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EVOLUTION OF DCS
Different stages of evolution of
Control system are :
DISTRIBUTED CONTROL
SYSTEM
DEFINATION :A Control System In Which Different Intelligent
Devices
Control
The
Process
Communication Loop.
And
Integrated
On
Same
ARCHITECTURES OF DCS
The master less deterministic type on single network
(Node Server)
The client server type with master less characteristic
on single network
The client server
NODE SERVER
A network with deterministic master less type of
protocol has a real master less node hierarchy,
which means that all the nodes, i.e., all
controllers as well as operator stations will have
the same priority and shall be always
communicating to the network together. In this
case, the failure of any one operator station, i.e.
any one node will lead to the non operation
of that node only and the rest of the
system stays healthy , thereby maintaining
the healthiness of the network.
Node
1
Node
2
Node
3
Node
4
Bus1
Bus2
All healthy
nodes and all
are at same
hierarchy
Node
5
Node
6
Node
1
Node
2
Node
3
Node
4
Bus1
failure
Node
5
Node
6
Bus2
All healthy
nodes and all
are at same
hierarchy
failure
Bus1
Bus2
Still Healthy
Nodes keep
system
healthy
Server
Client 1
Client 2
Client 3
Bus1
Bus2
Client 4
Client 5
server
Client 1
Client 2
Client 3
Bus1
failure
Client 4
Client 5
Bus2
Server healthy means
all nodes (clients)
communicating to the
server
Server
Client 1
Client 2
Client 3
Failure
Bus1
Bus2
Client 4
Client 5
Client 1
Client 2
Client3
server
Network I /Bus1
Network I /Bus2
Network II /Bus1
Network II /Bus2
Client 4
Client 5
Client 1
Client 2
Client3
server
Network I /Bus1
failure
Network I /Bus2
Client 5
Client 1
Client 2
Client3
Data
lost
server
failure
Data
lost
Client 4
Client 5
No. of nodes
Used for
Three (3)
Three Boilers
One(1)
Common section
One(1)
EWS
Five(5)
OWS
The EWS & OWS are also to Ethernet switch through O- NET cable.
DATA FLOW
LINE-1
LINE-2
O-NET
NODE-9
NODE-8
NODE-7
NODE-6
NODE-10
NODE-5
ITC
ITC
ITC
ITC
ITC
ITC
NIS
NIS
NIS
NIS
NIS
NIS
REDUNDENT C - NET
NIS
NIS
NIS
NIS
NPM
NPM
NPM
NPM
NODE-4
NODE-1
BOILER-1
BOILER-2
NODE
-2
BOILER-3
NODE
-3
COMMON
C-NET
C-NET is a unidirectional, high speed
serial data network that operates at a
10 megahertz communication rate. It
supports a central network with up to
250 system NODE connections.
SYSTEM CARDS
DCS SYSTEM
4-20 mA out of smart Txs., Superimposed with
hart signal, are terminated to HMS. Here, HART
Signal and 4-20 mA signals are separated using
patch cards. 4-20 mA goes to terminate to AI
cards through DCS Marshelling cabinet.
Termination of this 4-20 mA depends on
whether this is field powered or system powered.
MULTIPLEXER SYSTEM
Supplied by MTL,England.
Multiplexers are used for cable saving. Here non
critical signals have been taken through MUX.
There are four MUX stations for each boiler
installed in field itself.
All the twelve MUX stations having redundant
supply . MUX -1 & 2 for each boiler caters
mainly AI whereas MUX-3 & 4 caters mainly
DI/DOS.
MULTIPLEXER SYSTEM
The MUX uses redundant EBIM (Ethernet
bus interface module) processing data at
very high speed of 100 Mbps, whereas the
controller (MFP12) used in DCS system
for third party communication is Modbus
compatible, hence MOXA switches are
used to convert Ethernet to Modbus.
MULTIPLEXER SYSTEM
Hence redundant Ethernet cable have been laid
from each of the MUX to redundant MOXA
switches from MOXA, Ethernet Cable been laid
for HMS/MUX PC where WORKBENCH
Software is loaded for status monitoring of all
MUX modules.
Also RS-485 Cable laid from MUX-1 & 2 having
AIs only to HMS PC, through RS-485 to RS-232
Converter, for catering smart transmitters with
the help of CORNERSTONE Software loaded on
the same HMS/MUX PC.
SER-SEQUENCE OF EVENT
RECORDER
There is one SER of 512 points
comprising of two SER Stations - EL1 &
EL2.
