Learning /Study Strategy

• Why?
• What ?
• How?
• If?
Prerequisite for Training
• Basics of Instrumentation
• Sensing Elements,Transducer , Sensor……etc
• Basic Loops :Open Loops,close loop…etc
• Basic Knowledge of PID Controller
• Excel Formulas : Vlook up, Pivote Table, Concatination….etc
• ADC & DAC
• Basic Logic Gates , Timer ,Counter, Flipflops…etc
What is Instrumentation
Instrumentation is About Measurement & Control.
 Instrumentation Engineering is the
Engineering Specialization Focused on
the Design & Configuration of Process System.
 Instruments are Devices Which are Used in Measuring Attributes of Process
Systems.
 DCS (DISTRIBUTED CONTROL SYSTEM)

 It is Branch of Science In which Deals With the Study of Measurement

& Control.
 It is a Computerized Control System for a Process or Plant Usually
with many control Loops, in which Autonomous Controllers are
Distributed throughout the system, but there is no central operator
supervisory control.
 DCS & PLC
PLC DCS
Scan time so less because less IO capacity & less Scan time high than PLC because large IO capacity
complex loop & more complex loop
Example :Steam Drum Water Level
Control System For an Industrial Boiler
Types Of Process & System
• Continuous Process :
• SIS : ESD,FGS,BMS (Note:SIL Levels) (HAZOP study : hazardous operating
system)
• Batch Process : S88 Standards (Physical model,procedural ,control activity,
process Model), V Model, 21 CFR Part11, GAMP5,IQ,OQ,PQ,Validation,
verification.
• TAS : (terminal Automation System) :loading & Unloading Management.
SIL Levels : Probability of Failure on Demand
(PFD)
Types of Area & Io’s
• Hazardous Area:
• Non Hazardous Area:
• Critical IOS:
• Non Critical IOS:
• IO Types

• Analog Input : 4 -20 MA

• Analog Output : 4-20 mA
• (4 mA = 0 ,8 ma=25%, 12mA=50% ,16mA= 75%, 20mA= 100%.)
• Digital Input : 0 & 1
• Digital Output. : 0 & 1
• Analog Input:

• TT (Temp Transmitter):Temperature Element: Thermocouple, RTD, Thermistore

• RTD: Positive Temp Cofficient of Resistivity (temp increaseses than resisiance also increase)(in RTD is passive transducer as we
have to provide external power supply to power on)( RTD out put is in ohmper degree celcious) (EX:PT100)
• Thermocouple:Seebeck effect:having two disssimalier metals are connect together so voltage is generated between two junction.
thermocouple out put is micro volt per degree celcious
• Thermister: Negative Temp Cofficient (temp increase then resistance Decreases. junction.thermister out put is micro volt per degree
celcious

• FT(Flow Transmitter): Orifice, Rotameter Meter, Venturi, Electromagnetic Flow Meter. Mass Flow Meter, Ultra sonic Flow Meter,
Vortex Flow Meter.

• PT (Pressure Transmitter):Gauge Pressure ,Absolute ,Differential Pressure, Multivariable Pressure Transmitter,Capacitive,Resistive.

• LT (Level Transmitter): 1) Point Level: Float switch,Capacitance,Optical,Conductivity.

LT

• 2) Contineous Level Measurement: Ultrasonic ,Radar

Measuring units
• Temp : Fahrenheit (°F) , Celsius (°C), Kelvin (K)
• Pressure : kg/cm2,Psi ,Bar,mbar,pascal ,kpa,atm
• Level : M,MM,CM,Inches ,Feet .
• Flow : m3/h , m3/min, m3/s, liter/h, m3/day, , liter/day, , liter/min. , liter/
second,mL/H,ml/min….etc
Orifice Plate & Orifice Meter
Thermo well (TW) : Protective Housing for RTD/Thermocouple
which contain Silicon Oil .
 • Transmitter picture
LT PT DPT FT
TT
• Analog Output (control valve): Pneumatic & Hydrolic

Control Valves
• Digital Inputs : push buttons, limit switches, feedback

Push Buttons limit Switches

 • Digital output :start,stop,open,close..etc commands.

Solenoid Valves :Actuators Pump / motor

Process Variable
• LT,PT,TT,FT,
 DCS Architecture

 Flow from System to Field.

