Practical Distributed Control Systems (DCS) for

Engineers & Technicians

Contents
Chapter 1— Introduction to Computer Based Control Systems 1
1.1 Introduction to computer based measurement and control systems 1
1.2 Role of computers in measurement and (process) control 3
1.3 Basic components of computer based measurement and control
systems 4
1.4 Architecture – computer based process control system 7
1.5 Human Machine Interface (HMI) 12
1.6 Hardware for computer based process control system 13
1.7 Interfacing computer system with process 19
1.8 Economics of computer based system for industrial application 24

Chapter 2—Overview of Distributed Control Systems 25

2.1 Introduction 25
2.2 Basic concepts of Distributed Computing 26
2.3 Evolution of Distributed Computing System 27
2.4 Present market trends in DCS 31
2.5 Basic DCS specification 34
2.6 General description of a commercial DCS 34
2.7 Advantage of DCS systems 36
2.8 DCS selection criteria 37
2.9 DCS architecture 41

Chapter 3—An overview of SCADA systems 63

3.1 Introduction 63
3.2 Basics of SCADA system 63
3.3 SCADA key features 65
3.4 Remote terminal units (RTUs) 67
3.5 Typical requirements for an RTU system 69
3.6 PLCs used as RTUs 70
3.7 Consideration and benefits of SCADA system 70
3.8 DCS versus SCADA terminology 71
3.9 SCADA software package 73
Chapter 4— The basic controller 77
4.1 Introduction 77
4.2 Identification of the controller boards 77
4.3 Discrete and logic control 79
4.4 Sequential and batch control 80

Chapter 5— Basic DCS controller configuration 85

5.1 Historical 85
5.2 Control modes 85
5.3 Tracking and initialization in control slots used for
cascade control 86
5.4 Control functions 89
5.5 Control algorithms 94
5.6 Sequential programs for batch processing 106
5.7 Defining equipment procedures 108
5.8 Phase logic programming 108
5.9 Phase logic interface 111
5.10 Logic block functions in advanced controller 114
5.11 DCS controller configuration 116

Chapter 6— Introduction to communications for DCS & SCADA

systems 119
6.1 Purpose 119
6.2 Basic communications principles 119
6.3 Balanced and unbalanced transmission lines 123
6.4 EIA-232 interface standard (CCITT V.24 interface standard) 125
6.5 The EIA-485 interface standard 132
6.6 Open systems 136
6.7 Interoperability 140
6.8 ModBus protocol 140
6.9 HART protocol 145
6.10 The promise of FieldBus and DeviceNet 149
6.11 Benefits 149

Chapter 7— Programming of DCS systems 153

7.1 Development and growth of programmable controllers (PLC)
- an introduction 154
7.2 Need for standardization in programming approach 155
7.3 Drawbacks in conventional programming methodology 156
7.4 Features of IEC-1131-3 language definition 161
7.5 Summary of IEC-1131-3 162
7.6 PLC software architecture - software quality attributes 162
7.7 IEC software architecture 163
7.8 Component parts of IEC software architecture 164
7.9 Functions and function blocks 165
7.10 Local and global variables 166
7.11 Mapping software model to real life systems-Examples 168
7.12 Applications 169
7.13 Summary of PLC architecture 172
7.14 Common elements in IEC-1131-3 173
7.15 Elementary data types 174
7.16 Generic data type 177
7.17 Derived data types 178
7.18 Variables 180
7.19 Variable initialization 184
7.20 Functions 184
7.21 Programs 189
7.22 Resource 190
7.23 Tasks 190
7.24 Summary of common elements in IEC-1131-3 192
7.25 Structured text 193
7.26 Statements used for assignments 193
7.27 Expressions 194
7.28 Evaluating an expression 194
7.29 Statements 195
7.30 Conditional statements 196
7.31 Iteration statements 197
7.32 Implementation dependence 199
7.33 Summary of structured text 200
7.34 Function block diagram 200
7.35 Basics 200
7.36 Methodology 201
7.37 Signal flow 202
7.38 Feedback path 203
7.39 Network layout 204
7.40 Function execution control 204
7.41 Jumps and labels 205
7.42 Network evaluation rules 205
7.43 Summary of function block diagram 206
7.44 Ladder diagrams 206
7.45 Basic concept 206
7.46 Graphical symbols used in ladder diagram 207
7.47 Boolean expressions using ladder diagrams 209
7.48 Integrating functions & function blocks…. 210
7.49 Feedback paths 210
7.50 Jumps and labels 212
7.51 Network evaluation rules 212
7.52 Portability 212
7.53 Summary of ladder diagrams 213
7.54 Instruction List 213
7.55 Structure of IL programming language 214
7.56 Calling functions and function blocks 218
7.57 Portability and other issues 220
 7.58 Summary of Instruction List 221
7.59 Sequential function chart (SFC) 221
7.60 Steps 226
7.61 Transitions 227
7.62 Actions 228
7.63 Action qualifiers 230
7.64 Action control function block 233
7.65 Execution rules 233
7.66 Design safety issues 234
7.67 Top down design 235
7.68 Summary of sequential function charts 236

