CL8A1C8 ln1L8lACLS

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8equlre well englneered human lnLerface
sysLem for error free lnLeracLlon
Instrumentat|on and contro| eng|neers
seLLlng up and malnLalnlng conLrol sysLem
9|ant operator monlLorlng supervlslng and
runnlng Lhe process durlng sLarLup operaLlon
and shuLdown condlLlon
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Low level human lnLerface Lo local conLrol
unlL (LCu) or daLa lnpuL ouLpuL unlL (ul/uC)
vla dedlcaLed llne
Plgh level human lnLerface Lo LCu or ul/uC
vla shared communlcaLlon faclllLy
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ADVANTAGES
Reduction in control room size (no panel board instrumentation)
Reduction in wiring cost (LCU near process)
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lnLerface equlpmenL musL be deslgned Lo
meeL
Large as well as small sysLems
CenLrallzed and dlsLrlbuLed equlpmenL
conflguraLlon
C81 only operaLlon or panelboard lnsLrumenLaLlon
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8equlremenLs
9rocess mon|tor|ng
CurrenL values of all process varlables ln sysLem
ldenLlfled by Lag raLher Lhan address (descrlpLor
for LhaL Lag assoclaLed)
ulsplay of v ln englneerlng unlLs wlLh values
varlables (funcLlons of baslc v) avallable all
Llme ln formaL
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Alarming
Alarm status identiIied by control and computing devices
Ior each variable in DCS reported in clear manner
Also Ior computed variables
Display alarm along with PV or accessible to the operator
Alert and acknowledge Irom the operator
Multiple alarm in short time, inIormed with priority
Multivariable alarm (abnormal depend on several
variables) appropriate mechanism to report the same
%rend in time
ast access to recent history oI selected PV known as
trended variable(TV)
Requirements in trending
group related TV
Trend graph in engineering units
Able to obtain precise recent and trend variable
Also show auxiliary inIormation; to evaluate status
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!rocess control
4 Rapid access to all continuous and logic sequences
4 Continuous control loop: changing control modes, set
points and monitor results
4 Logic: starting and stopping pumps, opening and closing
oI valves
4 Batch process: observe current status, and interact to
initiate new steps or halt sequence
4 Both cases: access to and be able to manipulate (iI any
single point Iailure)
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3 !rocess diagnostics
Abnormal conditions caused by equipment or I&C
system, identiIy, correct
Ongoing tests and reasonable checks on sensors
Ongoing selI-tests on components and module
Automatic diagnostics Iunctions
1. irst-out alarming Iunction
2. Priority alarming Iunctions
3. Advanced diagnostic Iunction (Iailed process equipment
and mode oI Iailure)
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4 !rocess record keeping
Periodically note and record the current values
Record keeping requirements
1. Recording oI short-term trending inIormation
2. Manual input oI process data
3. Recording oI alarms(with tag name, time, return to normal,
operator acknowledgement)
4. Periodic records oI process variable inIormation
5. Long-term storage and retrieval oI inIormation
6. Recording oI operator control actions
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5 :idelines for h:man factors design
Convenience oI equipment vendor or architect-engineer
Later operator - ewer operator errors
Less operator Iatigue
EIIicient use oI personnel
Guidelines
1. ull range oI expected operator population (male, Iemale, large, small)
2. Minor disabilities (color blindness, near sightedness)
3. or operators not computer programmers
4. Rapid access to all necessary controls and displays
5. Arrange (equipment, displays) based on operational point oI view, cluster
6. Use colors, symbols, labels to minimize operator conIusion
7. Do not Ilood parallel inIormation, give prioritized, arranged and
meaningIul
8. Aid with operator guides, menus, prompts or interactive sequences
9. Detect and Iilter erroneous operator input, tell operator what to do next
10.Control room equipment is consistent with proper selection and design oI
equipments
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lowlevel CperaLor lnLerface
Motivations to use LLOI
Provides interIace that is Iamiliar to trained operator
(resemble type oI instrumentation)
Less expensive than HLOI
It can provide manual backup incase automatic or HLOI
Iails
LLOI includes
Control stations, indicator station, alarm annunciators and trend
recorders
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ConLrol sLaLlon conLlnuous
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ConLrol sLaLlon loglc
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High level operator interIace
LLOI uses panel board instrumentation
HLOI uses CRT, video display units
Uses keyboard instead oI switches
Microprocessor based digital technology
Advantages
1. Control space reduced signiIicantly
2. lexible (no panel board instrumentation)
3. Microprocessor cost eIIective implementation oI Iunctions
Consists oI
Operator displays, keyboard or input devices, main processor and
memory, interIace to shared Iacility and hard copy devices
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Disadvantages
All in one basket, vulnerable to single point Iailure
Single-processor, single-memory-less loops, datas