 System side
 Field Side
 SERVER CABINET:
Control Room : HMI HMI CPU
RJ45 RJ45

Primary N/W Secondary N/W NETWORK CABINET

Rack room:all RJ45
cabinets
S SYSTEM CABINET
P C P C A A D D
E
-1 -1 -2 -2 I O I O
R

Power cable
Barrier Barrier Relay Relay MARSHALLING
CABINET
Power cable
TB-1 TB-2 TB-3 TB-4
Armad cable (6 paair /12 pair)
FIELD JB
JB-1 JB-2 JB-3 JB-4

FIELD Limit Switches/

DEVICES Transmitter Control Valve Pump / SOV
Feedback
 SERVER CABINET:
Control Room : HMI HMI CPU
RJ45 RJ45

2nd area Primary N/W Secondary N/W NETWORK CABINET

RJ45
FOC converter
RJ45
Patch FOC S
P C P C A A D D Fire wall
LIUcord LIU convert E
FOC -1 -1 -2 -2 I O I O
er R
Patch 3rd party comm
cord
Power cable
Barrier Barrier Relay Relay MARSHALLING
CABINET
Power cable
TB-1 TB-2 TB-3 TB-4
Armad cable (6 pair /12 pair)
FIELD JB
JB-1 JB-2 JB-3 JB-4

FIELD Limit Switches/

DEVICES Transmitter Control Valve Pump / SOV
Feedback
 • Barrier
• The Barrier consist of a series resistor and a fuse plus a zener diode that is
grounded.

• The barrier thus ensures that either too much current or too much voltage will
blow the fuse. This will keep any dangerous energy levels away from the
hazardous area.

• Barrier will reduce the available loop current to a level that cannot produce a spark

• Note :it required Earthing.

• Barrier Picture: single Channel & Duel Channel
.
Isolator
• If having two different potential ex: 24 Vdc & 110vdc.so both voltage it will
isolate.
• Isolator not having current limiting circuit
• Ex:galvanic isolator

• Note : Not required Earthing because it works on optosensor principal.

Difference between Barrier & Isolator
Barrier (Zener) Isolator (Galvanic)
It imposes zero volt level on the system It provides complete isolation between signals
It is more Vulnerable to lightning & other It is less Vulnerable to lightning & other Surges
Surges
High accuracy & Linearity Less accuracy & Linearity
Good Frequency Response Limited Frequency Response
Low cost Higher cost
Higher packing density Lower packing density
Used where Restricted voltage is available in Used where Higher voltage is available in
Hazardous Area Hazardous & Safe Area
Loop powered Separate power supply
Low dissipation High dissipation (2 VA)
Used for front end engineering demand is high Used for application specific requirement
versatile
simple Complex with low MTBF value.

It reduces the loop current below the safe level It is used to interface signals having different
where it can not cause any spark common mode voltages.
 • Relay Card

• Relays are the switches which aim at closing and opening the circuits
electronically as well as electromechanically. It controls the opening and closing
of the circuit contacts of an electronic circuit.
• When the relay contact is open (NO), the relay isn’t energize with the open contact.
However, if it is closed (NC), the relay isn’t energize given the closed contact.
However, when energy (electricity or charge) is supplied, the states are prone to
change.
• Different type of relay are following:
1. Electromechanical Relay.
2. Electrothermal Relay.
3. Solid state Relay.
IS & NON IS
• Intrinsic Safe : Barrier / Isolator
• Non Intrinsic Safe
Compare HART & Non HART
HART Non HART
Smart device Non smart device
We can calibrate/simulate/configure this from If we want to configure/calibrate than we need
FDM (functional device manager) software no go in the field from field we can calibrate
need to go in the field (manually we need to calibrate ,not any
calibrator available)
Through HART calibrator we can also calibrate not any calibrator available for calibration
Compare HART & FF
HART FF
Power supply Module
Surge Protector (surge arister) :it
surge’s the voltage
Why We USE 4-20mA Only why Not
Other
• Dead zero & live zero detection
• Fault in loop or in signal that came to know.
• If 0 mA than induced Eddy current will affect on it so it will give error in Reading.
• If 4 mA than induced Eddy current will not affect on it so it will give correct Reading.

