INDUSTRIAL INSTRUMETATION AND
CONTROL SYSTEMS
Lecture 1. Overview
Assoc. Prof. Dr. BUI Dang Thanh
School of Electronic & Electrical Engineering,
Hanoi University of Science and Technology
1 Dai Co Viet road, Hà Nôi, Viêt Nam
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LECTURER INFORMATION
Assoc. Prof., Dr. BUI Dang Thanh
Lecturer at SEEE, Vice-director of ICEA
• Address: Room 305, Hi-tech Building, Hanoi University of Science of
Technology
• Phone: 024 3868 3518
• Email: [email protected]
• Education: PhD, ENS Cachan, France - Field: Automation
• Research Directions:
• Wireless Smart Device
• Industrial Instrumentation and Control Systems (PLC, SCADA, DCS)
• Envirronment Monitoring Systems
• IoT/AI Application for Smart Agriculture
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Contents
Chapter 1: Overview
Chapter 2: Structure and main component in IICS
Chapter 3 Industrial Instrumentation and Actuators
Chapter 4: Industrial control devices
Chapter 5: Technical Basis of communication in IICS
Chapter 6: Network components
Chapter 7: Industrial Protocols
Chapter 8: Typical industrial instrumentation and control
systems
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References
1. Hoang Minh Son, “Industrial Communication Network”, Science and
Technique Publisher, 2009
2. William C. Dunn, Fundamentals of Industrial Instrumentation and
Process Control, McGraw-Hill, 2005
3. Gregory K. McMillan, Douglas M. Considine, Process/ Industrial
Instruments and Controls, 5th Edition. McGraw-Hill, 1999.
4. K Padma Raju, Y J. Reddy, Instrumentation and Control Systems,
McGraw Hill Education P L, 2016
5. William C. Dunn, Fundamentals of Industrial Instrumentation and
ProcessControl, McGraw-Hill, 2005
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Presentation Outline
• Historical Overview of Industrial Instrumentation and Control
System (IICS)
• Plant hierarchy of IICS
• Fieldbus
• Future of Industrial Automation
• Examples
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Historical Overview of IICS
• At the beginning of 1960, a digital computer was for the
first time applied as a digital computer
• 1960s, digital communication network for automation
system
• 1970s SCADA
• 1980s DCS
• 2000s IIT, IoT
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Plant hierarchy of IICS
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Fieldbus
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What is a Fieldbus?
❑A Fieldbus is an industrial computer network for real-time
distributed control.
❑A complex automated industrial system usually needs an
organized hierarchy of controller systems to function.
❑Human Machine Interface (HMI) at the top, Programmable
Logic Controllers (PLCs) in the middle, and the Fieldbus at
the bottom.
❑The Fieldbus links the PLCs to the components which
actually do the work such as sensors, actuators, (electric
motors, console lights, switches, valves, and contactors).
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What is a Fieldbus?
❑Fieldbus is a generic term that describes a new digital
communications network that is being used in industry to replace
the existing 4-20 mA analog signal standard.
❑The network is a digital, bi-directional, multi-drop, serial-bus
communication network used to link isolated field devices, such as
controllers, transducers, actuators and sensors.
❑Bi-directional means it is a duplex port; the data can be
transmitted in two directions at the same time.
❑Multi-drop is also referred to as multi-access and it can be
interpreted as a single bus with many nodes connected to it.
❑Serial-bus means the data is transmitted serially according to
RS232 or RS485 standards. Profibus uses RS485.
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What is a Fieldbus?
❑Fieldbus works on network structures such as daisy-chain, star, ring,
branch, and tree network topologies.
❑Previously computers were connected using RS-232 by which only two
devices could communicate.
❑This is the equivalent of the currently used 4-20 mA communication
scheme which requires that each device has its own communication
point at the controller level
❑The fieldbus is the equivalent of the current LAN-type connections,
which require only one communication at the controller level and allow
multiple (100's) of analog and digital points to be connected at the same
time.
❑This reduces both the length of the cable required and the number of
cables required.
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Where are Fieldbuses Used?
➢In complex automated industrial
systems where an organized
hierarchy of controller systems is
needed.
➢In manufacturing plants where
many instruments need to be
connected.
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What are Fieldbuses Used For?
❑When fieldbuses work in the factory, the purpose has been to reduce
installation cost by moving the I/O interface from the programmable
logic controller (PLC) to a remote I/O unit mounted close to the machine
on the factory floor.
❑Factory automation fieldbuses are fast and deterministic. (Deterministic
means the maximum worst-case time to obtain data across the fieldbus
is accurately predictable and is not subject to chance.)
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Advantages of Fieldbus
❑A major advantage of fieldbus is the capital expenditure (CAPEX) savings
associated with cable elimination; multiple devices share wire-pairs in
order to communicate over the bus network and savings are also
available through speedier commissioning.
❑On going maintenance and process control system performance are
significantly enhanced through fieldbus systems, which results in
operations expense savings (OPEX).
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Disadvantages of Fieldbus
❖Disadvantages of fieldbus compared to the 4-20 mA analog signal
standard:
➢Fieldbus systems are complex, so more training needed
➢The price of fieldbus components is higher
➢Fieldbus test devices are more complex
➢Device manufacturers have to offer different versions of devices due
to different fieldbus standards. This can add to the cost of the
devices and increases the difficultly of device selection.
➢Standards may predominate or become obsolete, increasing the
investment risk.
