Practical Distributed Control Systems (DCS) for Engineers & Technicians. Contents

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1 Practical Distributed Control Systems (DCS) for Engineers & Technicians Contents Chapter 1 Introduction to Computer Based Control Systems Introduction to computer based measurement and control systems Role of computers in measurement and (process) control Basic components of computer based measurement and control systems Architecture computer based process control system Human Machine Interface (HMI) Hardware for computer based process control system Interfacing computer system with process Economics of computer based system for industrial application 24 Chapter 2 Overview of Distributed Control Systems Introduction Basic concepts of Distributed Computing Evolution of Distributed Computing System Present market trends in DCS Basic DCS specification General description of a commercial DCS Advantage of DCS systems DCS selection criteria DCS architecture 41 Chapter 3 An overview of SCADA systems Introduction Basics of SCADA system SCADA key features Remote terminal units (RTUs) Typical requirements for an RTU system PLCs used as RTUs Consideration and benefits of SCADA system DCS versus SCADA terminology SCADA software package 73

2 Chapter 4 The basic controller Introduction Identification of the controller boards Discrete and logic control Sequential and batch control 80 Chapter 5 Basic DCS controller configuration Historical Control modes Tracking and initialization in control slots used for cascade control Control functions Control algorithms Sequential programs for batch processing Defining equipment procedures Phase logic programming Phase logic interface Logic block functions in advanced controller DCS controller configuration 116 Chapter 6 Introduction to communications for DCS & SCADA systems Purpose Basic communications principles Balanced and unbalanced transmission lines EIA-232 interface standard (CCITT V.24 interface standard) The EIA-485 interface standard Open systems Interoperability ModBus protocol HART protocol The promise of FieldBus and DeviceNet Benefits 149 Chapter 7 Programming of DCS systems Development and growth of programmable controllers (PLC) - an introduction Need for standardization in programming approach Drawbacks in conventional programming methodology Features of IEC language definition Summary of IEC PLC software architecture - software quality attributes IEC software architecture Component parts of IEC software architecture Functions and function blocks 165

3 7.10 Local and global variables Mapping software model to real life systems-examples Applications Summary of PLC architecture Common elements in IEC Elementary data types Generic data type Derived data types Variables Variable initialization Functions Programs Resource Tasks Summary of common elements in IEC Structured text Statements used for assignments Expressions Evaluating an expression Statements Conditional statements Iteration statements Implementation dependence Summary of structured text Function block diagram Basics Methodology Signal flow Feedback path Network layout Function execution control Jumps and labels Network evaluation rules Summary of function block diagram Ladder diagrams Basic concept Graphical symbols used in ladder diagram Boolean expressions using ladder diagrams Integrating functions & function blocks Feedback paths Jumps and labels Network evaluation rules Portability Summary of ladder diagrams Instruction List Structure of IL programming language Calling functions and function blocks Portability and other issues 220

4 7.58 Summary of Instruction List Sequential function chart (SFC) Steps Transitions Actions Action qualifiers Action control function block Execution rules Design safety issues Top down design Summary of sequential function charts 236 Chapter 8 Alarm system management An alarm system Functions of the plant or process operator Functions of an alarm system An effective alarm system Design overview Human and ergonomic factors Structure of a good alarm system Safety integrity level (SIL) Definition of strategy Strategy for alarm system design Strategy for alarm system maintenance and management at the site/plant Generation of minimum design documentation for each alarm Measurement of the alarms Field measurements for deriving alarms Hardware for alarm processing Alarm displays Testing of alarms Generation of various types of alarms Selection of alarm settings Setting alarm priority Design of field sensors for generating alarms Logical processing of alarms Design of alarm list displays Measurement of performance Usefulness of alarms Measurement of number of alarms and average rate of alarms Measuring operator response Management of improvement program Alarm review Elimination of spurious alarms Intermittent and fleeting alarms Processing alarms Control of modifications 314

5 8.34 Hazard and operability studies (HAZOP) Hazard assessment Hazard and operability studies (HAZOP) 318 Chapter 9 Distributed control system reporting Introduction Operation of advanced DCS using multi-screen display 321 cross screen invocation and linking Alarm reporting, generation and acceptance Alarm reporting Generation of alarms Different types of logs and reports configurable on a DCS 329 Chapter 10 Distributed control system (DCS) configuration Introduction An engineering station System/project tree structure DCS system database Configuration of control functions Configuration of operator/monitoring functions Configuration of system hardware structure Configuration of system software Documentation Commissioning 345 Chapter 11 Maintenance consideration Introduction Maintenance requirements of system and system elements Requirements for in-built diagnostic and maintenance routines Requirement for installation of UPS system Recovery of a DCS following power outage 359 Chapter 12 Typical distributed control systems and SCADA systems Introduction Honeywell PlantScape system Foxboro I/A series distributed control systems Delta V system Citect Wonderware 388

6 Chapter 13 Distributed control system applications Introduction Use of DCS in pulp and paper environment Use of DCS in petroleum-refining environment Use of DCS in oil and gas processing environment 423 Chapter 14 Distributed control systems implementation Introduction System strategy Automation plan Project implementation Installation and commissioning Change management 438 Appendix A Fundamentals of control systems 439 Appendix B Integration of the complete FieldBus system 449 Appendix C Adaptive and predictive control 461 Appendix D Central site computer facilities 473 Appendix E Fuzzy logic control 485 Appendix F Stability and control modes of closed loops 489 Appendix G DCS and process control exercises 501 Appendix H Foundation Fieldbus 513 Appendix I Local Area Network Systems 551 Appendix J ProfiBus 583 Appendix K - Glossary 601

TECHNICAL SPECIFICATION

TECHNICAL SPECIFICATION IEC/TS 62443-1-1 Edition 1.0 2009-07 colour inside Industrial communication networks Network and system security Part 1-1: Terminology, concepts and models INTERNATIONAL ELECTROTECHNICAL