HART

LOGIC AND DISTRIBUTED CONTROL SYSTEM

*Programmable Logic Controllers (PLCs) are ruggedized industrial computers used for
*HART (Highway Addressable Remote Transducer) Protocol is the
automating and controlling various processes and machines.
global standard for sending and receiving digital information across
*Its primary function is to control and monitor machinery and processes in
analog wires between smart devices and control or monitoring system.
*It is a bi-directional communication protocol that provides data access manufacturing plants, factories, and other industrial settings.
between intelligent field instruments and host systems. Centralized Control: PLCs can exchange data, making it possible to control multiple
*A host can be any software application from technician's hand-held processes from a central location.
device or laptop to a plant's process control, asset management, safety Data Logging and Analysis: Networked PLCs can collect and transmit data for analysis,
or other system using any control platfor. improving predictive maintenance.
*The majority of smart field devices installed worldwide today are HART-enabled. Remote Monitoring: Allows for real-time monitoring of processes, reducing downtime.
*A DIGITAL UPGRADE FOR EXISTING PLANTS - Offers a reliable, long-term solution Flexibility: Easy reconfiguration and expansion of control systems.
for plant operators who seek the benefits of intelligent devices with digital FIELDBUS NETWORKS:
communication – that is included in the majority of the devices being installed . PROFIBUS: A widely used fieldbus protocol, it supports both discrete and process
*Since most automation networks in operation today are based on traditional automation. PROFIBUS DP (Decentralized Peripherals) is used for fast data exchange,
4-20mA analog wiring, HART technology serves a critical role because the while PROFIBUS PA (Process Automation) is suitable for process control.
digital information is simultaneously communicated with the 4-20mA signal MODBUS: A simple, open-source protocol that communicates via RS-232 or RS-485,
.Without it, there would be no digital communication. making it versatile for various industrial applications.
A CRITICAL, DIGITAL ROLE - HART technology is easy to use and very reliable DEVICENET: Primarily used in factory automation, DeviceNet is a low-speed network
when used for commissioning and calibration of smart devices as well as for that connects PLCs to sensors and actuators.
continuous online diagnostics. CANopen: Commonly used in automotive and embedded systems, CANopen is based on
*There following are the reasons for the host to communicate with smart devices. the Controller Area Network (CAN) protocol.
*Device Configuration or re-configuration ETHERNET-BASED NETWORKS
*Device Diagnostics ETHERNET/IP: Based on standard Ethernet technology, it allows seamless integration
*Device Troubleshooting with enterprise-level systems like ERP and MES. It uses CIP (Common Industrial
*Reading the additional measurement values provided by the device Protocol) for communication.
*Device Health and Status PROFINET: Developed by Siemens, PROFINET provides real-time communication and is
suitable for complex automation systems. It supports a wide range of devices and
redundancy options.
EtherCAT: Known for its high-speed and deterministic communication, EtherCAT is
commonly used in motion control applications and robotics.
NETWORK TOPOLOGIES
STAR TOPOLOGY
In a star topology, each PLC or device is connected directly to a central hub or switch.
All communication passes through the central hub, which manages data routing.
This topology is easy to set up, troubleshoot, and expand.
It provides good isolation, as a failure in one branch of the network does not affect the
rest.
*The HART Protocol communicates at 1200 bps without interrupting the 4-20mA BUS TOPOLOGY
signal and allows a host application (master) to get two or more digital updates per In a bus topology, PLCs and devices are connected in a linear fashion along a single
second from a smart field device. As the digital FSK signal is phase continuous, there communication backbone.
is no interference with the 4-20mA signal. Data is transmitted along the bus, and each device receives all data but processes only
*The HART Protocol can be used in various modes such as point-to-point the messages addressed to it.
(analog, from one to other)or multidrop (digital/FSK)for communicating It is a simple and cost-effective topology but can be vulnerable to cable failures.
information to/from smart field instruments and central control or monitoring systems. MESH TOPOLOGY
*The HART Protocol provides for up to two masters (primary and secondary). A mesh topology involves PLCs interconnected in a complex pattern, with multiple paths
This allows secondary masters such as handheld communicators to be used without for data to travel.
interfering with communications to/from the primary master, i.e. control/monitoring system. It provides redundancy and fault tolerance because if one path fails, data can take an
Advantages of HART alternative route.
Compatibility with standard 4-20mA wiring Mesh topologies are robust but can be expensive and complex to set up.
Simultaneous transmission of digital data RING TOPOLOGY
Simplicity through intuitive menu-driven interfaces In a ring topology, PLCs are connected in a closed-loop configuration, with each PLC
Risk reduction through a highly accurate and robust protocol connecting to two neighboring PLCs.
PHYSICAL LAYER Data travels in one direction around the ring.
