Presentation outline

Introduction to DCS in Thermal Power Station ❑ Introduction

INDUSTRIAL COMMUNICATION SYSTEMS
❑ DCS of ABB for Thermal Power Plant

Assoc. Prof. Dr. BUI Dang Thanh ❑ DCS of Yokogawa for Thermal Power Plant
School of Electronic and Electrical Engineering
Hanoi University of Science and Technology
1 Dai Co Viet road, Hà Nôi, Viêt Nam

“Nothing can stop an idea when its time has come”

Victor Hugo

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 Content

❑ Introduction to DCS

❑ History of Control Hardware

❑ Advantages of Digital System

Part 1
❑ Computer Control Networks
Introduction to DCS ❑ DCS Elements

❑ Advantages of DCS/Objective of DCS/Benefits of DCS

❑ Modes of Computer control

❑ Utilization of DCS

❑ DCS Vendors

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 Introduction to DCS and DAS History of Control Hardware

❑ DCS – Distributed Control System

❖ Pneumatic Implementation:
✓ Collection of hardware and instrumentation necessary for implementing
➢ Transmission: the signals transmitted pneumatically are
control systems slow responding and susceptible to interference
✓ Provide the infrastructure (platform) for implementing advanced control ➢ Calculation: Mechanical computation devices must be
algorithms relatively simple and tend to wear out quickly.
✓ geographical dispersion ❖ Electron analog implementation:
✓ dispersion of control ➢ Transmission: analog signals are susceptible to noise,
and signal quality degrades over long transmission line.
➢ Calculation: the type of computations possible with
electronic analog devices is still limited.

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 History of Control Hardware Advantages of Digital System

❖ Digital Implementation: ❑ Digital computers are more flexible because they are

➢ Transmission: Digital signals are far less sensitive programmable and no limitation to the complexity of the

to noise. computations it can carry out.

➢ Calculation: The computational devices are digital ❑ Digital systems are more precise.

computers. ❑ Digital system cost less to install and maintain

❑ Digital data in electronic files can be printed out, displayed on

color terminals, stored in highly compressed form.

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 Computer Control Networks Computer Control Networks

PC Control: Display
Programmable Logic Controllers:

❑ Good for small processes ❑ specialized for non-continuous systems

such as laboratory prototype such as batch processes.
or pilot plants, where the Main ❑ It can be used when interlocks are
Computer
number of control loops is
required; e.g., a flow control loop cannot
relatively small
Final
be actuated unless a pump has been
Dat a
cont rol P ROCESS
element
acquisit ion turned on.

❑ During startup or shutdown of continuous

processes.
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 Distributed Control System- DCS DCS Elements-1

❑ Most comprehensive ❑ Data Acquisition and Field Control Unit: Digital (discrete) and
Supervisory (host)
Computer analog I/O can be handle.

Operator Main Operator Archival – Controller module

Control Control Control Data
Panel Computer Panel Storage
– Input module ( Analog :4-20mA, RTD, TC…; Digital:)

– Output module
Data highway
To other Processes To other Processes
• Analog output
Local data acquisition and
control computers
Local
Computer
Local
Computer
Local
Computer
• Digital output
Local Display Local Display
– Power supply
PROCESS
– Communication module
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 DCS Elements-2 DCS Elements-3

❑ General Purpose Computer : This unit is programmed by a

❑ Batch Sequencing Unit: This unit controls
customer or third party to perform optimization, advance control,
a timing counters, arbitrary function
expert system, etc
generators, and internal logic.
❑ Central Operator Display: This unit typically contain several
❑ Local Display: This device provides consoles for operator communication with the system, and multiple
analog display stations, and video display video color graphics display units
for readout.
❑ Data Highway : A serial digital data transmission link connecting all
❑ Bulk Memory Unit: This unit is used to other components in the system. It allow for redundant data highway
store and recall process data. to reduce the risk of data loss

❑ Local area Network (LAN)

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 What is a DCS & PLC Functional Components of Distributed Control System

In a control system there are three

elements: Distributed control systems are
▪ measurement, made of several components
▪ control algorithm; (Figure), namely:
❖ I/O buses
▪ final control element. ❖ I/O cards
❖ Controllers
❖ Control technology (control
function libraries and
• A PLC: Programmable Logic Controller was historically for machine control. software)
❖ Plant control network
This means that it is primarily on/off control. Fast control loops, in the order ❖ Workstations
of milliseconds. ❖ Operation and control
software
• A DCS: Distributed Control System was historically for control of a process, ❖ Plant information network
❖ Gateways where applicable
where there are many analogue variables: pressure, temperature, flow:
❖ Engineering/configuration
constantly changing. software Architectural features of DCS
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 Communication in Distributed Control Systems Communication in Distributed Control Systems

Pneumatic Communications Electronic Analog Communications

• Earliest implementations of automatic control systems involved • In these systems electrical signals were used as a means for
pneumatic transmission of signals. They used compressed air as communication. They are significantly different from their
the medium for signal transmission and actuation. Actual control predecessors where in pneumatic signals were used in
commands were computed using elements such as springs and mechanical controllers. Electrical signals to pressure signals
bellows converter (I/P converters) and pressure to electrical (P/I
• A pneumatic controller has a high margin for safety and since it converters) are used to transmit signals to enable coexistence of
is explosion proof it could be used in hazardous environments. pneumatic and electrical signals. Analog signals have a
However, they have slow response and are susceptible to weakness as they are susceptible to contamination from stray &
interference. The pneumatic signals range from 3 psi to 20 psi. elds leading to degradation in signal quality over long distances.
The 3 psi represents the lower range limit (LRL) and 15 psi • The analog communication is standardized at 4–20 mA current
represents the upper range limit (URL). signals. Other common standard electrical signals include the 1–
5 V signal and the pulse output.

