DISTRIBUTED CONTROL SYSTEM
In process control technologies we have had numerous
advancements over the years. The following shows the modifications
that have taken place in chronological order:
Analog Control Systems
These systems used operational amplifiers for their control
operations.
Digital Control Systems
These systems use microprocessors and micro controllers for
their monitoring and control operations. They can be further
classified into:
Centralized Control System (CCS)
This method employs the idea of centralized
monitoring and centralized control.
In other words, there is only one processor which
performs both monitoring and controlling
operations of the plant.
Distributed Control Systems (DCS)
This method employs the idea of centralized
monitoring but distributed control.
In other words, different units of the plant are
controlled by different processors even though the
whole plant is monitored by one single master
station.
BASIC STRUCURE OF A CENTRALISED CONTROL SYSTEM (CCS)
INPUT SIGNALS FROM FIELD OUTPUT SIGNALS TO FIELD
SET VALUES
CENTRAL PROCESSING
UNIT
BASIC DCS LOOP
COMMUNICATION BUS
OUTPUTS TO FIELD
SET VALUES
OUTPUTS TO FIELD
SET VALUES
OUTPUTS TO FIELD
SET VALUES
INPUTS FROM FIELD
OPS1
FCS2
FCS3
FCS1
OPS2
BASIC COMPONENTS OF DCS
The basic components of a DCS are listed below:
Field Control Station/ Central Processing Unit
Human Interface Station
Operating Console Station
Engineering Station
Communication Bus
Field Control Station
This unit all the controlling and monitoring operations of the
plant.
All the instruments and interlocks created by software reside
in the memory of the FCS.
All the field instruments (inclusive of the Final Control
Elements) like transmitters and control valves are wired to the
FCS.
Operating Console Station
This is a part of the Human Interface System (HIS).
It is meant solely for monitoring and operating purposes.
A continuous real time picture of the plant including the
process variables and high resolution graphics appear on the
screen of the OPS.
Any changes in values of process variables, detection of faults
by alarms are enabled in the OPS.
Engineering Station
The Engineering Station constitutes the most important part
of the HIS.
It features the engineering software (Standard Builder
Function) which enables the system to perform the plant
generation and maintenance operations.
Creation of new control loops, modification of existing loops,
and introduction of new alarms, instruments, and graphics
are possible in this unit only, not in the OPS.
It has all the features of a general OPS as described earlier.
This station differs from the general OPS because it is
endowed with the extra packages for setup and cancellation
of FCS and HIS wherever necessary.
Communication Bus
These are used as a medium to facilitate communication
between the various plant units and their respective control
stations as well with the other control stations and sub
stations.
CENTUM CS-3000
Yokogawa was the worlds first organization to develop a real
time operating DCS. Its subsequent modifications in chronological
order are as follows:
CENTUM/ CENTUM V (first DCS ever)
CENTUM-XL
CENTUM CS
CENTUM CS 3000 R3
CENTUM VP
We shall limit our discussion to the CENTUM CS 3000 R3
version only.
SYSTEM SPECIFICATIONS
Maximum number of stations per domain: 64
Maximum number of HIS per domain: 16
Maximum number of FCS per domain: 48
Station number for HIS: 49, 50, 51,., 62, 63, 64
Station number for FCS: 1, 2, 3, 4, 5,,, 46, 47, 48
Maximum number of domains per system: 16
Numbering of Domains: 1, 2, 3,, 62, 63, 64
Maximum number of stations per system: 256
HIS SPECIFICATIONS
Maximum number of tags that can be monitored from
HIS : 100,000 (expansible up to 1,000,000 tags)
Maximum number of windows that can be created per
HIS : 4000
Maximum number of Trend Recording Points per HIS :
3328.
Engineering Station is used to do the engineering
builder for all the stations like HIS, FCS, CGW, BCV
etc.
ENG station is a PC loaded with engineering software
(Standard builder function).
It is mainly used to perform CS3000 system generation
and Maintenance Management.
The HIS can be loaded with engineering software, so
that it can be used as HIS as well as engineering
station.
Basic O/S Software: WINDOWS NT with Service Pack
6A / WINDOWS 2000 with Service Pack 4A/WINDOWS
XP with Service Pack 2.
Software: CS3000 R3 Packages with necessary
software licenses.
CS-3000 COMMUNICATION NETWORKS
V-Net Communication Network
This network is used solely for the purpose of data
communication.
They employ BUS TOPOLOGY.
Transmission Speed: 10Mbps.
Transmission Distance: 500m to 20Kms.