Not scalable, expensive Ior small systems
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irst available standard
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CL8A1C8 ulSLA?S
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ig picture of current plant condition
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Situation in a selected plant area
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Alarm and operational status of process variables in the plant,
but to control, require display similar to panel board instrumentation
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Group graphics display ncludes piping and instrumentation diagram
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Single loop or data points for control and analysis purpose
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Use to both operator and instrumentation engineer
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ueslgn conslderaLlon for dlsplays
noL cluLLered slmple as slmple
noL flashy and proper background for dlsplay
1op few llnes dlsplay common lnformaLlon
roper color convenLlons of lndusLry
lor color bllnd use underllne or bllnklng
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ueslgn conslderaLlon for operaLor lnpuL
ulsplayselecL commands
CursormovemenL commands
ConLrollnpuL commands
uaLa lnpuLs
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Lnglneerlng lnLerface
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Human interIace - to monitor and control
Engineer to put DCS onto Iield
Design Ior engineer to monitor, control, procure,
arrange, wiring, testing
Select device Ior operator, mount in panelboard,
wire, test
documentation
Error detected new module, wiring,
documentation update
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Dedicated inter module wiring replaced by shared
communication
CRT based instead oI huge panel board
Engineering made simple
Special hardware (part oI DCS) to make this painless
Engineering interIace
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Low-level engineer interIace
Min. Iunction devices
Inexpensive
Small
High-level engineer interIace
ull Iunction devices
PowerIul (expensive)
Medium and large
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unctions
System conIiguration
DeIine H/W conIiguration, interconnection, algorithms
Operator interIace conIiguration
DeIine equipment, relate this to DCS
System documentation
System and interIace Ior quick changes
System Iailure diagnostics
Determine existence oI Iailure, quick and eIIicient
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Requirements
Access sec:rity:
control logic and tuning parameter, unauthorized not allowed
Ergonomic design:
not Ior programmers,
many devices- interIace between them
Data reasonable and consistency:
check with previous entered value, prompt to correct,
enter not more than once,
many control Ior one- pick, keep track,
Ior several related H/W, system should provide check
User convenience
Easy storage when not in use
No need to shut down to connect or disconnect devices (convenient)
Cost effectiveness
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System conIiguration requirement
Manual work
determining control system requirement
Selecting and procuring H/W
Physically assembling
Connecting wires between transmitter and terminating point in
control room
1. DeIine address oI I/P, O/P points in system
2. DeIine tag name and descriptor, relate these to tags
3. Signal conditioning (iI required) oI I/P
Linearization, zero or span shiIting, conversion (O/P too)
4. Select, conIigure and tune control and computational algorithm
DeIine auxiliary Iunction- trending, logging
5. Requires transmission, deIine link Irom element to other
System to check, so preloaded, duplicate in mass storage
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CperaLor lnLerface conflguraLlon
requlremenL
Implement panel board or video display unit
unctions
To select and deIine devices and mechanism
Ior operator
Control station, indicators, recorders
Relate operator interIace or display to control
&instrumentation H/W in Iield
Labelling devices, display with tag
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uocumenLaLlon requlremenL
Bulk oI conIiguration through engineering
interIace and stores in mass storage
Include hard copy to support documentation
Support tabular and graphical data Iormat
Keep track oI Iield changes
EI must handle these changes, as well as original design
Automatic with less human eIIort
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ulagnosLlcs of sysLem requlremenL
SelI diagnostics (intelligent individual device)
IdentiIy Iailed devices
Sensors, power supply, communication devices
Partial Iailure
Severity and nature, to identiIy
Trouble shooting oI control system
Initial, online
Continuous, logic, batch
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Lowlevel englneerlng lnLerface
Micro-processor based
Can be
hand held
module that can be mounted
Minimal input, output
Plug and play-not needed throughout
Use oI code word, symbol min I/O,O/P
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System config:ration
H/W selected and conIigured manually
Provide with guides or documentation
LLEI to provide tool Ior conIigure algorithm
Enter control strategies, setting tuning parameters, alarm
limits, etc
Storage available, without controller, only with power
supply and controller limits