Category 5, shielded, twisted pair wire(to avoid electro static and electromagnetic Ring topologies offer redundancy because if one segment of the ring fails, data can still
Interference) flow in the opposite direction
Bus powered: 15 devices can be connected Integration with SCADA and HMI Systems
Analog: point to point SCADA (Supervisory Control and Data Acquisition):
Digital: FSK, Bell 202 Comm.std, SCADA systems are used to monitor, control, and visualize industrial processes.
BW: 2400, RS232+MODEM. They provide a centralized interface for operators to view real-time data, historical
HART Specifications trends, and alarms
The HART Protocol implements layers 1,2, 3, 4 and 7 of the Open System Interconnection HMI (Human-Machine Interface):
(OSI) 7-layer protocol model: The HART Physical Layer is based on the Bell 202 standard HMIs are localized interfaces typically installed on the factory floor, allowing operators
, using frequency shift keying (FSK) to communicate at 1200 bps. The signal frequencies to interact directly with machines and processes.
representing bit values of 0 and 1 are 2200 and 1200Hz respectively They provide control functions, status displays, and alarms
The HART Data Link Layer defines IIOT Integration (Industrial Internet of Things):
Data Link Layer: Error checking PLCs are increasingly integrated into IIOT ecosystems, enabling them to collect and
transmit data to cloud-based platforms for advanced analytics and predictive
maintenance.
This integration allows for remote monitoring and control of PLCs from anywhere with
an internet connection.
Edge Computing
Edge devices, such as edge PLCs or gateways, are being used to process data locally
within the PLC network.
Edge computing reduces latency, enhances real-time control, and minimizes the need
Preamble 1: Ready for communication, o: not ready for constant cloud connectivity.
SD: specify the direction like Master-slave or slave-master
Asyn. Mode. Tx one by one.
Two dimensional error checking (vertical and longitudinal parity check)
CD: 1 byte so 256 commands
ODD parity
Application Layer
Foundation fieldbus Access Sublayer (FAS) – Responsibility is to preprogram the ‘schedule’
in the LAS *Foundation Fieldbus Messaging Specification (FMS) – Contains ‘Object
Dictionary’ – a type of database that allows access to FF data by tag or an index.
INSTALLATION: PROCESSOR MODULE POWER SUPPLY REDUNDANCY
The processor is responsible for the self-detection of Power Supply Subsystem redundancy was designed to provide automatic
1.PLC I/O module installation potential problems. It performs error checks during its and bumpless switch over in the event of any failure.
2.Wiring considerations operation and sends status information to indicators that are The power supply subsystem can be made redundant just by adding a
3. Special I/O connection precautions normally located on the front of the processor module. second one.
a. Connecting leaky inputs Again no spare parts are required, since there is no special part number
b. Fusing outputs for redundancy.
c. Shielding WORK STATION REDUNDANCY
INSTALLATION OF I/O MODULES Multiple operator workstations are used in where each workstation
The type of I/O module: There are different types of I/O watches the entire plant. The loss of one workstation will not cause any
modules, such as digital input modules, digital output modules, loss of plant visualization or operation.
analog input modules, and analog output modules. RUN (Green); On steady indicates that A Redundant database server will assure that no historical data will be
The voltage and current ratings of the I/O module: The I/O the process is in the RUN mode. Flashing during operation lost in the event that one server goes down.
module must be compatible with the voltage and current ratings indicates that the process is transferring a program from CONTROL
of the field devices. RAM to the memory module. Off indicates that processor is There are two processors on each processor card. Each CPU performs the
The number of I/O points: The number of I/O points needed will in a mode other than RUN. same control computations, and the results are compared after each
depend on the number of field devices that need to be FLT (Red) : Flashing at power-up indicates that the processor computation.
connected. has not been configured. Flashing during operation If the results agree, then the card is assumed to be normal and the
The location of the I/O modules: The I/O modules should be indicates a major error either in the processor, chassis, or results are transferred to memory and bus interface card. The main
located in a place that is accessible for maintenance and memory. On steady indicates that a fatal error is present memory uses ECC (error- correcting code) which can correct transient
troubleshooting. (no communications).Off indicates there are no errors. reversed–bit errors.
Wiring Considerations BATT (Red) : On steady indicates the battery voltage has If the results from CPU1 and CPU2 do not agree, then the comparator
Use the correct type of wire: The type of wire used will depend fallen below a threshold level, or the battery is missing or takes this as “CPU abnormal” and switches to the standby processor card.
on the voltage and current ratings of the PLC and the field not connected. Off indicates that the battery is functional. BUS REDUNDANCY
devices. *Most PLCs incorporate a watchdog timer to monitor the Dual-redundant bus interface cards can be installed in the control unit
Use the correct wire size: The wire size must be large enough to scan process of the system. The watchdog timer is usually a The two cards are controlled by the software residing in the active CPU
carry the current required by the PLC and the field devices. separate timing circuit that must be set and reset by the to determine their active and standby status. Normally the card on the
Make secure connections: The wire connections must be secure processor within a predetermined period. active CPU side is given the active status and the other card the standby
to prevent arcing or overheating. Input Malfunctions: status. The standby side “Sleeps” and performs only diagnostic
Label the wires clearly: The wires should be labeled clearly so The first step in troubleshooting input malfunctions is to communications.
that they can be easily identified. This will make it easier to check your inputs for proper wiring, identifying your PLC IO Dual-redundant buses are used alternately, if an abnormality is detected
troubleshoot problems if they occur. from the provided schematics. in one bus then the other is used.