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 Communication in Distributed Control Systems What are the important features of a DCS?

Digital Communications
Distributed means:
• Digital signals are separate levels or values that are combined in
specific ways to represent process variables and carry diagnostic ❖ Distributed Risk: Reliability is important as many components
information. The method of digital communication is referred as a
protocol where the transmission used a proprietary means or an are linked together. Redundancy is a method of distributing
open standard based communication methods. the risk.
• Open protocols such as HART®, foundation & fieldbus®, Pro&
bus®, Modbus®, etc., which are standard based and are ❖ Distributed components: Controllers, Inputs and Outputs
governed by nonprofit organizations. Digital signals are far less
(measuring and control signals)
sensitive to noise. In digital signaling, the impact of noise is
reduced compared to an analog signal. ❖ Robust communication system to connect the components:
• The digital signals are used by the device directly which is
equipped with microprocessors. These devices are flexible as I/O, controllers, operator interface.
they allow programming to function as per the user needs.

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 DCS is the Centre of Information Pha Lai Architecture Diagram

Management

Load Dispatch Operator

DCS PLC
Controller

Auxilliary:
Coal Plant, Water Treatment
Field Signals
Boiler/Turbine

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 Power Station Control Advantages of DCS

❑ Complex Process: many relationships between many variables, ➢ Access a large amount of current information from the data highway.
❑ Plant efficiency is related to how well the control is tuned, ➢ Monitoring trends of past process conditions.
❑ The Control System must not be the limiting factor to achieve ➢ Readily install new on-line measurements together with local computers.
efficiency, ➢ Alternate quickly among standard control strategies and readjust
❑ Control must be robust to overcome plant problems, without a trip or controller parameters in software.

plant shutdown, ➢ A sight full engineer can use the flexibility of the framework to implement

❑ Availability of DCS must be almost 100% to achieve plant efficiency: his latest controller design ideas on the host computer.

➢ Digital DCS systems are more flexible. Control algorithms can be

✓ Redundancy to give reliability
changed and control configuration can be modified without having
✓ Ease of use of DCS to look at data
rewiring the system.
❑ Many Auxilliary Plants: often with PLC’s
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 Objective of DCS Benefits of DCS

▪ Safe operation of plant ▪ High reliability

▪ Lowesr cost of generation ▪ Improved response time

▪ Longest equipment life ▪ Improve operator interface to plant

▪ Minimum efficiency ▪ Improve accessibility of plant data to engineering &

managenment personals
▪ Energy conversation
▪ Historical storage and retrieval system

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 Modes of Computer control
Different Modes of Digital Control Systems

signals from digital

1. Manual computer Direct Digital Control
Local PID ❖ In DDC, a digital computer develops control signals that
2. Automatic controller directly operate the control devices. A single computer
digitally performs all signal processing, indication, and
• PID with local set point control functions, and therefore the name “direct digital
control”.
❖ Initially computers were very large and housed in large
3. Supervisory Supervisory Control mode buildings with substantial environment controls.
❖ These minicomputers were first deployed to realize DDC
• PID with remote set point Flow measurement Therefore, the cycle of control process is:
▪ The system performs input/output (I/O) scan and
(supervisory) to computer
valve setting takes the input from controller to system
from computer ▪ The system has specialized software which is
4. Advanced capable of processing the signal and as per the
algorithm de& ned in the system
▪ The control is given to the destined output or set Architecture of DDC
Direct digital Control mode
point or any chosen destiny. This control logic
generally holds true for any of the controls
however, the mechanism of scanning the IO and
processing the signal and sending it back may
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 Different Modes of Digital Control Systems Hierarchical Computer Control System

Supervisory Control Multiple processors and systems are

The following are the advantages of supervisory connected in a network within a limited
control: geography, such as plants, and all of them
❖ In supervisory control, the primary control still work for common purposes such as
be executed by the analog control where only monitoring, control and optimization,
the set point adjustments are done at the information storage, etc. These are typically
supervisory computer. In this way the applied in large refineries or power plants
computer is not used for time critical control and fertilizer plants, etc. A representative
functions and hence is not time intensive and depiction of hierarchical computer control
can be used for functions which are system is shown in Figure. The
computation intensive such as process understanding on the hierarchical control
optimization and plant management functions. becomes easy once we know the operations
❖ Sometimes the analog controllers added to the of the plants or industrial facilities. These Architecture of hierarchical computer control
direct digital controller add reliability to the Architecture of supervisory control systems follow a bottom-up approach in
overall systems. design and functionality. The level of access
❖ Control algorithms, which provide the set point to the control system increases from
to the analog control subsystem, operator to supervisor to engineer to
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 Utilization of DCS Utilization of DCS

❑ DCS vendor job: ❑ Implementation of advanced control:

➢ installation ➢ Developed software for control algorithms, DMC,

Aspen, etc.
❑ Control Engineer Job:
➢ Control-oriented programming language supplied by
➢ Configuration
the DCS vendors.
❑ Built-in PID control:
➢ Self-developed programs using high-level
➢ How to Tune the PID control?
programming languages (Fortran, C++)