Medium of Transmission: Coaxial cable (V-Net, VL-
Net)/Optical Fiber.
Bus Coupler:
V-Net Cables are compatible to the FCS, while the VL-Net
Cables are compatible to the HIS.
V-Net Cables are suited for communication between an FCS
and an HIS.
VL-Net Cables are suited for communication between two
FCS.
A device called BUS COUPLER is used in order to facilitate
communication in the system between the HIS and FCS.
An adjoined diagram shows the schematic of such a
network.
It basically performs level conversion of a data signal
outgoing from the data bus/ control bus.
A T connector is used wherever there is 1 FCS linked to
more than 1HIS.
A 50 ohm resistance is used as a terminator wherever
there is only one HIS connected to an FCS.
THE BASIC V-NET SYSTEM
COMMUNICATION BUS (ETHERNET CABLES)
BUS 1 BUS COUPLERS
BUS 2
HIS
1
HIS
2
HIS
3
HIS
4
FCS
1
FCS
2
FCS
3
FCS
4
V-Net/IP or Ethernet Communication Network
This network is employed for the purpose of data sharing
between a number of general purpose computers, printouts,
etc.
It is enabled by a Local Area Network (LAN).
It employs a STAR/ TREE topology.
Transmission Speed: 1Gbps (Hardware), 100Mbps (general
communication)
Medium of Communication: CAT5E, CAT6E, Fiber Optic
Cables.
Layer 2 Switch
It is a device that facilitates communication between the
FCS and HIS in a V-Net/IP domain.
The maximum number of L-2 switches that can be
connected in a domain is 7.
The max. allowable distance between an L-2 switch and a
station is 100m.
The maximum allowable distance between two L-2 switches
is 5km (when optical fibers are used).
THE BASIC VNET/IP SYSTEM
BUS 1
BUS 2 BUS 2
BUS1
FCS
1
HIS
2
HIS
1
LAY 2
SWITCH
2
FCS
2
LAY 2
SWITCH
1
The Domain Concept
A group of certain number of Field Control Stations (FCS)
and Human Interface Stations (HIS) connected together is
called a domain.
A maximum number of 64 stations can be connected per
domain.
Out of these 64, there will be a maximum of 48 FCS and 16
HIS.
Multiple Domains are used wherever:
There are more than 64 stations to be connected.
When there are multiple sections in the plant.
To reduce the load on the system.
Layer 3 Switch
It is a device used to connect two domains in a V-Net/IP
system.
It incorporates in itself all the features of an L-2 Switch too.
Bus Converter (BCV)
It is a device that links the domain of one system to the
domain of another system.
For example, it can connect the V net system bus of one
system to another CENTUM CS 3000 domain or to an
existing CENTUM or XL (micro XL) system.
Different types of Bus Convertors are:
V net to V net Bus Convertor: this is used to
connect CS3000 or Centum CS to CS3000 system.
HF Bus to V net Convertor: this is used to connect
Centum V or Centum-XL toCS3000 system or Centum
CS to CS3000 system.
RL Bus to V net Convertor: This is used to connect
Micro-XL to CS3000 system.
Communication Gateway Network (CGW)
This feature links the V-Net communication bus to the
Ethernet bus.
CGW wide area communication function is used to link two
CENTUM CS 3000 V nets in different places using a
dedicated telephone line.
Software Installation
Available Accessories:
1 Centum CS3000 software CD.
1 Floppy Disk for the key code/ license
1 key code is valid for 1 and only 1 HIS.
It is an alphanumeric code.
The network will reject the key code if it is used in more
than 1 HIS.
1 Instruction Manual CD
Installation of CS-3000 in VNet technology
Insert the installation disc into the CD slot.
Insert the floppy disc into the floppy disk drive.
A folder named COMDRV will appear on the disc along
with many other supporting system files.
We select the COMDRV SETUP file and install it.
We restart the system now.
The Network Adapter file is now installed.
We copy the license code from the floppy disc and paste it in
the field where it is asked for.
However while pasting the key code onto the required field
the floppy disk should be inside the system drive, otherwise
the installation procedure will be aborted.
The processor card VF701 (dip switch set) is kept
connected to the HIS in the PCI (processor card interface)
slot.
Enter the IP addresses in the Network Adapter field.
Change the computer name.
Restart the system.
Remove the firewall (includes the control panel and
windows firewall).
PING HIS and FCS.
Software settings are required only for the HIS before
installation.
The FCS will automatically download it from the HIS.
The system is restarted once again and now ready for use.
The installation CD and the floppy disk can now be safely
removed.
