DISTRIBUTED CONTROL SYSTEM

(DCS)
DISTRIBUTED CONTROL SYSTEM
Real Time Executive system Basics..
 Historical Perspective
• 1959: TRW, RW300 computer, refinery control, 72
temperature, 3 pressure, 26 flow sensors
• 1962: ICI, Ferranti computer, 129 valves, 224 sensors
• 1963: NASA, flight control system
• 1968: PDP (DEC), HP 2100, Data\ General Nova (MSI, LSI):
interrupt based systems, real-time clock, RTOS
• 1970+: VLSI, microcomputers, sensors miniaturization
• 1985+: distributed real time systems
 computer systems
Computer
System

Batch type Interactive type

Programe Output
Input Processing
 Interactive Systems
•It takes, process inputs

•Processes with prescribed program acts on

interventions / interrupts

• Issues desired Output .

•The programming takes Care of the process behavior

and patterns
 Interactive systems
Interactive
system (real-time,
reactive, embedded )

Soft real time "Hard real-time"

Statistical Where the information
Information for is processed in definite
supervision only/ time frame with
Info only. intentions to regulate
the process.
 Soft real-time system
Example :. time sharing system of A statististical multiplexor

Terminal

Terminal Multiplexor Computer

Terminal
 Definition: hard real-time , event driven,
embedded, process driven .
• real-time : "(A) Pertaining to the actual time during which a physical
process transpires. (B) Pertaining to the performance of a computation
during the actual time that the related physical process transpires in
order that the results of the computation can be used in guiding the
physical process" [The IEEE Standard Dictionary of Electrical an
Electronic Terms].

• real-time system: Any system in which the time at which the output is
produced is significant. This is usually because the inputs
corresponds to some movement in the physical world and the output
has to relate to that same movement. The lag from input time to outout
time must be sufficiently small for acceptable timeliness. [The Oxford
Dictionary of Computing]
 Watchdog timer
• The function of watchdog timeris to
ensure that the controller receives the Controller
input signals at desired frequency or
sampling rate . Interlock / interrupts

• If the signal is not received in defined Watchdog

Timer
time frame it issues interrupt command to
stop issuing output to process to avoid Output
damage due to loss of communication. Input (t)

processor

• Some time it de links controller from

process ( Trip to manual/ Timed out
warning ) and keeps thee system in safe
mode or status quo.
 Definition RTOS

A real-time operating system (RTOS) is an

operating system that guarantees a certain
capability within a specified time constraint.
 Multitasking
•It is easy to confuse multitasking with multithreading, a somewhat
different idea.
•In a computer operating system, multitasking is allowing a user to
perform more than one computer task (such as the operation of an
application program) at a time.
•The operating system is able to keep track of where you are in these
tasks and go from one to the other without losing information.
 Reference model
• Conceptual Realtime
system has physical Reference
process whichworks in
real time manner and it RTS

has inputs and outputs RTS output RTS input

sent to RT for Process
computation. Inputs Outputs
 Function Wise

• Open loop
• Data acquisition :Collection od Data with Time
stampings.
• Closed loop
 Open loop

• Open Loopm controls is Reference

unidirectional an
• It either .. RTS
– reads RTS output RTS input
or
Process
– Writes back to process Inputs Outputs
 Data acquisition
• Only RTS inputs
considered Reference

RTS
RTS output RTS input

Process
Inputs Outputs
 Closed loop
Closed loop control System has
following components
Reference
•Input
RTS
•Output
RTS output RTS input
•Reference or Set Point
Process
•Desired Control characteristic or Inputs Outputs
program
 Real Time Events
• Time Domain:

– Continuous Time related

– Random and irregular

• Regular with certain frequency..( Frequency domain)