SER Stations
DI Cards
No of events
handling capacity
EL1
288
EL2
224
NIS
C-NET
C-NET
TO
FIELD
FROM
FIELD
NPM
TU
SLAVE
BRC
TU
SLAVE
BRC
Sr.No.
No. of Nodes
Used for
Three(3)
Four(4)
Three(3)
Sequence (SEQ)
Two(2)
Turbine of TG 1 & 2.
One(1)
Common Section
Two(2)
RTDS 1 & 2
One(1)
EWS
Operating
Station
Are
Connected
Through
Operating
Station System
Professional Based.
Is
Windows
2000
SEQ
BMS
TG-1
TG-2
COM
C - NET
RTDS2
RTDS1
EWS
O-NET
HIS P
HIS R
CLIENT
COMPOSER
CPP
Architecture is Node
Server based.
Operating system is
Window XP
Professional based.
All critical loops are
redundant
DCS is PGP based
Architecture is Client
server based.
Operating system is
Windows 2000
professional based.
All critical loops are
not redundant .
DCS is PPB based.
ABB
YOKOGAWA
MODEL
Syphony
Harmony IT
Infi-90
CS 3000
CS 1000
HMI
Architecture
Node Server
option
Client Server
Node Server
Client Server
Operating
System
Window Based
Window Based
Window Based
Window Based
Window Based
Window NT
Window NT or XP
Window NT
Window
NT,XP,2000
Window NT,2000
Using C-Net 10
Mbps
Using C-Net 10
Mbps
Using V-Net 10
Mbps
Using VL-Net 10
Mbps
A) Power
Supply
Yes
Yes
Yes
Yes
Yes
B) System Bus
Yes
Yes
Yes
Yes
Yes
C) Controller
Yes
Yes
Yes
Yes
D) I/O Module
Present in critical
loop
optional with
extra
Present in critical
loop
E) Server
Yes
Yes
Yes
Yes
Yes
F)
Memory(system
)
Yes
Yes
optional with
extra
Yes
Data Bus
Redundancy
ABB
YOKOGAWA
Syphony
Harmony IT
Infi-90
CS 3000
CS 1000
A) System
User Defined
User Defined
User Defined
User Defined
User Defined
B) Controller
68040/25 MHz,
Motorola
VR5432(133MHz)
Proprietary
C) Controller
Memory
Up to 8Mb
16Mb
16Mb
32Mb
Online
Replacement
Yes
Yes
Yes
Yes
Yes
Online
Configuration
Yes
Yes
Yes
Yes
Yes
System Memory
User Defined
User Defined
User Defined
User Defined
User Defined
I/O capacity
Up to 100000 I/O
10
Web Connection
Possible with
isolation
Possible with
isolation
Possible with
isolation
Possible with
isolation
Possible with
isolation
11
Scan time<200ms
Possible
Possible
Possible
Possible
Possible
MODEL
Processor
FOXBORO
HONEYWELL
SIEMENS
MODEL
IA Series
Experience PKS
Teleperm XP
Telemerm ME
HMI
Architecture
Client Server
Node Server
option
Node Server
Client Server
Operating
System
Window Based
Window Based
Window Based
Window Based
DOS Based
Window NT,XP,2000
Window NT,XP,2000
Window NT
STRUK
Using Device-Net 10
Mbps
Using LCN 5
Mbps
UsingCS-272
<10Mbps
A) Power Supply
Yes
Yes
Yes
Yes
Yes
B) System Bus
Yes
Yes
Yes
Yes
Yes
C) Controller
Yes
Yes
optional with
extra
optional with
extra
D) I/O Module
optional with
extra
optional with
extra
E) Server
Yes
Yes
Yes
Yes
F)
Memory(system)
Yes
Yes
Yes
Data Bus
Redundancy
MODEL
FOXBORO
HONEYWELL
SIEMENS
IA Series
Experience PKS
Teleperm XP
Telemerm ME
A) System
User Defined
User Defined
User Defined
User Defined
INTEL PII
B) Controller
N/A
C 200
N/A
Virtual Processor
INTEL
80188(20MHz)
Processor
C) Controller
Memory
4000Kb
156Kb
Online
Replacement
Yes
Yes
Yes
Yes
Yes
Online
Configuration
Yes
Yes
Yes
Yes
Yes
System Memory
User Defined
User Defined
User Defined
User Defined
User Defined
I/O capacity
Up to 100000 I/O
Up to 100000 I/O
10000 tags
10
Web Connection
Possible with
isolation
Possible with
isolation
Possible with
isolation
Possible with
isolation
N/A
11
Scan time<200ms
Possible
Possible
Possible
Possible
Possible