• Note :Sensor Output in 1-5v.&

Transmitter having 250 Ohm Resistance.
MA to % conversion
formula
% = x * 6.25)-25
X= ma value
6.25 is the 100/span =100/upper range-lower range=100/20-4=100/16=6.25
25 is the in the 4-20 ma value starts from 4 (0-100 & 4-20) so taken 25.
Ex : 8ma to %
% = 8*6.25-25
= 50-25 = 25%
% to MA conversion
formula mA =(x/100)*16+4
X= % value
16= span=upper range-lower range =20-4=16
4 is the in the 4-20 ma value starts from 4 (0-100 & 4-20) so taken 4.
ex.
For 50%
Ma=(50/100)16+4 =0.5*16+4=8+4=12MA
Analog Scaling Formula
Note
• FIELD JB Type : Flame Proof JB & Explosive Proof JB.
• FD,GD,SD,Flammable GD,FD,GD.
• Ferruling : straight ferruling & Cross Ferruling.
• Crimping : straight & Reverse (Cross).
• Cables : Armad (6/12 Pair), ethernet cable ,Patch cord /fiber optic cable.
• Cold Restart : start from New enable for maximum time
• Hot Restart : start from the last good value/ last saved value.
• Idle :not any state
Types of Cabinets /Panels/Console
• Server Cabinet
• Network Cabinet
• System Cabinet
• Marshalling Cabinet : Analog marshalling , Digital Marshalling ,RMC (relay marshalling
Cabinet),MCCP (Motor control Center Panel),IRP (Inter posing Relay Panel)
• Power Distribution Cabinet.
• Hardwired Console : Annunciator window
• Operator Console / Table.
• IRP/MCC panel : for high voltage purpose used (cable came from field to switch gear &
switch gear to IRP panel & from IRP panel to Marshalling cabinet to system cabinet.
• Note : if any cable going from one cabinet to other than your cable must
terminate to first cabinet TB & than after it will go to other cabinet & there it
will terminate than after it will go to other cabinet.
• Different between 2wire, 3 wire, 4 wire transmitter.

2 wire transmitter 3 wire transmitter 4 wire transmitter

Energized by the loop current Energized by the supply voltage Powered by external power
in the transmitter source
Not suitable for long-distance Transmission distance is better Suitable for long-distance
transmission than 2 -wire type
Signal and power supply are Signal and power supply are not Signal and power supply are
isolated isolated isolated
2 wires are used for both the 3 wires are used commonly for 2 wires are used for the data
signal and the power supply the signal and the power supply signal and the other two wires
are used for the power supply
Low accuracy when compared Higher accuracy than the 2 -wire Good accuracy than the other
to the other two types transmitter two transmitters

Ex: FD,GD,SD,Flamable GD,FD,GD Ex: RTD,Thermocouple…etc

Ex: normal TT,PT,LT,FT…etc
2W Diagram
4W Diagram
3W Diagram
Types supply in panel
• 230 Vac
• 110Vac
• 24vdc : For Is Circuit / Devices.
Power Supply flow in Cabinet:
110 AC Supply from
PDB Cabinet (on TB)

MCB Isolation (upstream )

Bus Bar (110vac bus
bar)

MCB (Isolation)

Surge Protector
MCB (Isolation)

SMPS Module
 Power Supply flow in Cabinet
MCB (Isolation)

Diode Module

MCB (Isolation)

24Vdc Bus Bar

MCB (Downstream)

Controller,Card,Barrier,
Relay,…….etc
230 /110 VAC
• FaN
• Tublight
• Motors / pump
Earthing
• IE/SE- Instrument Earth/Shield Earth :Resistance less than 1 Ohm (for 24vdc
Devices)
• PE/NSE-Panel Earth/Non Shielded earth : Resistance Less than 5 Ohm.(for
AC Devices)
• DC Earth (for SMPS)
• SINKING AND SOURCING IN PLC
PID (PROPORTIONAL, INTEGRAL, DERIVATIVE)

• There are three major controllers included PID are following.

1.P-controller (Proportional controller)

2.I-controller(Integral Controller)

