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Understanding the Basic Architecture of DCS Systems

Learn about the system elements, internal structure, I/O devices, communication interfaces, and hierarchical structure of DCS systems at Nirma University. Dive into field control stations, intermediate stations, central computer stations, and more.

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Understanding the Basic Architecture of DCS Systems

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  1. System Architecture Nirma University

  2. Basic Architecture of DCS Nirma University

  3. SYSTEM ELEMENTS Nirma University

  4. DCS system element • Basic element of DCS are • Field control station • Intermediate station • Central computer station • Monitoring and control facilities element • Data communication link Nirma University

  5. Field control station Nirma University

  6. Filed control unit • Lowest level of DCS • It consist a few ( 1 or 8 or 32 ) measuring points or control loop • The primary function of field control unit is to • Collect and pre process analog and digital signals • Monitor and log the alarming message • Perform open loop and close loop control functions Nirma University

  7. BUS oriented Internal structure of MICON P-200 (VDO) RAM (10K) Back up data transfer PROM (24K) Vertical Data Transfer Lateral Data Transfer Nirma University Microprocessor Internal BUS Analog Inputs (AI) Display and Command Digital Inputs (DI) Analog Output (AO) Digital Output (DO)

  8. Internal structure of filed station Nirma University

  9. Filed control unit- I/O Devices • Its consists the process interface , a separate serial bus so that input output communication capacity of the station increase • The second bus used for interconnection between neighboring station. • Analog input: • Input current: 0-20ma, 4-20ma • Input voltage: 0-5v,1-5v,0-10v • Thermo elements: 0-25mv, 0-50mv, -10 to +10 v • Resolution: 8-12 bits Nirma University

  10. Filed control unit- I/O Devices Analog outputs: • output voltage: 0-5v,1-5v,0-10v • output current: 4-20ma, 0-20ma Binary input : • Input current: 0/10ma, 0/100ma, 0/200ma • Input voltage: 0/24V Binary output : • output current: 0/10ma, 0/100ma, 0/200ma • output voltage: 0/24V Nirma University

  11. Filed control unit- I/O Devices • Total number of analog input and output per field station is 4, 8, 16, 48 or 64. • RS-3 and TDC 3000 DCS system :- 128 • MOD 300, AS 215 DCS system :- 256 • AS 220, As 230, ASEA master :- 1024 • BINARY input output per station: • WDPF,CENTUM ,ASEA MASTER, NETWORK 90: 512 • AS 230 : 4096 • TIMER , COUNTER , MOTOR CONTROL, STEPPER , POSTION , PULSE CONTROL Nirma University

  12. Filed control unit- Communication Interface • TDC 3000- RS232 • P 4000, RS-3 and WDPF – RS422 • A 500, PROCONTROL 1 – RS 485 • Network 90 , PLS 80- IEEE 488 • A 500- Bit bus • ASEA Master , PLS 80, MICON- MODBUS • ASEA master , MOD 300- MAP/Ethernet Nirma University

  13. Intermediate stations • The intermediate functional system units which are placed in between the lowest and the highest hierarchical levels are known as group or supervisory stations. • The stations are the autonomous systems elements with the restricted domain of influence to a group of field stations, pertaining to a closed, well defined, and relatively autonomous part of the plant. • The most common functions of the intermediate stations are • State observation of the process variables • Calculation of reference values for control loops at “ lowest ‟ level (SV & PV) • Tracking of order processing and material and energy balances • Efficiency analysis and Reporting • Data exchange with “higher” level stations (central station) Nirma University

  14. Intermediate stations Nirma University

  15. Central Computer Station • Central computer station enables centralized plant monitoring, direct operation on plant instrumentation, and offers important program generation and system diagnostics services. • The stations connected to other system through the system bus which can initiate the necessary data transfers. • Central computer station also called process operator console • Its consist the display unit for plant monitoring and keypad for plant control • Functions of the central computer control can be classified as • Plant oriented • General application Nirma University

  16. Central Computer Station • Plant oriented • Process display and control • Data collection and retrieval • Inter level communications • System diagnosis • General application • Program generation and test • Scientific and commercial calculations • System simulations Nirma University

  17. Monitoring and Command Facilities • Screen Partition • Message area • Overview area • Main display area • Operator’s instruction area Nirma University

  18. Hierarchical Structure of Monitoring Nirma University

  19. Overview Area Nirma University

  20. Bar Representation Nirma University

  21. Group Display Nirma University

  22. Control Loop Display Nirma University

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  24. YOKOGAVA Centum CS 3000 Nirma University

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  26. Human Interface Station (HIS) • The HIS is mainly used for operation and monitoring – it displays process variables, control parameters, and alarms necessary for users to quickly grasp the operating status of the plant. • It also incorporates open interfaces so that supervisory computers can access trend data, messages, and process data. • Console Type HIS • This is a new console type human interface station, at which a general purpose PC is installed. • There are two types of console type HISs: • Enclosed display style: usual style appearance • Open display style: selectable configurations • Desktop Type HIS • This HIS uses a general purpose PC Nirma University

  27. Enclosed display style Nirma University

  28. Open display style Nirma University

  29. Field Control Station (FCS) • FCS for FIO • This FCS uses the Fieldnetwork I/O (FIO) modules, which are compact and consist of various lineup such as the connector types and so forth. • According to the application capacity, there are the standard model and the enhanced model. • Compact FCS for FIO • This is a compact FCS with I/O modules integrated into the Field Control Unit. • FCS for RIO • This FCS uses the Remote I/O (RIO) modules, which have many installation bases and M4 screw terminals to connect signal cables. • According to the application capacity, there are the standard model and the enhanced model. • Compact FCS for RIO • This controller is usually installed near the equipment or process it controls, and is ideal for communicating with subsystems. Nirma University

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  31. Compact FCS for FIO Nirma University

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  34. Engineering PC (ENG) • This is the PC with engineering functions used to perform CENTUM CS 3000 system generation and maintenance management. • It can be the same type of general-purpose PC as the HIS, and can even be the same PC as the HIS. • By having HIS operation and monitoring functions on the same PC, you can use the test (control station emulation) functions to provide an efficient and easy-to-use engineering environment. Nirma University

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  49. Other Major Components • Bus Converter (BCV) • This links the V net system bus to another CENTUM CS 3000 domain or to an existing CENTUM or µXL system. • Communications Gateway Unit (CGW) • This links the V net control system bus to an Ethernet bus (to a supervisory computer system or general purpose personal computer). • By CGW wide area communication function, you can also link two CENTUM CS 3000 V nets in different places using a dedicated telephone line. • Migrated Field Control Station (RFCS2) • You can leave the I/O cards and field wiring of a CENTUM-XL or CENTUM V system “as is”, and replace the CPU nest with an KFCS, which can be connected to the V net just like a CENTUM CS 3000 system FCS. • SI bus is used as a (dual-redundant) bus connecting existing FCS I/O units to new FCS CPU. Nirma University

  50. Other Major Components • Advanced Process Control Station (APCS) • The Advanced Process Control Station (APCS) is a personal computer (PC) connected to the V net and applied to advanced process control and efficiency improvement. • Generic Subsystem Gateway Package (GSGW) • GSGW is a PC connected to V net. It uses OPC servers for subsystems, facilitating subsystem data acquisition and setting without creating specific communications programs. • Exaopc • This provides OPC Server functions to enable applications in a supervisory PC to access CENTUM CS 3000 data. It provides a link between control layer and business data processing layer. Nirma University

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