Contents

Chapter 1—SCADA systems hardware (and firmware) 1

1.1 Introduction 1
1.2 Comparison of the terms SCADA, DCS, PLC and smart
instrument 3
1.3 Considerations and benefits of SCADA system 9
1.4 Remote terminal units 10
1.5 Digital output module 20
1.6 PLCs used as RTUs 27
1,7 System reliability and availability 32

Chapter 2— SCADA systems software and protocols 35

2.1 Introduction 35
2.2 The components of a SCADA system 35
2.3 The DCS and SCADA software package 38
2.4 New technologies in SCADA systems 43
2.5 The twelve golden rules 44
2.6 OPC 45

Chapter 3— Typical distributed control systems and SCADA systems 51

3.1 Introduction 51
3.2 Honeywell PlantScape system 51
3.3 Foxboro I/A series distributed control systems 62
3.4 Delta V system 70
3.5 Citect 72
3.6 Wonderware 80
3.7 Intellution iFIX v2.5 system 86
3.8 Comparison of vendors 86

Chapter 4— The basic controller 87

4.1 Introduction 87
4.2 Identification of the controller boards 87
4.3 Discrete and logic control 90
4.4 Sequential and batch control 91

Chapter 5— Basic DCS controller configuration 95

5.1 Historical 95
5.2 Control modes 95
5.3 Tracking and initialization in control slots used for
cascade control 95
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5.4 Control functions 99

5.5 Control algorithms 104
5.6 Sequential programs for batch processing 117
5.7 Defining equipment procedures 119
5.8 Phase logic programming 120
5.9 Phase logic interface 123
5.10 Logic block functions in advanced controller 126
5.11 DCS controller configuration 129

Chapter 6— Introduction to communications for DCS & SCADA

systems 131
6.1 Purpose 131
6.2 Basic communications principles 131
6.3 Balanced and unbalanced transmission lines 135
6.4 EIA-232 interface standard (CCITT V.24 interface standard) 137
6.5 The EIA-485 interface standard 145
6.6 Open systems 150
6.7 Interoperability 154
6.8 ModBus protocol 154
6.9 HART protocol 159
6.10 The promise of FieldBus and DeviceNet 163
6.11 Benefits 164

Chapter 7— Local area network systems 169

7.1 Introduction 169
7.2 Network topologies 170
7.3 Bus topology 170
7.4 Star topology 171
7.5 Ring topology 172
7.6 Media access methods 173
7.7 IEEE 802.3 Ethernet 174
7.8 MAC frame format 181
7.9 High speed Ethernet system 182
7.10 100BaseT (100BaseTX, T4, FX, T2) 183
7.11 Fast Ethernet design considerations 186
7.12 Gigabit Ethernet 1000BaseT 187
7.13 Network interconnection components 191
7.14 TCP/IP protocols 196
7.15 SCADA and the Internet 200
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Chapter 8— ProfiBus 205

8.1 Introduction 205
8.2 Architecture of the ProfiBus protocol 207
8.3 Application larger service specification 210
8.4 ProfiBus communication model 212
8.5 Relationship between application process and communication 212
8.6 Communication objects 213
8.7 FieldBus message specification 214
8.8 Network management 218
8.9 Fault management 218
8.10 Configuration management 218
8.11 ProfiBus FMS profiles 218
8.12 Performance 219
8.13 Diagnostics 220
8.14 System configuration 220

Chapter 9—Foundation FieldBus 225

9.1 Introduction 225
9.2 Overview 225
9.3 Physical layer 227
9.4 Data link layer 237
9.5 Application layer 239
9.6 User layer block 243
9.7 System management 259
9.8 Device description 260
9.9 Application example 261

Chapter 10— Programming of DCS systems 263

10.1 Development and growth of programmable controllers (PLC) - an
introduction 263
10.2 Need for standardization in programming approach 264
10.3 Drawbacks in conventional programming methodology 265
10.4 Features of IEC-1131-3 language definition 271
10.5 Summary of IEC-1131-3 272
10.6 PLC software architecture - software quality attributes 272
10.7 IEC software architecture 273
10.8 Component parts of IEC software architecture 274
10.9 Functions and function blocks 275
10.10 Local and global variables 277
10.11 Mapping software model to real life systems-Examples 278
10.12 Applications 280
10.13 Summary of PLC architecture 283
10.14 Common elements in IEC-1131-3 283
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10.15 Elementary data types 284