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 DCS Vendors

• ABB

• Yokogawa
Part 2
• Honeywell
DCS of ABB for Thermal Power Plant
• Siemens

• …

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 Content The Benefit of Power Plant Control

Power Plant Targets Control system solutions

Symphony System Components
• Reduction of operational cost Performance optimization
Harmony System Terms Degree of automation
– Manpower Advanced control solutions
Harmony Power System and Packing Total plant DCS
– Fuel Optimized redundancy
Harmony Rack I/O
– Maintenance cost 2 out of 3 protection
Detailed and fast diagnosis
Harmony Rack Control & Communications • High availability hot replacement
Engineering Tools – Composer – Less trips by Scalable system in Hardware and
Software
Human System Interface – OperateIT Process Portal protection Optimized Startup and Operation
intervention
– No downtime by
DCS
• Reduction of initial cost
• Take part in power bidding
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 Tasks of Power Plant Control Systems Tasks of Power Plant Control Systems

Operation, Measurement, Recording

Reliable power generation

High Fast
availability on-line
capability

Hazards Long
eliminated service life

High High
Close loop control Open loop control safety efficiency

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 Automation - Field to Board Room The Symphony Components
The control system: Nerves and brains of the power plant Performer Series
Information Processing Domain
Information-
management

Control Room Composer Series

Process Portal Series
Equipment Plant Operation Network System Engineering, Operation
Human-System Interface and Maintenance Tools

Analog control
Binary control
Protection
Switchgear
Control Network
Sensors Harmony Series
Actuators Signal and Logic
Processing Domain
Field Network

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 Symphony System Structure The Symphony Components
Plant Network
Plant coordination for higher efficiency and performance
Information
Composer Process Portal Process Portal Process Portal
Clients Configure Server Management
Historian Server Client
Servers and Clients

Unit automation
Operation Network
Composer Process Portal
Server and Process Portal
Clients
Connectivity Server and
Client
Redundant Connectivity Server and Client Boiler automation Turbine automation

Boiler Burner Fuel/ Tempe- Balance Turbine Turbine Turbine

Control Network Protection Mana- Air rature of Protection Control Auxiliaries Generator
gement Supply Control Plant

One system for all application in the plant

Process I/O Process I/O
Symphony Symphony
Harmony Control Unit Harmony Control Unit

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 Content Harmony System Terms

Symphony System Components

Harmony System Terms
Harmony Power System and Packing
Harmony Rack I/O
Harmony Rack Control & Communications
Engineering Tools – Composer
Human System Interface – OperateIT Process Portal

Harmony (Rack) Module Harmony Cable Harmony Termination Unit

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 Harmony System Terms Harmony System Terms

Cabinet: Cabinets are used to house the modules and terminations. Control Network (C-Net): C-Net is a unidirectional, high-speed serial
data highway shared by all Symphony nodes. Redundant coaxial or
fiber optic communication cables connect individual nodes to form a
closed ring system. C-Net can support up to 250 nodes per ring and
250 rings per system. Multiple sub-rings link to the central ring through
local and remote interfaces that can be redundant.

System Cabinet Termination Cabinet Marshalling Cabinet C-Net: Co-Axial Cable (Electrical)
Twin-Axial Cable (Electrical)
Fiber Optic (Ball of light passing through a glass tube)

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 Harmony System Terms Harmony System Terms

Node: Refer to Harmony Control Unit (HCU), Human System Interface Harmony Control Unit (HCU): A HCU usually consists of an entire
(PPB) and Computers connect to the C-Net. Harmony system cabinet containing power supplies, fans, HCU to C-
NET interface modules, controllers and I/O modules. Each HCU must
have its own unique address on the C-Net, the address could be from 1
Operation Network (O-Net): O-Net connects a number of computers to to 250.
share information or exchange data.Normally a Network Interface Card
(NIC) is used to allow the computer to connect and communicate to the C-Net to HCU Interface: Communication interface between the HCU
network. and the C-Net. It consists of two modules: INNIS11 Network Interface
Slave and INNPM12 Network Processing Module. Hardware
Redundancy is supported.

The NPM gathers data from the controller modules in its HCU and
transfer to the NIS. The NIS examines the data and transmits to the
specified destination on the C-Net. NIS also receives data sent by other
NIS in the system and sends this date to NPM for distribution to the
controller modules in the HCU.

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 Harmony System Terms Harmony System Terms

C-Net to Computer Interface(ICI): Allow computer to access C-Net for C-Net to C-Net Local Interface(IIL): The IIL provides bidirectional
data acquisition, system configuration and process control. Engineering
workstation and PPB are connected to C-NET by using ICI.The ICI communication between a central C-Net and local satellite C-Net. The
includes INICI03 and INICI12. INIIL02 Local Interface consists of two INNIS11 Network Interface Slave
modules and the INIIT03 Local Transfer Module. One of the INNIS11
The INICI03 interface consists of the INNIS11 Network Interface Module,
the INICT03A Computer Transfer Module, and the IMMPI01 modules operates on the central network side and the other operates
Multifunction Processor Interface Module. The computer connects on the satellite network side. Communication between the central
through either an RS-232-C serial link at rates up to 19.2 kilobaud or
through a SCSI parallel port at rates up to 4MBytes/sec. network and the local satellite network is through cable connection to
the NTCL01 termination unit. The maximum distance between
The INICI12 interface consists of the INNIS01 Network Interface
termination units on the two communication networks is 45.8 meters
Module and the INICT12 Computer Transfer Module. The computer
connects through the RS-232-C serial link at rates up to 19.2 kilobaud. (150 feet). The IIL supports hardware redundancy.