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Location of the field bus in the plant hierarchy
File
Edit
SCADA level Operator 23 12 Engineering
4 2 2
33
Plant bus
Programmable
Plant Level Logic Controller
Field bus
Field level
Sensor/
Actor
Bus
Sensor / direct I/O
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Expectations
✓ Reduce cabling
✓ Increased modularity of plant (each object comes with its
computer)
✓ Easy fault location and maintenance
✓ Simplify commissioning (mise en service, IBS =
Inbetriebssetzung)*
✓ Simplify extension and retrofit
✓ Large number of off-the-shelf standard products to build “Lego”-
control systems
✓ Possibility to sell one’s own developments (if based on a
standard)
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The original idea: save wiring
marshalling tray
I/O bar capacity dumb devices
PLC
(Rangierung,
tableau de brassage (armoire de triage)
COM
PLC
field bus
but: the number of end-points remains the same !
energy must be supplied to smart devices
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Marshalling (Rangierschiene, Barre de rangement)
❑ The marshalling is the interface
between the PLC people and the
instrumentation people.
❑ The fieldbus replaces the
marshalling bar or rather moves it
piecewise to the process
(intelligent concentrator / wiring)
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Distributed peripherals
✓ Many field busses are just
extensions of the PLC’s Inputs
and Outputs, field devices are
data concentrators.
✓ Devices are only visible to the
PLC that controls them
relays and fuses
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Field busses classes
Office
network
TCP IP
Ethernet
Plant Network
Ethernet, ControlNet
Fieldbus
intelligent field devices
FF, PROFIBUS PA, LON
Sensor Busses
simple switches etc.
CAN, DeviceNet, SDS, ASI-bus, Interbus-S
The field bus depends on:
• its function in the hierarchy
• the distance it should cover
• the data density it should gather
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Geographical extension of industrial plants
1 km .. 1000 km Transmission & Distribution
Control and supervision of large distribution networks:
• water - gas - oil - electricity - ...
1 km .. 5 km Power Generation
Out of primary energy sources:
• waterfalls - coal - gas - oil - nuclear - solar - ...
50 m .. 3 km Industrial Plants
Manufacturing and transformation plants:
• cement works - steel works - food silos - printing - paper
pulp processing - glass plants - harbors - ...
500m .. 2 km Building Automation
• energy - air conditioning - fire - intrusion - repair - ...
1 m .. 1 km Manufacturing
flexible manufacturing cells - robots
1 m .. 800 m Vehicles
• locomotives - trains - streetcars - trolley buses - vans -
buses - cars - airplanes - spacecraft - ...
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Future of Industrial Automation
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• HMI technology in process control
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• Basic architecture of the integrated SCADA-HMI systems
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• Gradually replacement of the classical automation pyramid
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• General topology of a communications network
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• Fieldbusand data flow in Industrial control systems
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Examples
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Fieldbus over a wide area: example wastewater
treatment
✓ Pumps, gates, valves, motors, water level sensors, flow meters,
temperature sensors, gas meters (CH4), generators, … are spread
over an area of several km2
✓ Some parts of the plant have explosive atmosphere.
✓ Wiring is traditionally 4..20 mA, resulting in long threads of cable
(several 100 km).
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Fieldbus over a wide area: Water treatment plant
Japan source: Kaneka, Japan
Control Room
LAS
Malaysia
Remote SCADA Ethernet
Maintenance
System Bus Monitor
H1 Speed Fieldbus
JB Segm ent 1 Segm ent 3 JB Sub Station
AO
AI
PID
PLC
AO
PID
AI AI AI AI AI AI AI AI PID AO
AO AO
DI M.C.C.
FB Protocol
Converter
JB Segm ent 2 JB Segm ent 4 Digital Input/Output
AI AI
S S S S S
AI AI AI PID AI PID AI AI AI AI
AO AO
Numerous analog inputs (AI),
low speed (37 kbit/s) segments merged to 1 Mbit/s links.
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Fieldbus application: Building Automation
Source: Echelon
low cost, low data rate (78 kbit/s), may use power lines (10 kbit/s)
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Fieldbus Application: locomotives and drives
radio power line
cockpit
diagnosis Train Bus
Vehicle Bus
brakes power electronics motors track signals
data rate 1.5 Mbit/second
delay 1 ms (16 ms for skip/slip control)
medium twisted wire pair, optical fibers (EM disturbances)
number of stations up to 255 programmable stations, 4096 simple I/O
integrity very high (signaling tasks)
cost engineering costs dominate
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Fieldbus Application: locomotives and drives
radio power line
cockpit
diagnosis Train Bus
Vehicle Bus
brakes power electronics motors track signals
data rate 1.5 Mbit/second
delay 1 ms (16 ms for skip/slip control)
medium twisted wire pair, optical fibers (EM disturbances)
number of stations up to 255 programmable stations, 4096 simple I/O
integrity very high (signaling tasks)
cost engineering costs dominate
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Fieldbus Application: automobile
- 8 nodes
- 4 electromechanical wheel brakes
- 2 redundant Vehicle Control Unit
- Pedal simulator
- Fault-tolerant 2-voltage on-board power supply
- Diagnostic System
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Application: Avionics (Airbus 380)
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Networking busses: Electricity Network Control:
myriads of protocols
Inter-Control Center Protocol
SCADA
control IEC 870-6 control ICCP control High
HV Voltage
center center center
Modicom IEC 870-5 DNP 3.0 Conitel RP 570 serial links (telephone)
RTU RTU RTU RTU Remote Terminal Units
COM RTU
substation substation
MV Medium
Voltage
FSK, radio, DLC, cable, fiber,... RTU
RTU
houses RTU RTU
Low
LV Voltage
low speed, long distance communication, may use power lines or telephone modems.
Problem: diversity of protocols, data format, semantics...
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Thank you for your attention!
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