block
simulator is
used as
preliminary
debugger of
application,
allowing to
simulate
application
functioning in
DM, thus
helping to find
errors, before
loading to
PMD system.
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I/O definitions

• I/O definitions is
a last step in
block
configuration
before loading to
PMD system.
• I/O definitions are
done using
System Builder.
• When I/O
definitions are
done, deptio3.sdf
file is generated.
This file includes
all the I/O
definitions.

Menu bar -> I/O definitions

Definition/Cards and I/Os
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System Builder 1

PMD Explorer ->

Application/Depa
rtment/
System/System_
structure -> Edit

• System builder
is used for
making I/O and
system
definitions, such
as departments,
process and
alarm areas,
modules etc. and
loading them to
PMD system.

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System Builder 2

• All definitions are made in pop-up windows called-up from

appropriate menu Definitions items.
• Every definition pop-up window has tool bar with buttons
for adding and editing the definitions, browsing, searching
printing and saving them to the definitions database and
loading to PMD system.

• When definitions are made

they can be loaded to PMD
system.

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System definitions

• Department – Name of PMD system’s configuration (field controllers, PMD

server, HMI stations etc.) controlling mill department’s processes,
machinery etc.
• Highways – communication networks or lines between modules in PMD
system.
• Modules – units of distributed PMD control system.
• Cards and I/Os – extension cards of modules and I/O definitions of I/O
cards.
• Process areas – subdivisions of PMD system, intended for controlling
processes or machinery of mill department’s sections or other parts
department divided to.
• Alarm areas - subdivisions of PMD system, intended for handling alarms
according to controlled process or machinery part they originated from.
• Local area network interfaces – Ethernet-based department’s IP-network
units’ (PMD Server, Field controllers etc.) communication settings.

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Block Monitoring

Tool bar ->

Monitor

• Block monitor is
a tester and
debugger of the
application loaded
to PMD system’s
Field controller
(FC).
• Block monitor’s
purpose and user
interface is
identical to Block
simulator only
differing in
application
execution
environment.
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Daxmon

PMD Explorer ->

Menu
bar/Execute/Daxmon

• Daxmon is a DM’s
command-prompt
based maintenance
tool for PMD system
condition monitoring
and troubleshooting.
• It allows, for example,
to check FC’s
operating system and
loaded blocks running
condition, FC’s
communication
interfaces condition
and many other things.

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Fieldnet Builder

PMD Explorer ->

Application/Depart
ment/Field_networ
k\Fieldnet_Builder
• Fieldnet Builder
is a field network
configuration and
troubleshooting
tool, which
supports most of
the standard field
buses such as
PROFIBUS and
INTERBUS
• Fieldnet builder
is considered in
more detail in a
separate course.

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HMIWeb Builder

Windows Start ->

Programs/HMIW
eb/HMIWeb
Display Builder

• Display builder
is an operator
interface
displays
configuration
tool.
• Display builder
is considered in
more detail in a
separate course.

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