For reinstallation we have to select the COMDRIVE
UNINSTALL file.
The system is then restarted and the above procedure is
repeated.
The general internet connectivity is provided by a separate
bus and supported by a Local Area Network (LAN).
Installation of CS-3000 in VNet-IP
technology
Insert the installation disc into the CD slot.
Insert the floppy disc into the floppy disk drive.
Two folders named COMDRV and COMDRV OPN will
appear on the disc along with many other supporting
system files.
We select the COMDRV SETUP file first and install it.
We restart the system now.
The Network Adapter file is now installed.
We copy the license code from the floppy disc and paste it in
the field where it is asked for.
However while pasting the key code onto the required field
the floppy disk should be inside the system drive, otherwise
the installation procedure will be aborted.
The processor card VF701 (dip switch set) is kept
connected to the HIS in the PCI (processor card interface)
slot.
Enter the IP addresses in the Network Adapter field.
Change the computer name.
Restart the system.
Remove the firewall (includes the control panel and
windows firewall).
PING HIS and FCS.
Software settings are required only for the HIS before
installation.
The FCS will automatically download it from the HIS.
We now select the COMDRV OPN SETUP file and install
it.
This extra file is required as the data communication as well
as the general internet communication (given by LAN) is
both supported by the same kind of buses.
We restart the system now.
The system is restarted once again and now ready for use.
The installation CD and the floppy disk can now be safely
removed.
For reinstallation we have to select the COMDRIVE
UNINSTALL and COMDRV UNINSTALL files.
The system is then restarted and the above procedure is
repeated.
POWER SUPPLY
The power supply delivered to an FCS is generally a 110V
AC, 220V AC or 24V DC system.
The system is parallel and redundant.
When the active source is in operation, another similar power
source runs parallel in standby mode.
Online Power Supply Replacement
Ensure that at least one switch is working properly.
Turn OFF the replaceable power supply switch.
Replace the switch.
Turn ON the system again.
DIP SWITCHES
These are certain adjustable miniature switches used for
setting the domain and station addresses of an FCS/HIS.
The Dip Switches are located on the Central Processing
(CP) Card of the FCS.
Station addressing is discussed later in the report.
CENTRAL PROCESSORS
In any DCS, the central processors exist in the form of
redundant numbers so that failure of one processor doesnt
cause the whole network to trip.
To prevent tripping, we generally employ the concept of either
Active Standby or Pair and Spare.
In the active standby mode, both the processors will be
active however only one of them shall be performing
controlling and monitoring actions, while the other will be
ready to take over whenever necessary.
Basic Scan Period:
It is a fundamental property for any processor card and
is therefore an important criterion for measurement of
FCS performance.
It has a maximum value of 1 second (slow but thorough
scan).
It can however be adjusted to 500ms (Medium Scan) and
200ms (Quick Scan).
Idle Time:
It is the time given to a processor for free diagnosis after
completion of scan time.
It is done so as to ensure that the system doesnt suffer
from loading errors, caused by low scan time.
Percentage Load on Processor:
It is given by % Load= [{60-idle time}/60]*100
Online Processor Replacement
Choose which processor to replace
Ensure the presence of an anti static strip.
Dip switches should be correctly set.
If the Standby Card is replaced:
Stop and remove the current standby processor card.
The active card is not disturbed.
Replace the standby PCI slot with a new card.
If the Active Card is replaced:
Check if the Standby Card is working properly.
Stop and remove the Current Active Processor Card.
The Standby Card is not disturbed.
Replace the Active PCI slot with a new card.
STATION ADDRESSING
The figure adjoined in the next page, gives a brief description
on the addressing of a station (valid for both FCS and HIS). The
standard procedure is as follows:
Two dip switches are selected.
One dip switch is for domain addressing
The other dip switch is for station addressing.
There are a number of ports on the Dip Switch which have to
be turned either ON/ OFF depending on the address to be
allocated to that respective station.
The number of switches turned ON should always be of
ODD PARITY.
If in any case the number of ON switches is even, we turn ON
the MSB to make the resultant number of ON switches as
odd.
The general prescribed format for denoting an FCS or HIS is
FCS/DD/SS or HIS/DD/SS respectively.
Here, DD denotes domain number.
Here, SS denotes station number.
