MATCH DCS Operator Training

Emerson DeltaV System Overview

EVONIK Degussa Specialty Chemicals (Shanghai) Co. Ltd. MATCH Plant Engineering

Objective of this Training

This training just supply a simple introduction for Emerson DeltaV System based on the MATCH project. Base on the Degussa DCHI standard, include the basic knowledge of DeltaV system and related operation of MATCH control system. At the end of training, customer shall be able to operate the DeltaV operator interface

MATCH Plant Engineering

System Overview
DeltaV Simple System Architecture

MATCH Plant Engineering

System Overview
System Network Overview Introduce a basic DeltaV control system Control Network components.
DeltaV Workstation A personal computer, running the Windows XP operating system, connected to the DeltaV Control Network. Used for engineering control strategies, operating the process and diagnostics of the DeltaV system on-line. DeltaV Controller The DeltaV system computer running the program which controls the process equipment. It also communicates the process data to the operator. Input/Output Subsystem Consist of the I/O cards and terminal blocks used to interface to the field devices such as motors, valves, transmitters, etc.

MATCH Plant Engineering

System Overview
DeltaV System Workstation
The DeltaV software, installed on each workstation, has various installation options that define the workstations functionality. The workstation will be one of the following types: Operator Station Provides operator interface capabilities. Professional PLUS Station Used to configure, operate and diagnose the system and contains the system database. Only one workstation will be a Professional PLUS. Application Station Integrates the DeltaV system into the plant LAN. Also used to support the Continuous Historian, Batch Historian, and Batch Executive products.

The DeltaV Workstation uses Microsoft Windows XP as its operating system software.
MATCH Plant Engineering

MATCH Control System Overview

MATCH Control System is a big system. In this system have following element:
1 Professional PLUS. 2 application stations. AMS,Historian/AS01, PIMS/AS02 3 operator stations/BPHT, 3 controllers/BPH, 2 controllers/TF, 1 SIS/TF. 3 operator stations/PMMA, 2 controllers/PMMA,2 controllers/TMR,1 SIS/PMMA. 6 operator stations/MMA, 5 controllers/MMA,2 controllers/MTBE, 1 controller/INFRA. 2 operator stations/MUSC, 1 controller/MUSC.

MATCH Plant Engineering

DeltaV Operation
Button Toolbar

Working Area

Alarm Banner
MATCH Plant Engineering

DeltaV Operation
Operation Overview
Toolbar Contains buttons for quick access to frequently used applications or additional functionality within DeltaV Operate. Working Area A graphic representation of the plant and its current operating data. The data is automatically updated to show current process values Alarm Banner Displaying, from left to right, the five highest ranked alarms. It dynamically changes as new alarms become active or as existing alarms change state.

MATCH Plant Engineering

Toolbar Description

MATCH Plant Engineering

Alarm Banner Description

MATCH Plant Engineering

DeltaV Operation
Dynamos
As you develop a system of operator pictures, you may need to use an object (such as a pipe, pump, or valve) in more than one picture. You can save such custom built objects as reusable graphics.

Pop-up windows
Pop-up windows provide additional operating information and detailed parameters. The pop-up windows shown above are: Faceplate Provides you with the operating parameters for a control module. Depending on the type of control module the operating parameters displayed will vary. Detail Window Provides you with the parameters for a control module which may be tuned, including alarm trip points, control loop gain, reset and rate. These parameters may be changed based on your assigned security level.

MATCH DCS Faceplate and Detail Windows introductions

MATCH Plant Engineering

DCHI - AI Dynamos
Tag name Process Value Engineering Unit

Module state Normal State Active warning Active critical

Alarm inactive and not acknowledge

Static Display

Blinking State 1

Blinking State 2

IO-Failure

MATCH Plant Engineering

DCHI - DI Dynamos
Tag name Alarm Text Indication

Module state Normal State Active critical

Alarm inactive and not acknowledge

Static Display

Blinking State 1

Blinking State 2

IO-Failure

MATCH Plant Engineering

DCHI - ON/OFF Valve Dynamos

FC valve Module state Static Display FO valve Blinking State 1 Blinking State 2

Valve Closed Valve Opened Valve in MAN mode, Interlock not active Valve in AUTO mode, Interlock active Undefined state: close and open feedback of valve are wrong, so displaying Valve Failure IO-Failure
MATCH Plant Engineering

DCHI - PID Controller Dynamos

PID controller output indication Data Entry window

PID controller set point indication

PID controller mode indication Mode type Selected window

PID controller PV indication

Engineering Unit

MATCH Plant Engineering

DCHI - PID Controller Dynamos

Module state PID controller in MAN mode PID controller in AUTO mode PID controller in CAS mode PID controller in IMAN mode PID controller Interlock active Active Critical alarm IO-Failure Static Display Blinking State 1 Blinking State 2

MATCH Plant Engineering

DCHI - Control Valve Dynamos

FC valve Module state Valve Closed, in MAN mode ,Interlock active Valve Opened, in MAN mode, Interlock not active Valve in AUTO mode, Interlock not active IO-Failure FO valve Blinking State 1 Blinking State 2