Route the wires properly: The wires should be routed in a way Then, typically, the problem source can be narrowed down
that prevents them from being damaged. The wires should be by comparing the actual status of the suspect I/O with the
kept away from heat sources, sharp objects, and moving parts. controller status indicators Foundation Fieldbus Protocol
Ground the PLC: The PLC must be grounded to prevent electrical Output Malfunctions Evolution of Signal Transmission Technology
shock. As with input malfunctions, the first step in troubleshooting From 1940 to 2000, instrumentation has progressed from pneumatic to
Special I/O connection precautions an output malfunction is to check the outputs for proper digital technology that is fieldbus technology.
wiring, identifying the PLC IO from the provided schematics.
a) Connecting leaky inputs: If the output circuit LED is on and the output device is OFF,
several things could be the cause:
Some field devices have a small leakage current even when
● Incompatible devices: Check for PNP/NPN
they are in the OFF state.
output specification.
A typical device that exhibits this leakage situation is a
● Wrong output circuit wiring: Check output
proximity switch. This type of leakage may also occur when an
module wiring.
output module drives an input module.when there is no other
● Low or NO voltage across the load: Check for
load.
short-circuit or damaged wires.
B)Fusing outputs:
PLC Program Error:Start program troubleshooting by
*Solid-state outputs normally have fusing on the module, to
identifying the outputs that operate properly and the
protect the triac or transistor from moderate overloads.
outputs that do not Fieldbus
*If the output does not have internal fuses, then fuses should be
Identify common logic errors. Fieldbus is a digital, two-way, multi-drop communication link among
installed externally (normally at the terminal block) during the
Use Force On/Force Off to turn specific bits on/off for intelligent field devices and automation systems.
initial installation.
testing purposes. Fieldbus is a protocol to connect field devices to the control system;
*When adding fuses to an output circuit, the user should adhere
where control system is referred to as host system and nature of signal
to the manufacturer’s specifications for the particular module.
REDUNDANCY IN DCS is purely digital and not analog like in conventional systems.
c) Shielding
Comparison of Communication Protocols
Control lines, such as TTL, analog, thermocouple, and other low-
level signals, are normally routed in a separate wireway, to
reduce the effects of signal coupling.
For further protection, shielded cable should be used for the
control lines, to protect the low-level signals from electrostatic
and magnetic coupling with both lines carrying 60 Hz power and
other lines carrying rapidly changing currents.
The shield should be connected to control ground at only one
point and shield continuity must be maintained for the entire
length of the cable. The shielded cable should also be routed
away from high noise areas, as well as insulated over its entire
DCs -Distributed control and centralized monitoring
length.
Basic components of dcs
-CPU
TROUBLESHOOTING OF PLC
-OPS (operator station)
Identify the problem: The first step is to identify the problem.
-Communication bus
This can be done by observing the PLC and the process that it is
The FCU consists of Types of Fieldbus
controlling.
• Two Power Supply Units *FOUNDATION Fieldbus
Gather information: Once the problem has been identified, the
• Two processor modules H1 ~ speed ~31.25kbps
next step is to gather information about the PLC. This includes
• Eight slots for Input Output cards HSE (high speed ethernet) ~speed ~ 100Mbps
the PLC's programming, the I/O configuration, and the PLC's
Out of these eight I/O slots, if I/O expansion is required, • ControlNet
operating environment.
two slots are used for ESB module and the rest six slots are • PROFIBUS and PROFInet
Isolate the problem: The next step is to isolate the problem. This
used for IO modules • P-NET
can be done by testing the PLC's components and by checking
REDUNDANCY: • WorldFIP
the PLC's wiring.
Duplication of critical components or functions of a system • INTERBUS
Correct the problem: Once the problem has been isolated, the
with the intention of increasing reliability of the system, • SwiftNet
next step is to correct the problem. This may involve replacing a
usually in the case of backup or fail-safe.
component, updating the PLC's programming, or making changes
Redundancy level available in DCS :
to the PLC's I/O configuration.
Power supply
Verify the correction: The final step is to verify the correction.
Controller
This can be done by testing the PLC and the process that it is
Bus/ Network
controlling.
Work station
The source of a problem can generally be narrowed down to the
❖ Processor module
❖ I/O hardware,
❖ Wiring