3.D-controller(Derivative Controller)
• P-CONTROLLER
•Proportional or P- controller produces an output that is proportional to present error e(t).
•It compares the desired or set point with the actual value or feedback process value.
•The resulting error is multiplied with a proportional constant to get the output. If the error
value is zero, then this controller output is zero i.e. this controller is only takes action as
long error is there in the system.
•But when controller action stops then in that case error starts to build up again so P
controller tries to remove that error again so this process continues forever that means p
controller takes action after the error takes place in the system so there is always an
error present in the process and this error is called as offset error.
• P controller provides stable operation and also removes steady state error but not
completely.
•The speed of the response is increased when the proportional constant Kc increases.
General PID Equqtion
• Gain is always Multiplying
• Bias is adding
• P-Controller Diagram
 • I-CONTROLLER
• Due to the limitation of P-controller where there always exists an offset between
the process variable and set point so I-controller is needed, which provides
necessary action to eliminate the steady-state error which is was offset in case of
P controller.
• It integrates the error over a period of time until the error value reaches zero that
means it completely remove steady state error.
• Integral control decreases its output when a negative error takes place. As we
increase the gain of I controller it increases overshoot (it is deviation from desired
value or set point). In simple words it increases settling time(it is a time that
system take to reach its stable value) of the system so system will take more time
to reach at steady state. So it makes the system sluggish.
I-CONTROLLER
• In the below figure, as the gain of the I-controller decreases, the steady-state error
also goes on decreasing.
• For most of the cases, the PI controller is used particularly where the high-speed
response is not required.
• D-CONTROLLER
• I-controller doesn’t have the capability to predict the future behavior of error.
• D-controller overcomes this problem by anticipating the future behavior of
the error because it works on the rate of change of the error so D controller
knows the what will be the future error according to the current rate of
change of error .It takes action according to rate of change of error and that
derivative of error is multiplied with derivative constant.
• As it takes action according to rate of change of error so if there is more
error more quick action it will takes so the increasing system response that
means it will makes system stable more quickly. Hence it improves the
stability of the system as it decreasing the overshoot.
 • WHAT EXACTLY DONE IN PID
• P-MODE:P-controller in PID reduces the steady state error and also improves
stability up to some extent but it can not eliminate steady state error.
• I-MODE: I-controller basically eliminates that offset error which was present in
P-controller that means it eliminates steady state error completely.
But problem with I-controller is that it increases overshoot and thus
increases system response time and makes the system less stable.
• D-MODE:D-controller basically use to remove that overshoot which was
happening in case of I-controller. So it decreases the settling time of
the
system that means system takes less time to reach steady state.
Note :
1.Measured variable/process variable(PV):
It is the variable which we want to control i.e. level,
temperature, pressure, flow etc.
2.Set point (SP)/Controlling Variable (CV):
It is value set as a reference point to PID so that PID will adjust
its output according to the given set point.
3.Manupulated variable:
It is the parameter that is adjusted to bring the process back to
the desired set point.
Note :Error signal :
Error signal is the difference between the measured variable
and the set point.
Types of PID
• Direct Acting PID :
• Reverse Acting PID :
PID Modes
• Auto Mode : The setpoint is adjusted by an external source and the loop
calculates the output based on the algorithm
• Manual Mode :The output is set by the operator.
• CAS Mode : The setpoint is adjusted by another function block through the
CAS_IN parameter and the loop calculates the output based on the algorithm
• Initialize Manual (IMAN) –The block output is being set in response to the
status of the BKCAL_IN parameter. For example, when the secondary loop is
not in Cascade, the primary loop goes to IMAN to prevent windup
• Out of Service (OOS) : The block does not perform the algorithm. The status
is set to Bad
PID Modes

• RCAS Mode:
• RMAN Mode:
• Rout Mode:
Situation in PID
• Reset Windup & Anti reset Windup in PID:
• Bumpless & Bumped Transfer in PID:
RESET WIND UP IN PID
• Though PID is the best controller to control a process it has some basic disadvantages too like
reset wind up.
• RESET WIND UP:
• This phenomenon happens during I-controlling mode in PID.
• If we are controlling a level of the tank using a PID and a control valve located at inlet pipe of the
tank if due to any disturbance level in the tank starts decreasing so PID will take action and tries to
maintain a level by opening a control valve.
• But even after opening the valve 100% the level is not getting maintained according to the set point
provided so integral controller will increase its action further to open the valve further but value has
reached its saturation level so integral term will gather more and more and it will reach to a very
high value and this is know as integral wind up.
• Now if the disturbance is gone and level started to increase in the tank as valve is fully opened and
now even level of tank has reached as per set point. So in this case PID controller should take
action to maintain that level but it fails to maintain the level and level goes beyond set point still
previous accumulated value in the I controller is completely used up.
METHODS TO AVOID RESET WIND UP
• We have to assign saturation limits to the PID so that it will not wind the
values after the valve saturation is achieved.(or provide the saturation Limit
in PID so PID will not Windup beyond the Saturation Limit )
• Or we can reset the PID to restart the process according to the given set
point.
• Anti Reset Windup.
PIDA equations
• Proportional Integral and Derivative (PIDA) Block The PID block is a
regulatory control block that operates as a proportional-integralderivative
(PID) controller. The PID block has at least two analogue inputs - a process
variable (PV – connected to the analogue input) and a set point (SP – written
by operator via EPKS diss or another function block). The difference
between PV and SP is the error and this block calculates a control output (OP)
that should drive the error to zero. The output signal will be in the range
0-100%. In BPCS, Controller Algorithm are referred as Control Equation Type
and it is parameter of PID function block named “CTLEQN”. The parameter
“CTLEQN” has a dropdown menu with below options.