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 Harmony System Terms Harmony System Terms

Controlway: High speed, redundant, peer-to-peer communication link. Setpoint: A set point is the target value set for a process variable or
standard representing desired performance of the process variable.
Used to transfer information between controllers, controllers and HCU
communication interface(NPM) modules. Cnet-to-Cnet interfaces also
Process Variable: A variable that is regulated by the control strategy of
use dedicated Controlway for redundancy communication. a control device. The process cariable is also the controlled variable.

Control Output: Control output is the control system signal that

influences the operation of a final control element.
I/O Expand Bus: Also known as Slave Bus.Parallel communication bus
between the controller and its I/O slave modules. Wild Variable: A wild variable is used as a reference for a control loop.

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 Harmony System Terms Harmony Packing

Symphony System Components At a Glance

Harmony System Terms The Harmony Control Unit
Harmony Power System and Packing encloses all of the Harmony
Components
Harmony Rack I/O Harmony Applications Platform
Host for the Harmony Controller and
Harmony Rack Control & Communications Computer Communication Interface for
software applications
Engineering Tools – Composer Harmony I/O
I/O subsystem for the Harmony Controllers
Human System Interface – OperateIT Process Portal Harmony Power System
Provides power to Harmony electronics and
field devices

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 Harmony Power System

Highlights
Symphony System Components
• Multi-Voltage DC Power System Harmony System Terms
– System Power (5, +/-15, & 24VDC)
– Field Power (24, 48, & 125VDC) Harmony Power System and packing
• Versatility
– 120 & 240 VAC, 125VDC Inputs Harmony Rack I/O
– 2N & N+1 Configurations
– 15 Pre-engineered Configurations Harmony Rack Control & Communications
• High Reliability
– Load Sharing for 5 & 24V Outputs Engineering Tools – Composer
– MTBF > 400,000 Hrs
– Front Access Maintenance Human System Interface – OperateIT Process Portal

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 Harmony Rack I/O Harmony Rack I/O
At a Glance
Termination Options
• Modular to meet varying
I/O requirements
• Interface between field device
and I/O modules
• Used for A/D Conversion
• Packaging selections
and signal processing
– Low density, ring lug, 12 gauge
• Configurable fail safe output modes termination points

• Dedicated, secure, fast response – MMU Mounted Terminations

– IS Barriers
communication
– Rail mount terminations
to a single Controller pair
– Interposing relays

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 Harmony Rack I/O Harmony Rack I/O

Cnet

Network
Interface Rack Controllers

Expander Bus
64 Addresses

x-bus

•••

Process I/O

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 Harmony Rack I/O Harmony Rack I/O

Analog Input Modules Distributed Sequence of Events

I/O Capabilities Description
I/O Capabilities Description Termination Module
Module Unit
INSEM01 Records, Stores, Processes Sequence of Events Master Module
IMFEC12 • Current (4-20mA) • 15 independently NTAI05 and Manages up to 1500
• Voltage (-10 – 10VDC) configured input SOE Points
channels
INTKM02 • Synchronizes the time for • Time Keeper Master Module
inputs in HCUs • Supports IRIG-B receiver
IMASI23 • Current (4-20mA) • 16 independently NTAI06
• ±1 ms resolution
• High Level Voltage (-10 to configured input
10 VDC) channels
IMSET01 • Time Stamps Inputs • Sequence of Events Time Synch
• Programmable A/D • Synchronizes Controller Module
• Low Level Voltage (-100 to
100 millivolt DC resolution (16-24bit) with TKM • 16 input channels
• Thermocouple
• RTD IMSED01 Time Stamps Inputs • Sequence of Events Digital Module
• 16 input channels

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 Harmony Rack I/O Content

Distributed Sequence of Events Architecture

Symphony System Components
Cnet
Harmony System Terms

BRC
Harmony Power System and packing
NIS SEM TKM NIS NPM or
MFP Harmony Rack I/O
x-bus
Harmony Rack Control & Communications
SET ••• SOE
Inputs
Engineering Tools – Composer
SED
modules
Human System Interface – OperateIT Process Portal
To Next HCU

NTST01 NTST01
Sattelite
IRIG-B Time-synch
Clock Twinax Cable

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 Harmony Control and Communications Harmony Control and Communications
Redundant INFI-Net
250 x 250 Addresses
Cnet
At a Glance Overview
Network
Interface Rack Controllers
• Controller Modules ▪ Multi loop, analog, sequential, batch
and advanced control processor
– IMMFP12, BRC100
▪ Supports multiple programming
32 Addresses • Communication Modules
Redundant Controlway
environments to suit a variety of
– HCU Communications application requirements
x-bus Expander Bus

••• ▪ Backward compatible with older

64 Addresses
• INNIS11, INNPM12
– Computer Interface generation MFC and MFP
• INICI12, INICI03 Controllers
– Bridges / Gateways ▪ On-Line, “hot” replacement
• INIIL02, INIIR01 capability
allows for ease of maintenance
Process I/O ▪ “Self Boot-Up” support; non-volatile
memory
▪ Redundant Support

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 Harmony Control and Communications Harmony Control and Communications