Upload Irom controller, or download to controller
Not support high-level language
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Operator Interface Config:ration
Minimum devices manually
Assign tag names, labeling station
DiIIicult, time consuming, prone to error
Doc:mentation
Manual with standard Iorms
Diagnosis Of System !roblems
Not always connected
Rely on SelI test oI equipment
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High-level Engineering InterIace
Cost-eIIective Ior medium and large system
CRT console or VDU
Similar to HLOI
Modular- keyboard, printer added- Ilexibility
Same elements oI Operator interIace used Ior
Engineer interIace
Interact through Communication Iacility
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D:al - console f:nction
Operator- display, mode selection, control operation
Engineer- control logic conIiguration, modiIication,
tuning, documentation
Engineering interIace not required always
Using switch can be changed to OI or EI
Cost eIIective
Switch also provides security Ior EI
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Special hardware req:ired
Operator interIace- not much input/output, so simple
keyboard
Engineer interIace- wider range oI input, use oI
general purpose keyboard
Special characters- special purpose
Printers or plotters Ior documentation
!ortable Engineering interface
Compromise between Iull Iunction and minimum
Iunction
Bulk memory, plug and play type, Ior single LCU or
cabinet
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System config:ration
HLEI major role in automating process
Control structures, computational algorithm stored in HLEI. ollowing
inIormation
Number, type and location oI H/W in LCU
DeIinition oI any H/W selected on each module
DeIine input point to H/W module
Number, type and location oI all operator and engineering consoles in the
system
Number, type and location oI any other device that communicate using
shared communication Iacility(special logging or computing device)
Some manually others automatic using broadcast messages
Control and computational inIormation
Tags, descriptors, deIinitions, addresses
Logic state descriptors Ior digital system
Signal conditioning in DI/OUs
Communication linkages
High-level language computation algorithms in LCU
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Control and computational logic conIiguration
ill-in-the-blanks Iunction; through sequence oI prompts and
responses
Graphics capability engineer draws using light pen, similar to
CAD
Enter debug and check high level language routines
Storage oI conIiguration
Use oI mass memory to store conIiguration inIormation
Control logics without presence oI target H/W
VeriIy engineer input to LCU; comparison Irom mass storage
ailed devices replaced with new one, conIiguration
downloaded to it
Upload conIiguration Irom device to interIace
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Operator interface config:ration
ConIigure or change display structures
Number oI areas in plant, identiIying tags and descriptors
Number oI groups in each area
Assignment oI control loops and input points to group
Types oI display at each level (preIormatted or custom)
Linkages between displays
Assignment oI points in system Ior special Iunction
Layout oI display
Graphic symbols
Static background elements
Dynamic graphics elements
Dynamic alphanumeric elements
Control stations
Poke points- touch screen
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Operator input mechanisms
Special Iunction deIinition
Graphics drawing and editing
Symbol modiIications
Macro symbol operations
Display transportability
Expanded display deIinition
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Doc:mentation
ollowing documentation automatically
List oI H/W modules and their location
Control conIiguration and associated tuning parameters Ior
each LCU
Listing oI tags, descriptors, H/W address oI I/P or O/P
modules
Listing oI special operator interIace Iunction with tag
Operator display in system with drawing and display
hierarchy
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Diagnosis of system problems
Most oI H/W devices is microprocessor based,
intelligent to perIorm on-line selI-diagnosis
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GENRAL PURPOSE COMPUTERS IN
DISTRIBUTED SYSTEM
lexibility, modularity and user-Iriendliness
Motivations to use general purpose computers
SoItware investment- soItware package based on speciIic
computer replaced- cost reduced
Specialized language requirements- application implemented
by languages not in systems provided by distributed vendors
Extensive computational requirements- high speed and better
memory
PC Ior small systems
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CompuLer lnLerface deslgn lssues
Handle all types oI messages transmitted
Travel at speed required by computers
Time delays across the interIace small
Computer time &memory Ior interIace minimal
No demands on shared communication Iacility
InterIace must support Iull range oI general purpose computers
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CompuLer
CompuLer
lnLerface
To shared
communicatio
n facility
Standard line
(eg RS 232C)
CompuLer
CompuLer
lnLerface
Computer /O
bus
To shared
communicatio
n facility
CompuLer
CompuLer
lnLerface
To shared
communicatio
n facility
Shared
memory
Computer memory bus
Type A
Type B
Type C
Computer interface
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