• Pages :107 & 108.

Redundancy Test
• Redundant Controller : both Controller are Handshaking with each other &
Internal Polling happen with each other.
• Network Switch Redundancy.
• IO Card Redundancy.
• Network cable , power supply module ,diode module,surge protector (surge
arister)
• Control Loops

 There are 7 type of control loops are using in process automation it is are
following.
1. Open loops
2. Close Control Loops
3. Feedback loops
4. Feedforward loops
5. Cascade loops
6. Split range loops
7. Ratio control loops
• Open loops
• Open-loop Control System. Definition: An open-loop system is a type of
control system in which the output of the system depends on the input but
the input or the controller is independent of the output of the system.
• These systems do not contain any feedback loop and thus are also known as
non-feedback system.

PI

PT
• Closed loops
• A Closed-loop Control System, also known as a feedback control system is a
control system which uses the concept of an open loop system as its
forward path but has one or more feedback loops (hence its name) or paths
between its output and its input.
Feedback Control loops :
Feedforward Control loops :
• Cascade Loops
• The cascade loop would have a second measurement and also secondary
feedback. In a cascade control system, there would be two controllers and in
which the output of one controller would drive the set point of the other one.
This is a multi loop structure in which the output of the controller in the outer
loop which is called primary, is the set point of the controller in the inner loop.
So two controllers are used in the cascade control because the process is
divided into two and one process variable will be manipulated
• Cascade loop drawing
CASCADE LOOP
• In cascade Loop we used two controller.(TIC & FIC).
• The output of TIC will be remote set point for FIC controller.
• Temperature Transmitter (TT) will send feedback of water temperature to TIC controller & TIC
controller will compare with his set point value & produce output value for FIC controller that is
called remote set point.
• FIC check its remote set point & compare with its Flow transmitter & produce output for control
valve & valve will open or close as per system requirement.
• When one controller output will remote set point for another controller then this loop is called
cascade loop.
• If we assume that temperature of water is 30ºC & we manually give some set point to TIC is
60℃ then TIC controller will try to reached up to 60℃. So TIC controller produce output(Remote
set point) send to FIC controller. This controller will check flow through FT & Send command to
control valve for open & increase the flow of steam so water will get heats again.
• Failed to open and closed (FO & FC) :Ex:CV

• Failed to open
Fail open means a valve will open at a loss of signal or power. If it is
pneumatic valve then these types of valves require air pressure to stay closed.
Once the required air pressure is gone, the valve will be in open condition.
• Failed to closed.
Fail close means the valve will close at a loss of signal or power. If it is
pneumatic valve then these types of valves require air pressure to stay open.
Once the required air pressure is gone, the valve will be in closed condition.
MOV ( motor operated valve)
• It valve will be operated through motor
• If we give start command to motor than motor will start & valve is opening slowly inside
the valve there is flenge & that flenge / flap is moving once valve open fully at that time
flenge / flap touched to limit switch than we get DI (feedback) of fully open.than after
motor will stop ( this case motor moving in forward direction).
• If we want to close the valve than again we start the motor but in this case motor will
move by reverse direction & valve will be close & we getting close feedback (DI) than
after motor will stop.
• Valve opening & closing time we configured in logic if in defined time period valve will
not open /close than we get command fail alarm in the form of DI.
• In in case power off than in MOV having capacitor with help of that charge in capacitor
that valve will come to open / close.
• Note : in MOV not having FO & FC concept. In that having STAYPUT concept.
• STAYPUT : as it is position if power gone.
ROV ( Remote operated valve)
• Split range Control loop

• Split range control is used, where there are several manipulated variables, but
a single output variable. The coordination among different manipulated
variables is carried out by using Split Range Control.
Split range Control loop:
Split range calculation
• Y=Mx+c
• Y=output
• M=Gain /slope
• X=input
• C=bias
• Example : 1st valve: 0 to 50 operate & operated in 0 to 100
• 2nd valve : 50 to 100 operate & operated in 0 to 100.
• First valve Gain & Bias calculation
• Y =mx+c
• 0-100=M(0-50)+0 (assume c=0)
• M=0-100/0-50
• M=2
• 2) when y=0,x=0 than C=?
• 0=M(0)+C
• 0=2(0)+c
• C=0
• 2nd valve Gain & Bias calculation
• Y =mx+c
• 0-100=M(50-100)+0
• M=0-100/50-100
• M=2
• 2) when y=0,x=50 than C=?
• 0=2(50)+C
• c=(0)-2(50)
• C=-100
• Ratio control loop