Static Display

MATCH Plant Engineering

DCHI - SIMOCODE Dynamos

Module state Motor OFF Motor permitted Motor ON Motor in MAN mode, Interlock not active
Motor local OFF

Static Display

Blinking State 1

Blinking State 2

Motor in AUTO mode, Interlock active. State not acknowledge Electrical Failure

IO-Failure
MATCH Plant Engineering

DCHI - VFD Dynamos

Module state Motor OFF Motor permitted Motor ON Motor in MAN mode, Interlock not active
Motor local OFF

Static Display

Blinking State 1

Blinking State 2

Motor in AUTO mode, Interlock active, State not acknowledge Electrical Failure

IO-Failure
MATCH Plant Engineering

DCHI SIS Dynamos

Related to SIS Dynamos
This pressure transmitter first go to SIS system, then display on DCS. Alarm not active. This level switch first go to SIS system, then display on DCS. alarm active.

This ON/OFF is related to SIS system, when SIS instrument alarm active, valve will be cut instrument air. . This ON/OFF is related to SIS system, when SIS instrument alarm not active again. Click Reset button, like this operator can open valve again.

Reset button

SIS symbol

MATCH Plant Engineering

General Elements on Faceplate

Position button: Display this faceplate in other monitor Push pin: Fix this faceplate at current position on the monitor Close the faceplate Open detail window Open Primary control picture Open Interlock module Open control module Open process history view Acknowledge Alarm Display activated Interlock status

MATCH Plant Engineering

Alarm state on Faceplate

Low Alarm WARNING active High Alarm WARNING not active Deviation Alarm Currently being disable Inactive Switch &Alarm and not acknowledge

Interlock CRITICAL active Low Switch Point CRITICAL active High Switch Point CRITICAL not active

Interlock CRITICAL not active

High Alarm Currently being disable

MATCH Plant Engineering

AI Faceplate with 4 Alarm

Tag name Tag Description Range High Scale Process Value

IO-Failure Alarm or Trip Point Engineering Unit Range Low Scale Disable Low Switch Value

PV bar Enable High Alarm

Push Pin: This window does not close if you open another window of the same type.
MATCH Plant Engineering

AI Detail with 4 Alarm

Alarm or Trip value

Enable Alarm or Trip

Enable simulate

Diagnostics information IO-Failure

MATCH Plant Engineering

AI Faceplate and Detail with 8 Alarm

MATCH Plant Engineering

ON/OFF Valve Faceplate

Close Button

Open Button Valve default state when in auto mode

Mode Buttons

Reset FA Button, Supervisor have right . Alarm Indication

Device Status Fail Alarm

Device State: Records the current state of the DC_STATE parameter in the Device Control block . Fail Alarm :Records the current state of the FAIL parameter in the Device Control block.
MATCH Plant Engineering

ON/OFF Valve Detail

Reset First out Arrow Bypass Interlock

First out Arrow Interlock description Interlock not active

MATCH Plant Engineering

DI Faceplate and Detail

Normal state

Active Alarm Inactive Alarm IO-Failure

MATCH Plant Engineering

Other Type Faceplate and Detail

MATCH Plant Engineering

PID Faceplate
SP entry High SP limit Mode buttons Actual Mode SP slew keys Output slew keys Low SP limit PV

FO valve Indication

SP bar PV bar

High Output limit

Low Output limit

Output slider

SP slider

FC valve Indication

Output entry

Output bar
MATCH Plant Engineering

PID Detail

P.I.D parameter

DeltaV Tune button

MATCH Plant Engineering

SIMOC Motor Faceplate

OFF button Permit button Start button

Motor Current Indication

Reset FA Failure (usernames that are higher than supervisor have operation right to this button)
MATCH Plant Engineering

SIMOCODE Motor Detail

Reset SIMOCODE Failure button

SIMOCODE communication Address mapping

MATCH Plant Engineering

Note: Operator have operation right to Reset SIMOCODE Button. Please dont high frequency click this button, otherwise will make some trouble to you.

VFD Faceplate

Communication break
MATCH Plant Engineering

VFD Detail

Reset VFD Fail button

VFD communication Address mapping

MATCH Plant Engineering

Totalizer Faceplate

Set point value For Target Accumulated Value PV Indication

Actual status

Reset Accumulated value button

MATCH Plant Engineering

Pause Accumulating button

Start to accumulate button

Totalizer Detail

Ramp mode ON Ramp OFF button

Dosing control Curve

MATCH Plant Engineering

Normally Open ON/OFF Valve

Ensure have no active interlock conditions; Ensure instrument air is ok; Ensure FA Alarm clear and Reset button disappear on Faceplate; Ensure operating mode in MAN, so operator can open valve from DCS Faceplate.