ADDRESS ASSIGNMENT TO A
FCS or HIS
OFF ON OFF ON
22 2
7
2
7
2
6
2
6
2
5
2
5
2
4
2
4
2
3
2
3
2
2
2
2
2
1
2
1
2
0
2
0
FOR DOMAIN-03 FOR STATION-03
(DIP SWITCH) (DIP SWITCH)
MSB 1
1
1
1
1
1
1
1
MSB 1
1
1
1
1
1
1
1
NETWORK ADDRESSING
For addressing a V-Net network:
Card used: VF701.
Driver software used: V-Net N/T adapter (for both data
buses)
IP address: 172.16:DD:SS
Subnet Mask: 255.255.0.0
For addressing an V-Net/IP network:
Card used: VI701
Driver software used:
V-Net N/T adapter: Data Bus (Bus 1)
V-OPN adapter: Bus 2 (for General LAN/ Internet
connectivity with V-Net/IP).
For addressing general LAN/ Internet connectivity only:
IP address: 192.168: (128+DD): (128+DD+SS)
Subnet Mask: 255.255.255.0
Creation of Project
The following is a standard procedure to create a project:
From the Start menu, we go to system view window.
Create a Default Project.
Creation of a default project includes the following:
Project name
Project information
Miscellaneous details
Create a new FCS and a new HIS.
This is required as any project will consist of at least 1
FCS and 1 HIS.
Duplicate Next Card Tab
When a new FCS is created, it is necessary to
assign it the address of FCS:01:01
By default, the redundant FCS is then
automatically generated with address
FCS:01:02
Similar is the case when a new HIS is created.
It is observed for both an FCS as well as HIS
that the initial slot is always an odd
number while the redundant slot is always
an even number.
Create Nodes using IOM (Input Output Modules) to
enable conversion and transmission of signals from field
to control stations and vice versa.
The IOM is a function that enables the creation of
nodes.
A maximum of four nodes can be created by an IOM
in an FCS.
The first node must always be a local node, while
the other three may be local as well as remote
nodes.
Local Node
A node that resides in the memory of the
FCS itself is called a local node.
This first node will always reside adjacent
to the power supply port in processor
card.
Remote Node
These nodes are located in the plant
cabinets and are composed of an
interface of ER BUS Interface and I/O
modules.
Next we design the individual I/O modules after taking
the various input and output processes under
consideration.
This is done using the IOM BUILDER DEFINITION
function.
Input and Output channels are configured for their
respective roles by programming the FCS using this
user defined function.
Project Attribution:
There are 3 kinds of projects as defined by
CENTUM CS 3000. They are:
Default Project (created when a system is run
for the first time)
Current Project
o When a default project is downloaded
onto an offline FCS it is called a current
project.
o Online/ Real-time monitoring of
functions and operations is possible onto
that project then.
User Defined Project: A project copied from
either a default or current project is called an
user defined project.
According to the previous definitions, we will
attribute our project to one of these (as the case
may be).
Downloading to FCS
This option transfers the FCS execution data from
the HIS to FCS.
The execution data is a database containing the
application logic to be copied onto the processor
card of the FCS.
There are 3 modes of downloading:
Offline Download: This function downloads a
database generated by the application logic
developed in the HIS for the first time.
Online Download: This function downloads
only those application logics created in the HIS
that were updated previously.
IOM Download: This function downloads only
those application logics that are active as new
I/O modules (at present) having been
previously replaced.
After designing the logic, we update it and then
we save the Control Diagram.
This will initiate the downloading of data and
information into the FCS.
Now, the project is created and is ready to be worked on.
The various Control Loops required to meet the demands
of the process plant can now be created which is
discussed in the next section.
Creation of Closed Control Loops
This feature is enabled only in the Engineering Station
of a system.
A number of functional and user defined blocks are
available for creation of simple and complex/ multiple
process control loops.
Let us use the PIO (Process Input/ Output block).
We use a PID (Proportional Integral Derivative) block as a
controller.
Each block in the control drawing shall have to be
endowed with the necessary operating instructions which
are given in the form of certain codes known as syntax.
We are also required to fill up the Tag numbers of the
respective control blocks and they must match the
information filled in the syntax.
In the Control drawing we make the necessary wiring
connections and fill up the required information fields.
The Control drawing is now saved, after updating the
individual block details.
Upon applying an input to the PID controller we will now
get the visual display of an output change on a graphical
icon called the faceplate.
We can assign as well as remove alarms wherever
necessary.
We can further perform logic operations like AND, NAND,
NOR, NOT, OR, X-OR, etc wherever necessary using
Logic Operation Blocks.
A special feature inside the logic blocks enables us to
create time shifted responses.
The process controlling mode can also be programmed to
change.
The loop is now ready to receive inputs and give us the
desired outputs.