• The ratio control loop uses the rate of the wild flow to determine the rate of
controlled flow so that the materials are mixed in the appropriate ratio.
Over ride Logic/ Loop
Safety Logic
• V2003 Logic
• V1002 Logic
2003 Voter Logic
1002 Voter Logic
• Hot and cold loop test

1. What is hot loop Check?

Once you power up your field instruments through DCS/PLC system by
simulating process inputs from respective fields instruments and cross
check it
response at DCS/PLC system.
2. What is cold loop Check?
Checking of wires continuity of respective field instrument junction box
DCS/PLC marshalling panel terminal.
• Dry and Wet contact

1. What is dry /potfree contact?

Dry contact is the one in which the power is always being supplied by another
source. Output power is completely isolated from input power.
E.g.. Relay has dry contacts as in relay circuit.
2. What is wet /Potential contact?
Wet contact is the one in which the power is being supplied by the same power
source that the control circuit is used to switch the contact. Output power is
not isolated from input power.
Measuring Equipment
• Multi Meter
• Source / Sink Meter
• Clamp Meter/true RMS Meter
• HART Calibrator.
• Megger Kit : for Megger test / insulation resistance test.
 Source,Clamp,HART & Megger Meter
Picture

Source / Sink Meter Clamp Meter/true RMS Meter HART Calibrator Megger Kit
• P&ID (piping & instrument diagram)
1. What is P&id ?
graphical representation of the actual process system that includes the piping,
equipment, valves, instrumentation, and other process components in the
system. All components are represented using various P&ID symbols.
2. What is information does P&id provide?
1. Heat tracing & insulation details.
2. Instrumentation
Piping components:

1. Size
2. Class
3. Tag number
• P&ID (piping & instrument diagram)
Information required for design, construction & operation such as:
1. Slope of the line
2. Minimum &maximum distance
3. Minimum & maximum length.
How to read P&ID?
1. How many field tag
2. How many DCS tag
3. How many SIS tag
4. Different Symbols
5. How many open loops
• P&ID (piping & instrument diagram)
1. How many closed loops
2. How many cascade loops
3. How many split range control
4. How many ratio control loops
5. Process Flow.
6. End User Name (Owner):
7. EPC Name: Engineering Procurement Consultancy (Contractor)
8. Project Name.
9. P&ID Name
10. P&ID No,Revision,Note,Instrument Information…etc
• P&id symbols
• P&id symbols
• P & id symbols
 Digital Output Valve tags:
• Solenoid valve/ON OFF Valve open Tag :
11XV1123_OP
• Solenoid Valve/ON OFF Valve Close Tag :
11XV1123_CL

Digital Input Valve tags:

• Solenoid valve ON OFF/valve open feedback tag:
11XVL1123_OP_FB
• Solenoid valve ON OFF/valve close feedback tag:
11XVL1123_CL_FB
 Digital Output Motor Start & Stop Tags:
• Motor Start Tag:
11M2233_START
• Motor Stop Tag:
11M2233_STOP

Digital Input motor feedback Tags:

• Motor running feedback tag:
11M223_START_FB
• Motor local/remote feedback Tag:
11M2233_STOP_FB
 OPEN LOOP

103-
103
PT112
3 --------------------
PI1123

FIELD TAG DCS

TAG
103PT1123- 103PI1123
AI
 CLOSE LOOP
-----------------

---
------------ - - -
103-
103PIC
PT112
3 ----------------------- 1123 --------------

103PV1123

FIELD TAG DCS TAG

103-PT-1123-AI 103PIC1123
103-PV-1123-AO
 103-FIC-1123 103-TIC-1123

103-FT-1123 103-TT-1123
103-PV-1123

FIELD TAG DCS TAG

103-TT-1123-AI 103-TIC-1123
103-FT-1123-AI 103-FIC-1123
103-PV-1123-AO
 SPLIT RANGE CONTROL LOOP
------------

---
----------
-------------------

-------------------
FIELD TAG
103-PV-1123-AO 103-PV-1123-AO
103-PV-1123-AO
103PIC
1123
DCS TAG
103PIC1123
------------

----
----------

------------------

103-PV-1123-AO
 MOTOR

103-XS
M FB
-------------------------- -1123

Field Tag

103-XS-1123-STA-FB DCS Tag

DI 103XS1123
103-XS-1123-STO-FB

103-XS-1123-STA DO
103-XS-1123-STO
 SOLENOID VALVE
Field Tag
DCS Tag
103- 102XV1123
XV11
23 103-XV-1123-OP DO
103-XV-1123-CL