Highlights Application Support

• Standard Function Codes
❑ Serial communication interface • User Defined
Function Codes
to intelligent devices
• “C”/Basic Languages
➢ Interfaces created in “C”
• Batch/Sequential
language and resident within Control Languages
the controller • Expert System

➢ Over 150 custom interfaces • Multi-Variable Control

Output layer
• Ladder Logic
have been created for PLC’s, fi() Hidden
wij layer
• Infi-Neural Net
weigh scales, analyzers, etc. xi Input layer

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 Harmony Control and Communications Harmony Control and Communications

Function Code –The Building Blocks for Control Configuration

Redundant INFI-Net
250 x 250 Addresses
Control Network (Cnet)
Cnet ▪ High speed, high throughput and
Network
high-security redundant highway
Interface Rack Controllers
▪ Exception Reporting System
Redundant Controlway
increases effective band width
32 Addresses and security
x-bus Expander Bus ▪ Secure communications utilizing
••• 64 Addresses
CRC and message
acknowledgment
▪ Multiple (up to 250) Cnets and/or
older generation Plantloops can
be linked via Gateways

Process I/O

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 Harmony Control and Communications Harmony Control and Communications

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 Harmony Control and Communications Harmony Control and Communications

Cnet #1
Bridges and Gateways
Network
Interface Bridge / ❑ Cnet to Cnet Remote
Gateway
– INIIR01
– Support RS-232-C
Communication
• Transceiver
Cnet #2 • Modem
Three main reasons for redundant communications (Dual • Satellite Link
Network
communication): Interface
Bridge /
Gateway
❑ Cnet to Cnet Local
– INIIL02
✓ In the case of a cable break or short
– Direct Loop to Loop
✓ Constant quality checking Communication
✓ Online configurable (adding nodes)

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 Harmony Control and Communications Content

Symphony System Components

Harmony System Terms
Harmony Power System and packing
Harmony Rack I/O
Harmony Rack Control & Communications
Engineering Tools – Composer
Human System Interface – OperateIT Process Portal

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 Engineering Tools – Composer Engineering Tools – Composer
Performer Series
Information Processing Domain
Overview
• System Engineering
Database Maintenance
Composer Series
Process Portal Series Control Strategy
Human-System Interface Operations Network System Engineering, Operation
and Maintenance Tools Process Graphics
• Documentation Control
Cabinet Arrangements
External Connection Drawings
• Maintenance Tools
Control Network Wiring Diagrams
Harmony Series
Signal and Logic
Troubleshooting
Processing Domain
Field Network
• Developed for Windows NT/2000
Integration with other popular PC
based application tools

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 Engineering Tools – Composer Engineering Tools – Composer
Composer Clients
Composer Clients
•On-line Control Monitoring ▪ Client/Server architecture ▪ All clients need
•On-line Configuration Changes
•On-line Control Monitoring
•Interface to Configuration ▪ Multiple clients to single •On-line Configuration Changes connection to the
Server
server provides a multi- •Interface to Configuration Server configuration server
user engineering ▪ Via Operations Network
environment
Composer Server
▪ Phone modem, RS-232,
Configuration
Server
Composer Server ▪ Supports multiple users Modem
RS-232 Configuration
or Internet
working on the same Internet Server ▪ Connection to
Communication configuration server communication server
Server ICI ICI
▪ Provides a single database provides on-line
C-Net and library for project functions
configurations ▪ Direct connect via CIU
Coupler
Harmony ▪ Supports sharing of Configuration

Control Unit Harmony Server

▪ Through configuration
communication server Control Unit
Communication
Server server via operations
network
Typical Composer Architectures Typical Composer Architectures

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 Engineering Tools – Composer Engineering Tools – Composer

Integrated Explorer Integrated

Explorer…System
▪ User interface
Window
patterned after
Microsoft Explorer Document View
▪ Provides navigation and of Module
•Displays all
total view of
Logic
configuration server Documents
▪ Integrates controllers Associated with
and HSI system Controller
resources into a single Document View of
application Module with
Imported
▪ Double clicking on Documents
System Window
•System window displays
objects launches •WORD & Excel
Output Window
all system resources and •Advises user of appropriate editor Documents are
configurations operations performed Associated with
Controller

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 Engineering Tools – Composer Engineering Tools – Composer

Integrated Explorer…Document View Integrated Explorer…Module Tag

with Imported Documents View
• Documents of other applications Tag view shows all tags
can be imported to the associated with selected
configuration server system resource (in this
– Cabinet arrangements case module 30)
– P&ID’s Tags can be fully edited from
– System wiring diagrams
this view
– Web links
Tag icon displays tag
• Documents that are imported properties for editing from a
become associated with the window menu view
system project, double click to
view and edit

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 Engineering Tools – Composer Engineering Tools – Composer

Integrated Explorer…Module Integrated Explorer…Console

Tag View Document View

All graphic displays associated

Tag to logic document with HSI are shown
navigation Supports Process Portal and
Navigate directly from tag other types of consoles
view in Explorer to
Double click on graphic display
function code on logic
document in Automation
to launch appropriate editor
Architect

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 Engineering Tools – Composer Engineering Tools – Composer
Object Exchange Object Exchange
Library of reusable “control” components
and for the entire configuration server Edit directly from the library
Library consists of two areas: Objects in library support double
System folders includes components supplied click to launch appropriate editor
with the product
User folders contain project specific
components
User defined organization
“Drag and Drop” into Automation
Architect or system window