MATCH Plant Engineering

Normally Start SIMOCODE and VFD

Ensure have no active interlock conditions; Ensure device already powered on; Ensure have no profibus failure; Ensure have no SIMOCODE &VFD failure; Ensure local switch in Release position; Ensure FA alarm clear and Reset button disappear on Faceplate; Ensure operating mode in MAN, so operator can start pump from DCS Faceplate.
MATCH Plant Engineering

View Process Alarms

The Alarm List picture, displayed by clicking the Alarm List button , lists up to 250 alarms. This allows you to view alarms that are not visible on the alarm banner.
Alarm List button

Inactive critical alarm

MATCH Plant Engineering

Alarms List
Alarms are ranked in order based on the following four criteria:
Most Unacknowledged alarms More important than acknowledged alarms. Important Alarm with equal acknowledgment status Active alarms are more important than inactive alarms. Alarms with equal acknowledgement status and active status Alarms with higher priority have the greatest importance. Alarms with equal acknowledgement status, active status and priority Newer alarms (i.e., alarms with more recent time stamps) are more Least Important important.

Note: Alarms are displayed on the Alarm Banner left to right based on the same criteria.

DeltaV Alarm Priority: Critical

Warning

Advisory

Log

MATCH Plant Engineering

Alarm Filtering
Alarms on the list may be filtered by plant area using the Area Filter button on the Main toolbar.
Area Filter button

Plant Area Alarm Disable

Alarm List Access button

MATCH Plant Engineering

Alarm Filtering
The Area Filter picture displays a summary of active, unacknowledged and suppressed alarms by plant area. By selecting a plant area the alarms for that particular plant area are listed in the lower portion of the window. The Area Filter picture also provides the ability to disable alarms by plant area for personnel with the appropriate security privilege.

MATCH Plant Engineering

Alarm Sorting
In addition to filtering, the Alarm List can be sorted by module, time of occurrence, or time of last state change by clicking the appropriate button as shown below. By default, alarms are sorted in the same ranked order as the Alarm Banner.

Sort by Alarm ID Sort by Time of occurrence

Sort like Alarm Banner Sort by Time of Last State Change

MATCH Plant Engineering

Process History View

Process History View allows you to view process data trends and events in the same application.

Chart

Events

MATCH Plant Engineering

Launching Process History View

Launching Process History View from on the DeltaV Operates Toolbar or faceplate will initially display only Events by default.

MATCH Plant Engineering

Event Filter Setting

MATCH Plant Engineering

Charts Configuration

MATCH Plant Engineering

Setting Time Scale of Configure Chart

MATCH Plant Engineering

Add Trend
Additional trends can be added by pressing the Add Trend button shown above. These added trends can not be saved if the chart was opened from a faceplate.

MATCH Plant Engineering

Creating a Custom Chart

With the variety of viewing preferences you may want to customize your own chart. This would also allow you to define what trends will be grouped together for a specific piece of equipment, such as Tank-201. Charts are then named and saved with the standard file buttons.

Create a new chart Open an existing chart Save the open chart

MATCH Plant Engineering

X Axis Scroll Buttons

The X axis represents time. With historical data it may be necessary to move forward and back in time. Commonly used buttons are shown below.

Scrolls back in time by 90% of the window. Scrolls back in time by 10% of the window. Scrolls forward in time by 90% of the window. Scrolls forward in time by 10% of the window. Scrolls to the current time.

MATCH Plant Engineering

X Axis Scroll Buttons

The time span of the window can also be increased and decreased by selecting the buttons shown below.

Increases the time span to show more data. Decreases the time span to show less data.

MATCH Plant Engineering

Setting Connection with Data servers

MATCH Plant Engineering

DeltaV Safety Instrumented Systems

SIS (Safety instrumented systems) are applied to a process to reduce the risk from costly or dangerous failures in industrial processes.
Based on process safety and Degussa standard, We shall pay more attention for following items: 1. Everybody doesnt bypass and force any parameters to start-up related equipments under normal operation. 2. If having request to change the SIS function, must be proved by HAZOP. Plant manager must agree and sign the related MOC. 3. Operator shall know the difference between SIS and DCS from daily operation. Operator can confirm if SIS interlock is active from looking at the interlock display and checking related dynamos.

MATCH Plant Engineering

Question for Training

1. How to use different username logon deltav under normal operation, and get different right? 2. How many ways operators can view plants process pictures? 3. What do symbols mean? 4. How many records do contained in the Alarm List? Alarm List 5. If control loop is cascade control loop, on the master controller actual mode is displaying the IMAN. What cause IMAN ? IMAN? 6. How to use Area Filter to just get alarm for related plant? Area Filter Alarm List 7. If valve and pump having SIS interlock, and SIS interlock already inactive, how to reopen this valve and restart pump again? SISSIS

MATCH Plant Engineering

Question for Training

8.

9. 10. 11. 12. 13. 14. 15. 16.

How to confirm that valve can open or not? How to use Alarm&Event and history view to track reason of instruments interlock that lead to valve or pump stop! Alarm&Event How to use Alarm&Event filter to Filter events based on related instruments status? Alarm&Event How to get the ideal history trend? How to add a temporary line in history view? What does Inactive alarm mean? What is the symbol in the Alarm List? Inactive Alarm Alarm List What happened to the module history picture if you open one faceplate? module history picture How to directly access to faceplate and primary control picture from alarm list or alarm banner? ? How to do if operator open few faceplates at same time?
MATCH Plant Engineering