103-XV-1123-OP_FB DI
103-XV-1123-CL_FB
 - 103-PV-1123-AO

--- -----
----------- 8 ----------------- --------- FIELD TAG

--------------------------------------------------------------
103- 103-FT-1123-AI

------------------
FT-112 103-FT-1123-AI
3
103-PV-1123-AO

------
FY ----------------- 103FIC ----------------- MIXER DCS TAG
1123 ----------- 103FIC1123
----------
---------------------

103-
------------------- FT-1
123
------
103-PV-1123-AO
--------------- 8 ------------- -----------
Production base ratio
control singal
------------------ ----
RATIO CONTROL LOOP
Communication protocol.
• Purpose of Communication Protocol
• Types of Communication Protocol
• Mod Bus : RTU ,TCP/IP, Ascii ( now a days Ascii protocol is Disappear from
Industry not used any ware)( mostly used RTU & in OPC communication TCP/
IP used.)
• Profi Bus
• Profi Net
• HART
• FF
MODBUS protocol
• It is data communication protocol originally published by Modicon in 1979 for
use with its PLC.so now it is used every were in all company.(connecting
electronic devices)
Communication Protocols
( Modbus RTU)
• MODBUS define method is used for transmitting information over serial line
between electronic devices.
• We can connect 247 device to master in Modbus. But after 32 device we
need to use repitter .
1. Why need to use repiter?
• If we connect 242 device at one time there miscommunication between
slaves and voltage drop occure. So by using repitter that limitation is
eliminated.
• We have assigned unique Slave ID each Slave. Slave unique ID must be
different for each Slave.
• We can select Slave ID range 1 to 247.
Modbus RTU
MODBUS RTU
• In above figure, master and slave are communicate to each other.
• But MODBUS master is requesting the information to slave.
• After receiving the request from slave give the respone to master.
• As per above figure, that communication can be achieved after requeting
information to slave.
• Speed of Modbus is 9600 Baud Rate.
Configuration Parameter
1) Boud Rate
2 ) Data type
3) Data Direction
4) Register Address
5) Port Type
6) Parity: even & odd.
7) Divice / Signal Address
8) Protocol
9) Register offset
10) No of Values
11) Data set Tag
12) Data bit
13) stop bit
14 ) Mode :master /slave
15) Retry count
16)Message time out (ms)
17)Transmit delay (ms)
• 18) enable the port
• 19) Number of values
Addressing Format
For reference picture,How to assigned Slave Unique Id
MODBUS function Code
Parity Bit
• The parity bit are used for error detection.
• There are two type of parity are following.
1. ODD parity.
2. Even Parity.
For Reference picture, Parity bit
Identify Parity Bit
• In above figure, if count number of 1 is even the select parity bit is 0. and If
Count number of 1 is odd then parity will be select 1.
• For odd parity, if count number of 1 is odd then the select parity bit 0 and if
count number of 1 is even then parity bit will be select 1.
• In RS 232 : we can connect less device i.e 1 to 5 in single network & it is used
if distance up to 15 meter.
• In RS 484 : we can connect up to 31 devices & it used if distance more than
15 meter.
Modbus TCP/IP
• Modbus TCP/IP (also Modbus-TCP) is simply the Modbus RTU protocol with
a TCP interface that runs on Ethernet. The Modbus messaging structure is
the application protocol that defines the rules for organizing and interpreting
the data independent of the datatransmission medium.
• In Modbus TCP/IP, One is client and other is server. As of Modbus RTU there
is some difference between and Modbus TCP/IP and Modbus RTU.
Modbus TCP/IP
Modbus TCP/IP
• In Modbus TCP/IP client and server work. Server act as master bur we called
is server in TCP/IP. Client act as slave but we called is client in TCP/IP.
• MODBUS is serial communication between two electronic device.
• In TCP/IP client work as master server work as master. Anybody become
(client and Server) master and slave no restrication.
• There is no need of requesting information in TCP/Ip like maser and slave.
Profibus ( long from : Process Field Bus )
• There are three type of Profibus.
1. Profibus DP
2. Profibus PA
3. Profibus FMA
• Profibus support single wire cable wirring of multiple inputs
• 32node is used without Repeater and 126 node is used with repeater.(1 segment we can connect 126
slave devices & their addressing is 0-126)
• Network length is 24 km with repeater.
• Speed of profibus is 31.25kbps
• Two devices are supported
Master plc – Send message without request
Slave Plc – Send Message only on Request
Both side address will be same. (device address given for every device.)
Profibus DP (Decentralised pherapheral : siemens)
• Profibus DP ( without Profibus Dp)
 PLC and I/o Block centralized in control room.