10.16 Generic data type 288
10.17 Derived data types 289
10.18 Variables 291
10.19 Variable initialization 294
10.20 Functions 295
10.21 Programs 300
10.22 Resource 301
10.23 Tasks 301
10.24 Summary of common elements in IEC-1131-3 303
10.25 Structured text 304
10.26 Statements used for assignments 304
10.27 Expressions 305
10.28 Evaluating an expression 305
10.29 Statements 306
10.30 Conditional statements 307
10.31 Iteration statements 309
10.32 Implementation dependence 311
10.33 Summary of structured text 311
10.34 Function block diagram 311
10.35 Basics 311
10.36 Methodology 312
10.37 Signal flow 313
10.38 Feedback path 314
10.39 Network layout 315
10.40 Function execution control 315
10.41 Jumps and labels 316
10.42 Network evaluation rules 316
10.43 Summary of function block diagram 317
10.44 Ladder diagrams 317
10.45 Basic concept 317
10.46 Graphical symbols used in ladder diagram 318
10.47 Boolean expressions using ladder diagrams 321
10.48 Integrating functions & function blocks…. 322
10.49 Feedback paths 323
10.50 Jumps and labels 323
10.51 Network evaluation rules 324
10.52 Portability 324
10.53 Summary of ladder diagrams 325
10.54 Instruction List 326
10.55 Structure of IL programming language 326
10.56 Calling functions and function blocks 330
10.57 Portability and other issues 332
10.58 Summary of Instruction List 333
10.59 Sequential function chart (SFC) 334
10.60 Steps 338
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10.61 Transitions 339

10.62 Actions 341
10.63 Action qualifiers 343
10.64 Action control function block 347
10.65 Execution rules 347
10.66 Design safety issues 347
10.67 Top down design 349
10.68 Summary of sequential function charts 349

Chapter 11— Alarm system management 351

11.1 An alarm system 351
11.2 Functions of the plant or process operator 352
11.3 Functions of an alarm system 355
11.4 An effective alarm system 355
11.5 Design overview 358
11.6 Human and ergonomic factors 359
11.7 Structure of a good alarm system 361
11.8 Safety integrity level (SIL) 370
11.9 Definition of strategy 371
11.10 Strategy for alarm system design 371
11.11 Strategy for alarm system maintenance and management at the
site/plant 372
11.12 Generation of minimum design documentation for each alarm 372
11.13 Measurement of the alarms 376
11.14 Field measurements for deriving alarms 377
11.15 Hardware for alarm processing 377
11.16 Alarm displays 378
11.17 Testing of alarms 380
11.18 Generation of various types of alarms 380
11.19 Selection of alarm settings 387
11.20 Setting alarm priority 389
11.21 Design of field sensors for generating alarms 395
11.22 Logical processing of alarms 400
11.23 Design of alarm list displays 406
11.24 Measurement of performance 411
11.25 Usefulness of alarms 414
11.26 Measurement of number of alarms and average rate of alarms 417
11.27 Measuring operator response 423
11.28 Management of improvement program 424
11.29 Alarm review 425
11.30 Elimination of spurious alarms 426
11.31 Intermittent and fleeting alarms 426
11.32 Processing alarms 427
11.33 Control of modifications 433
11.34 Hazard and operability studies (HAZOP) 433
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11.35 Hazard assessment 434

11.36 Hazard and operability studies (HAZOP) 436

Chapter 12—Distributed control system reporting 439

12.1 Introduction 439
12.2 Operation of advanced DCS using multi-screen displays,
cross screen invocation and linking 439
12.3 Alarm reporting, generation and acceptance 445
12.4 Alarm reporting 446
12.5 Generation of alarms 449
12.6 Different types of logs and reports configurable on a DCS 450

Chapter 13—Distributed control system (DCS) configuration 459

13.1 Introduction 459
13.2 An engineering station 459
13.3 System/project tree structure 460
13.4 DCS system database 461
13.5 Configuration of control functions 462
13.6 Configuration of operator/monitoring functions 465
13.7 Configuration of system hardware structure 466
13.8 Configuration of system software 466
13.9 Documentation 468
13.10 Commissioning 468

Chapter 14—Maintenance consideration 471

14.1 Introduction 471
14.2 Maintenance requirements of system and system elements 471
14.3 Requirements for in-built diagnostic and maintenance routines 478
14.4 Requirement for installation of UPS system 485
14.5 Recovery of a DCS following power outage 486

Chapter 15—Distributed control system applications 487

15.1 Introduction 487
15.2 Use of DCS in pulp and paper environment 487
15.3 Use of DCS in petroleum-refining environment 507
15.4 Use of DCS in oil and gas processing environment 521
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Chapter 16—Distributed control systems implementation 523

16.1 Introduction 523
16.2 System strategy 523
16.3 Automation plan 524
16.4 Project implementation 532
16.5 Installation and commissioning 535
16.6 Change management 538

Chapter 17—The future of distributed control systems 539

17.1 Introduction 539
17.2 Creation of E-commerce solution 541

Appendix A—Fundamentals of control systems 457

Appendix B—Integration of the complete FieldBus system 469
Appendix C—Adaptive and predictive control 483
Appendix D—Central site computer facilities 497
Appendix E—Fuzzy logic control 511
Appendix F—Stability and control modes of closed loop 515
Appendix G—DCS and process control exercises 529
Glossary 541