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 Engineering Tools – Composer Engineering Tools – Composer
Output Window Automation Architect
Displays status Function code
information resulting configuration for
from program compiling, control applications
loading, and conversion Logic documents provide
operations grouping for function
Displays controller status code logic
information
Compilation errors can be
used to navigate directly
to the error source
Object Exchange Library
Control Logic Document

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45
 Engineering Tools – Composer Engineering Tools – Composer

Human System Interface Process

Automation Architect
Portal Display Editor
Monitor and Tune Mode
Off-line editing of displays
▪ Logic documents can
display operating values Tight integration of Composer
directly from controllers and Process Portal permits
▪ Function codes can be use of GraphX in either
tuned directly from logic product
documents
▪ Tuning changes
automatically
synchronized between
Document Displays Runtime Values
controller and
Directly From the Controller configuration server

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46
 Engineering Tools – Composer Content

International Language Support

Symphony System Components
Harmony System Terms
Harmony Power System and packing
Harmony Rack I/O
Harmony Rack Control & Communications
Engineering Tools – Composer
Human System Interface – OperateIT Process Portal

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47
 Human System Interface – Process Portal Human System Interface – Process Portal
Performer Series
Information Processing Domain
Enterprise Automation Process Portal
Unified Enterprise Information Window Management
Scalable Solutions Process Graphics
Composer Series Interoperability Alarm Manager
Operate IT Process Portal Series Operations Network System Engineering, Operation True Openness Trends
Human-System Interface and Maintenance Tools
Engineering Efficiency Historian
Evolution Without Obsolescence Reports
Controller Integration

Control Network
Harmony Series
Signal and Logic
Processing Domain
Field Network

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48
 Human System Interface – Process Portal Human System Interface – Process Portal

Planning & IT
Scheduling Design Cornerstone for Industrial
Business
Plant Systems
Engineering

Opera
Asset
Lifecycle
tions

Asset
Management
Multiple Aspects Design

Maintenance

Production
Operations

The Aspect ObjectTM Approach

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49
 Human System Interface – Process Portal Human System Interface – Process Portal
“ ...one integrated thing that Aspects
Production order
Simulation hides all the differences"
Product
Functional Production
Control
specification
Description schedule IFS Graphics
Process
Real ABB Operator Interaction
Object Object
Maintenance
Operator record
interaction
Operator
Stockof
Cost Operator
interaction
Control
report
operation Graphics Control Builder
MS Word
Control
Data sheet

Simulation
ElMaster Model
iGES
Quality Production
Production
Quality
report report
report Simulation
Electrical Model
diagram
report

MS Excel
AutoCad
P&I Diagram
Profile
P&ILoop
Diagram
spec
dataMaintenance Record Aspect
Systems
Information Integration

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 Human System Interface – Process Portal Human System Interface – Process Portal

Immediate and consistent Scalable Solutions Very Large

system-wide access to
Modular design
all relevant information System size
about plant entities from Tag quantity
any context Functionality Large
Products & options
Default Aspects Number of workplaces
- Faceplate - Help Expand workplaces as
- Trend - Parameters needed
- Group - Documentation Performance
- Section Display - Point Display Split Servers Medium
- Overview Display
Benefits
Extended Aspects Incremental Capital Investment
Facilitates Asset Optimization Invest in exactly what you need
Flexible Expansion Small
Integration of 3rd party
Software

Very Small
Intuitive Navigation

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 Human System Interface – Process Portal Human System Interface – Process Portal

Efficient Engineering
Standards Based Solutions
Selected views of
True Openness based on information
standard technology arranged by
Windows 2000 Area
Internet Explorer Unit
SQL Server Equipment
ActiveX Controls Object Type
OPC - OLE for Process Control Object Template
Microsoft Component Object Plant Explorer
Model (COM) Operation
Configuration

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 Human System Interface – Process Portal Human System Interface – Process Portal

Window Management

Standard MS Windows is optimized

for MS Office use
Many open windows at once
All shown at the same priority

Windows Tailored for Process

Automation Needs
Safe Area
Stacking Order
Pinning of Windows
History List

Safe Area

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 Human System Interface – Process Portal Human System Interface – Process Portal

Window Management – Stacking Order Personalized Interface

Windows 2000 Process Portal Personalize your
Last window called up is always Each type of display has a
on top priority that controls its environment
If you click on a window it comes stacking order Window Layout and
to the top E.g. Faceplate is always
on top of trend displays
Content
Filtered Information Theresa
Favorites
Profiles for each user/user
groups
Increased Operator
Familiarity
Reduced Operator Errors
Paul
Reduced Training Costs

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54
 Human System Interface – Process Portal Human System Interface – Process Portal

Multi Monitor Support

User Enhanced Interface
Operation with
Single Monitor
True Client-Server
Dual Monitors
You can access all
Up to (4) Monitors
information from each
client Monitor Arrangement
Individual Event Bar on all
Web Enabled monitors
Enabled for Auxiliary
Defaults for Up to 4 Windows on
Clients each Monitor
Internet Explorer + plug-
Move the cursor from one Screen
ins to the other
Microsoft Internet Explorer Home

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55
 Human System Interface – Process Portal Human System Interface – Process Portal

Security in Process Portal

Secure Access
Windows 2000 Security Standard Windows 2000
Flexible security based on Logon is Used
Process Portal Security
Who you are Windows 2000 Logon Information
Enter a User name and a Password that is PC / Network Administration
Where you are valid for this System

