Contents

Chapter 1SCADA systems hardware (and firmware)

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

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1 3 9 10 20 27 32

Chapter 2 SCADA systems software and protocols

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

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35 35 38 43 44 45

Chapter 3 Typical distributed control systems and SCADA systems 51

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

Chapter 4 The basic controller

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

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87 87 90 91

Chapter 5 Basic DCS controller configuration

5.1 Historical 5.2 Control modes 5.3 Tracking and initialization in control slots used for cascade control

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95 95 95

2 Contents

5.4 Control functions 5.5 Control algorithms 5.6 Sequential programs for batch processing 5.7 Defining equipment procedures 5.8 Phase logic programming 5.9 Phase logic interface 5.10 Logic block functions in advanced controller 5.11 DCS controller configuration

99 104 117 119 120 123 126 129

Chapter 6 Introduction to communications for DCS & SCADA systems

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 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

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131 131 135 137 145 150 154 154 159 163 164

Chapter 7 Local area network systems

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 Introduction Network topologies Bus topology Star topology Ring topology Media access methods IEEE 802.3 Ethernet MAC frame format High speed Ethernet system 100BaseT (100BaseTX, T4, FX, T2) Fast Ethernet design considerations Gigabit Ethernet 1000BaseT Network interconnection components TCP/IP protocols SCADA and the Internet

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169 170 170 171 172 173 174 181 182 183 186 187 191 196 200

Contents 3

Chapter 8 ProfiBus
8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 Introduction Architecture of the ProfiBus protocol Application larger service specification ProfiBus communication model Relationship between application process and communication Communication objects FieldBus message specification Network management Fault management Configuration management ProfiBus FMS profiles Performance Diagnostics System configuration

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205 207 210 212 212 213 214 218 218 218 218 219 220 220

Chapter 9Foundation FieldBus

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 Introduction Overview Physical layer Data link layer Application layer User layer block System management Device description Application example

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225 225 227 237 239 243 259 260 261

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

4 Contents

10.15 Elementary data types 10.16 Generic data type 10.17 Derived data types 10.18 Variables 10.19 Variable initialization 10.20 Functions 10.21 Programs 10.22 Resource 10.23 Tasks 10.24 Summary of common elements in IEC-1131-3 10.25 Structured text 10.26 Statements used for assignments 10.27 Expressions 10.28 Evaluating an expression 10.29 Statements 10.30 Conditional statements 10.31 Iteration statements 10.32 Implementation dependence 10.33 Summary of structured text 10.34 Function block diagram 10.35 Basics 10.36 Methodology 10.37 Signal flow 10.38 Feedback path 10.39 Network layout 10.40 Function execution control 10.41 Jumps and labels 10.42 Network evaluation rules 10.43 Summary of function block diagram 10.44 Ladder diagrams 10.45 Basic concept 10.46 Graphical symbols used in ladder diagram 10.47 Boolean expressions using ladder diagrams 10.48 Integrating functions & function blocks. 10.49 Feedback paths 10.50 Jumps and labels 10.51 Network evaluation rules 10.52 Portability 10.53 Summary of ladder diagrams 10.54 Instruction List 10.55 Structure of IL programming language 10.56 Calling functions and function blocks 10.57 Portability and other issues 10.58 Summary of Instruction List 10.59 Sequential function chart (SFC) 10.60 Steps

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Contents 5

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

339 341 343 347 347 347 349 349

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

6 Contents

11.35 Hazard assessment 11.36 Hazard and operability studies (HAZOP)

434 436

Chapter 12Distributed control system reporting

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

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439 439 445 446 449 450

Chapter 13Distributed control system (DCS) configuration

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

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Chapter 14Maintenance consideration

14.1 14.2 14.3 14.4 14.5 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

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471 471 478 485 486

Chapter 15Distributed control system applications

15.1 15.2 15.3 15.4 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

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Chapter 16Distributed control systems implementation

16.1 16.2 16.3 16.4 16.5 16.6 Introduction System strategy Automation plan Project implementation Installation and commissioning Change management

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523 523 524 532 535 538

Chapter 17The future of distributed control systems

17.1 Introduction 17.2 Creation of E-commerce solution

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539 541

Appendix AFundamentals of control systems Appendix BIntegration of the complete FieldBus system Appendix CAdaptive and predictive control Appendix DCentral site computer facilities Appendix EFuzzy logic control Appendix FStability and control modes of closed loop Appendix GDCS and process control exercises Glossary

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