Chapter 8— Alarm system management 237

8.1 An alarm system 237
8.2 Functions of the plant or process operator 238
8.3 Functions of an alarm system 241
8.4 An effective alarm system 241
8.5 Design overview 243
8.6 Human and ergonomic factors 244
8.7 Structure of a good alarm system 247
8.8 Safety integrity level (SIL) 255
8.9 Definition of strategy 256
8.10 Strategy for alarm system design 256
8.11 Strategy for alarm system maintenance and management at
the site/plant 257
8.12 Generation of minimum design documentation for each alarm 257
8.13 Measurement of the alarms 261
8.14 Field measurements for deriving alarms 261
8.15 Hardware for alarm processing 262
8.16 Alarm displays 262
8.17 Testing of alarms 264
8.18 Generation of various types of alarms 264
8.19 Selection of alarm settings 271
8.20 Setting alarm priority 273
8.21 Design of field sensors for generating alarms 279
8.22 Logical processing of alarms 284
8.23 Design of alarm list displays 289
8.24 Measurement of performance 293
8.25 Usefulness of alarms 296
8.26 Measurement of number of alarms and average rate of alarms 299
8.27 Measuring operator response 305
8.28 Management of improvement program 306
8.29 Alarm review 307
8.30 Elimination of spurious alarms 308
8.31 Intermittent and fleeting alarms 308
8.32 Processing alarms 309
8.33 Control of modifications 314
 8.34 Hazard and operability studies (HAZOP) 315
8.35 Hazard assessment 315
8.36 Hazard and operability studies (HAZOP) 318

Chapter 9—Distributed control system reporting 321

9.1 Introduction 321
9.2 Operation of advanced DCS using multi-screen display 321
cross screen invocation and linking 321
9.3 Alarm reporting, generation and acceptance 325
9.4 Alarm reporting 326
9.5 Generation of alarms 328
9.6 Different types of logs and reports configurable on a DCS 329

Chapter 10—Distributed control system (DCS) configuration 337

10.1 Introduction 337
10.2 An engineering station 337
10.3 System/project tree structure 338
10.4 DCS system database 338
10.5 Configuration of control functions 339
10.6 Configuration of operator/monitoring functions 342
10.7 Configuration of system hardware structure 343
10.8 Configuration of system software 343
10.9 Documentation 344
10.10 Commissioning 345

Chapter 11—Maintenance consideration 347

11.1 Introduction 347
11.2 Maintenance requirements of system and system elements 347
11.3 Requirements for in-built diagnostic and maintenance routines 353
11.4 Requirement for installation of UPS system 359
11.5 Recovery of a DCS following power outage 359

Chapter 12— Typical distributed control systems and SCADA

systems 361
12.1 Introduction 361
12.2 Honeywell PlantScape system 361
12.3 Foxboro I/A series distributed control systems 371
12.4 Delta V system 378
12.5 Citect 380
12.6 Wonderware 388
Chapter 13—Distributed control system applications 395
13.1 Introduction 395
13.2 Use of DCS in pulp and paper environment 395
13.3 Use of DCS in petroleum-refining environment 412
13.4 Use of DCS in oil and gas processing environment 423

Chapter 14—Distributed control systems implementation 425

14.1 Introduction 425
14.2 System strategy 425
14.3 Automation plan 426
14.4 Project implementation 432
14.5 Installation and commissioning 435
14.6 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