User name
What you are accessing Password Printer / Hard Disk access
OK Cancel Help
Ensures that only authorized personnel
Internet / Intranet access rights
have read/write access
From the complete plant, to Process Portal Security
process areas, down to
settings on your control loops Acknowledge Event Tuning Control Extends the access rights
Straight forward configuration and Disable Event Setpoint Control
Read, Write, Operate,
administration Online Configuration Reset Acknowledge,..
Based on standard Windows Offline Configuration Override Mode Industrial IT Objects
security and user groups Access Lock Control ...
per Tag, Object, Tag.Atom

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 Human System Interface – Process Portal Human System Interface – Process Portal

Security in Process Portal Flexible Process Graphics

ActiveX Controls 2D & 3D Graphics Process Graphics
Rights Groups User
User Users Attain the Sum of Their
Operation Access Rights
Area A User 1
User Security Group Definition
Group
Tuning 2 Plant Area A
Area A A User Plant Area B
Animated Gifs
3 Remote User
Maintenance
User
Operation Supervisors
Area B User 4 Administrators
User Others (No Hard Limit)
Group
Tuning 5 Operator Allocation
Area B B User Live Video
To User Groups Scanned Images/Photo
6 To User Rights
Operator Default Settings
Operation
Area A+B
Remote User
User 7
Configurati
on
Area A+B

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 Human System Interface – Process Portal Human System Interface – Process Portal

Abnormal Situation Handling –Information & Navigation

Advanced Alarm Management
Lists/Pages
Operators always have access
to the latest status
information
Alarm Manager features Instructions on what do to
Filtering
Sorting
Wav-Sound
User defined comments Alarm Sequence Bar
Unlimited filters and lists
Support of System Events and
Process Alarms Alarm Band Alarm comments
Time Stamped at Controller
or I/O
Time Stamp Displayed
Down to 1 ms

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58
 Human System Interface – Process Portal Human System Interface – Process Portal

Integrated Historian Comprehensive Historian

Key Features Key Benefits
3rd party
Long time storage of data Standard OLE DB Interfaces
Sequence Of Events (SOE) Applications Universal Data Integration
for access to Increased Data Integrity
Redundancy Supported
Event Reduce System Cost
records of your production Data Compression Reports
Page Fast Data Access
raw data for optimization SQL based Historian
error search Trend Data:
Avg. Trends
Exception based collection Max.
saves hard disk space Min.
Report Data Archive 1h
Any tag variable can be System Availability
Historian
1 day
1 week
Automatic Archival
collected 1 month e.g. compressed data
1 year
Unlimited user defined
collection profiles
Events Data
Compression
Real Time Data

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 Human System Interface – Process Portal Human System Interface – Process Portal

Trends X - Y Plot Diagrams

Seamless integration
For example,
between historian and run
Compare Pressure
time data
and Temperature
Easy to add new traces on
For Surge Control of
the fly with independent
on/off
pumps and
Time and Engineering Unit
turbines
Scaling On-Line Bitmap of the pump
Time Scroll with Scale specific diagram
Compression and can be integrated
Expansion
Pan and Zoom

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60
 Human System Interface – Process Portal Human System Interface – Process Portal

Reports
Integrated Information
A single window to plant information
Spreadsheet Reports – all information at your fingertips
On-Line Reports at Process
Portal B PCs System architecture assures integration
Full Array of Graphic Charts Efficient Engineering
Bi-directional Access to all One time data entry
Tag Data Easy Re-use
Hardcopy Report Generation Automated Object Creation
Flexibility (on-line changes, one-time entry of data)
Open Communication
Uses standard systems and commodity components
Highly Scalable
Suits all applications – large and small
Optimum solution in all situations
Scalable from 50 to 60000 tags

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61
 Human System Interface – Process Portal

Unrivalled Scope
Integrated products/systems
A user interface for Industrial IT enabled
products

Part 3
Complete HSI-functionality
Workplace, Process
Graphics, Alarm & Event
Manager, Trends, Historian DCS of Yokogawa for Thermal Power Plant
Ease of Use
Windows-based environment
Powerful navigation
Customized workplace; Layout, security,
information

6/18/2024 [email protected] 124

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62
 Content System Architecture of DCS

Plant Ethernet
❑ What are the main issues for DCS, how do they relate
Operator
to Power Station Control Station

❑ The DCS is the source of all information on a Power V net

Station, it is the cement holding the bricks together Engineering Historian/

Field Control Workstation Performance
Station
❑ As it is the centre, it must be the most reliable
Local
I/O Nodes
component of the Power Station

Remote
I/O Nodes

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63
 Centum CS3000 Remote I/O Capability Field - Input/Output capabilities

ER BUS
Dual redundant
• Full isolation available
10 Mb/s (channel to channel and
185 m max (10 base 2) system to field)
2 km with fibre optics
• On line replacement
• No disturbance of cabling
• Full dual redundancy if
required
Remote I/O racks
I/O modules single or dual redundant
Dual redundant coupling to ER bus
8 Slots for I/O modules
8 Racks per FCS

127 128

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64
 Key Issues: System Components Redundancy in the Field Control Station

Dual CPU Cards

• Redundancy Dual Power
Supplies

– System Hardware
Dual V net
– Field Devices

– Interface to Historical Data

• Communication
• Integration of third party systems
– Fieldbus: Foundation Fieldbus and Profibus
Dual RIO Bus Dual Fans

– PLC’s
129 130

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65
 Redundancy in the Field Control Station Redundancy in the Field I/O System

1. Redundant Configuration
• Pair and spare technology • Remote I/O Bus : Redundant
• I/O Power Supply Unit : Redundant
• Active redundancy • I/O Node Back Plane Bus : Redundant
• No interruption to control • I/O Card (All Types) : Redundant (Option)
2. Operation Environment
• Guarantees no break • Zone2 / Class 1 Div 2 Compliant
during CPU changeover • Temperature from -20 to 70 degC (Option)
• Corrosion Gas Resistant G3 (Option)
• On-line replacement

• Extremely high reliability -

most systems have
NEVER had a failure!