PLC I/O Blocks Sen

sor
Profibus DP
• Profibus DP ( with Profibus Dp).
• PLC and I/O block dcentralised and I/O Block moved to field Control.

Sen
Plc I/O Block sor

Profibus
Saving Field
Wiring Test
Profibus
• Multiple Master allowed
• Each slave Assigned to Only One master.
• Multiple Master can read from any device.
• Only one master can write to one device.
Profibus PA(Process automation)
• Profibus PA all sensor could be connected to same bus. So no individual
wirring neded I/O block Removed.
• In profibus PA need segment coupler for interfacing between Profibus Dp and
profibus PA.
• Profibus PA is used for Intrinsally safe Application.
• For interfacing optical Fibre cable is used.
Profinet
• Profinet is mechanism to exchange data quickly between controller and
devices.
• Profinet is newer Ethernet Based Industrial Communication Protocols.
• The Physical Interfaced is standard RJ-45 Ethernet Jack.
• The speed of profinet is 100mb/s
For Profinet need address like this following-
1. Device name
2.IP address given for device.
3.MAC Address.
• Communication protocol.

Sr. No. Protocols Baud rate Length Node

1 Ethernet (TCP/IP) 100mb/s Few 255
2 Profibus 9-12mb/s 15 km 127
3 Profinet 100mb/s and few km 256
1gbit/s
4 Modbus RTU 38400b/s 15m 247
• RTU : 38.4 KBPS
• Profi bus / FF : 31.25 KBPS
• TCP/ IP : 100 MBPS
• Profibnet : 100 Mbps.
Foundation Field Bus (FF)
Foundation Field Bus Profi Bus

Single cable connected to One JB /Segment Single Cable Connected to Multiple JB /

means if one cable in fault than only That Devices /RIO in looping means If first JB /
particular JB / Segment in Fault. RIO in fault than all JB / RIO will be in fault (if
that cable connected in daizy chain fashion
than not in fault)
 HART FF

We can not simulate transmitter from system We can simulate transmitter from system by using
Asset management system / Functional device
manager.
OPC Communication
• Purpose of OPC Communication.
• OPC : OLE for Process Communication
• OLE :Object Linking Embedding
• DCOM Setting for Server & DCOM setting for Client configuration doing in
both system.
• It is used for access any third party tag / IO.
• OPC Watch it.
Firewall (FW)
• A firewall is a network security device that monitors the incoming and
outgoing network traffic and permits or blocks the data packets based on the
set of security rules.
• The Firewall acts like a barrier between the internal network and the incoming
traffic from external sources (such as the internet) in order to block
malicious traffic like viruses and hackers.
• The firewall shall be either hardware or software based.
FW Configuration

Inside Outside
Internet (Unsecured Network)

Firewall
FW Architecture
Sample Architecture
 • Project Flow Execution :Detail Egn,FAT,SAT.
1.
Kick off meeting P& Id diagram , I/o list,point
data base refrence, control
logic philosophy, system
Architecture, I/O assignment.

HMI Development, Software

Logic Development Development, Data base
Development, Scada
Development.

Panels, System Cabinets,

Hardware Development Marshalling cabinets, network
cabinets, server Cabinets ,
PDB Cabinets
 General Arrangement, internal
Checklist Arrangement, Power
Distribution.

Transmitter –Field JB-Marshalling

Typical loop drawing Cabinet-Terminal box-Barrier-
system cabinet-Network Cabinet
– Server Cabinet
Wiring Diagram

Heat Load Calculation HMI checking, Software checking,

Hardware Checking,Meger Test,
GA,IA,PD, Loop Checking ,Burn IN
FAT(Internal ) Test Report.with the help of FAT
procedure

FAT (Customer) FAT MOM(minute of meeting)

 Site Ready ness check list , Material
SAT(site Acceptance Checking as per BOM, Erection,
Test) locating panel as per control layout,
inter cable cabling, Megger test
(insulation Resistance test) ,Power
On
Hot loop and cold loop check
from field to panel and panel to
Commissioning
field & Special Logic Test with
the help of SAT Procedure

Handover (SAT MOM)

Handover system to customer.

FS,FDS,SAT,FAT,MDI/DCI,H/w,S/
Documents: w Manuals,control Room Layout,
Base frame drawing,,Duct
Layout,MCT(cabinet & Room),
Earthing Drawing…….etc