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66
 Centum CS3000 Data Highway Interface to Third Party Systems: Fieldbus

FIO Bus
V-net data highway
• Dual redundant ALF111

• Cyclic alternating SB40 SB40

Ethernet 1 1
redundancy IOM IOM IOM IOM IOM IOM or or PSU PSU
EB50 EB50
• 10 Mbaud, deterministic 1 1

token passing protocol

• Cannot overload, even
V-net
during major plant upset Redundant Configuration
Available
• On-line expansion is
Field
possible Devices ALF111 Specifications (FF-H1)
No. of Segments No. of Points
4 Segments / ALF111 - 48 Points / Segments
ooo

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67
 Key Issues: Information Display and Access CS3000 Operation and Monitoring

– Alarms • Human Interface Station

(HIS)
– Trending: open access to all devices (on-line)
• Fully independent MMI
– Fast Display Time: 1-2 seconds guaranteed (multiple redundancy)
• 1 sec response
– Smart Graphics: Trends and Alarms embedded
• Large capacity
– System Fault Diagnosis (over 100,000 tags)
• Operator friendly
– Process Fault Diagnosis

– Management Information (OPC)

– Remote Display using Web Technology

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68
 Centum CS3000 Operator Keyboard Operator Windows

User friendly purpose-designed keyboard option

• Operator Guide Window
• 40 Message / HIS

• Process Alarm Window

• 200 Alarm / HIS

• Process Report Window

• Tag Report
• I/O Report
137 138

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69
 139 140

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70
 141 142

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71
 Process Diagnostic Displays

⚫ Access to Dynamic Control Drawing

⚫ Internal Database in builder finds the
master drawing for the tag displayed, EWS Dynamic Display

without searching.
Control Drawings

Alarm Status of Tag

PV of Tag

Condition True
Tuning Display shows:
Conditions
⚫ Tuning Trend Logic Charts
Logic Actions
⚫ Tag attributes and settings

⚫ Access to Dynamic Control Drawing

Condition False

143 144

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72
 145 146

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73
 Hardware Diagnostic Displays Design Manual 1
P&ID of Process Area or
Function
• System display shows status of every module
LP DRUM LEVEL SETPOINT

LP DRUM LEVEL SIGNAL

• Operators can identify problems I

HS
L010
ENABLE VALVE
TO OPEN

• All modules can be replaced on-line

ENABLE VALVE
TO OPEN HS
M010

ISOLATION VALVE ENABLE LOGIC

I
-GAS TURBINE IN START
- DIVERTER DAMPER NOT FULLY
CLOSED (IF EQUIPPED)

ISOLATION VALVE CLOSE LOGIC

-LP STEAM TURBINE IN ADMISSION

PRESSURE CONTROL s
VENT A/S ZI ZI
ZI
O C
O
M
ZS
P O
ZS O
ZSC
O S
FROM HRSG LP DRUM
TO BLOWDOWN SYSTEM
(EVAPORATOR)
MOV-010 LCV-010
LP BLOWDOWN
ISOLATION LP START-UP BLOWDOWN
LEVEL CONTROL

TITLE
LP BLOWDOWN CONTROL REVISIONS
(START-UP) NO.
DAT
E
DESCRIPTIO
N

DATE SCAL
ORIGINAL E

Aug. 2000 N/A

0 8/00 Original
LATEST CHECKE DRAW
JOB NO.
REVISION D N

Rev. 0 DM:9 JK JF

147 148

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74
Design Manual 2
Centum CS3000 Testing
What is in the Design Manual? Where can it be used?

• Virtual test function

HMI Standards • Debug without FCS
Control Design • Full simulation
Design • Complete operation
Methodology
HMI Design
without FCS hardware
Control
PC
Standards Operation • Target test function
Manual
• Debug using FCS
ETHERNET
Interface
Standards
Project • Can “close” control loops HIS
Documentation
to provide realistic
operation for testing
Auto Sequence
V-net
Philosophy
PFCS
149 150

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75
 Remote monitoring and support Solutions for an Integrated Power Solution

Long Term System Support

Yes
Maintenance Level

CS 3000 Management Performance Simulation Management

Yes
Reporting System Monitoring System Training Systems Level

Operator Engineering
Operation

Yes
Interface Builder Level

▪ Network communication through modem connection

Control
▪ Access plant status over public communication Boiler

Yes
Turbine/Generator Auxiliary Plant Level
Controls
Controls Controls
▪ Engineering support
▪ On-line remote diagnostics
Emerging Field/Plant
▪ Web-based graphic window display Measuring Control

Yes
Technology Level
Devices Elements/MCC
“Fieldbus”

151 152

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76
 Thank you for your attention!

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77