 Type of event patterns
Event
• periodic pattern:
cyclic pattern, with a fixed period
Event period
• bounded: next event cannot occur
before a given amount of time after a Event
previous event (interarrival time)
Interarrival time
• bursty: events may occur arbitrarily
close toe each other, but there is a Event
bound on the number of events
(burst size) that may occur during a Burst interval
specified burst interval
No. of events = burst size
 Events 2
• Irregular: interarrival
intervals are not constant but
are known before the event t1 t2 t3 t4
occurs Interarrival time

• Unbounded: an arbitrary
number of events can arrive
during any given time Distribution
Probability
window; characterization by function
a distribution function
Interarrival time
RTS- Architecture

• Real time software

 Structure of RTS - Hardware Controller
• It consists of fillowing functional controllers
– Operating softwre
– Communication facilities (Bus or Local Area Networking )
– Input / Output subsystem
 Structure of RTS software
• Operating system
RTS-software
• Application tasks
application application
tasks tasks

operating system

hardware

External events

physical proces
 Role of RTS software
• Communication with the environment is defined in terms of external
events: Application Tasks must react to these events;
• The responsibility of OS: execution of tasks in accordance to external
events and prescribed schedule;
• Operating System = software (hardware) to facilitate execution of
application programs (tasks);
• Tasks request services from the OS (make calls to OS). These are
internal events. Examples: activate task, stop task perform a
communication, etc.
• Functions of OS: resource management (processor, memory,
peripherals, data);
 RTOS
• OS-resource management + events handling,
• under constraints (predefined time limits);
 RTOS activities: uniprocessor system
cycle EventHandling; TaskDispatching endcycle;
or
cycle EventHandling endcycle;
or
cycle TaskDispatching endcycle;

TaskDispatching: Making a task run

// denotes interleaved execution of both activities
 RTOS activities: uniprocessor system
On a uniprocessor system only one task may run a the same time; Scheduling
looks at time constraints and decides which task must run;
cycle
EventHandling; Scheduling; TaskDispatching
endcycle;

Before a task can be dispatched (assigned to run) the resources i.e. memory
must be assigned to it:
cycle
EventHandling; Scheduling; MemoryManagement; Assign;
endcycle;
 Summary
• Main activities
– Event Handling
– Scheduling
– Memory Management
– Assignment
 Scheduling issues
• Ordering of task executions,
• Assignment of tasks to processors,
• Security,
• Protection,

Scheduling is crucial and distinct

 Memory management issues
• Virtual memory
• Swapping of tasks
• Sharing of memory (synchronisation, communication)
• ROM, RAM, Hard disks
• Buffers, pools, queues
 File management issues
• Standard file operations
• Event handling (device management) issues:
– Physical process interfacing
– Interfacing of devices
– Interfacing of non-standard devices
– Absence of disk -> debugging, development
– Host-target approach
 Implementation of RTOS
• Small executive implements
a number of basic OS Application task Application task
functions
• More complex OS-functions
are implemented as special System task
System task
System task
System calls interface
System task
(High / Low priority, RTOS
memory management) tasks
Executive (or kernel)
• The interface to OS is
formed by System Calls Hardware
 Distributed Operating Systems
• Distributed OS control a netwerk
of communicating computers;
• Tasks running on the different task task task task
controllers (computers) have a
identical / similar view of the
system (Single image) Controller HW Controller HW
• Distributed OS hides the
communication network
complexity of the distributed
hardware to the tasks / Distributed Operating System
programmer
 Implementation of Distributed OS
• Interceptor: distinguishes Application task Application task
between local and global
operation system call interceptor and emulator

• Global executive: coordinate System task

System task Global executive task
System task task
System
global system calls
Local Executive (or kernel)
• Local part: executes local
Communication
Computation hardware hardware
 Type of processors
•Microcomputers
•Programmable logic controllers
• Parallel or Multi Processors on a single board /
platform ( Client - Sever architecture)
•Processing through multiple processors through
Networking.
 Some examples - Foxboro
Foxboro SPEC 200; Philips PCS 8000;

Physical Process

Controller S/A

Sensors,
Displays Actuators

Operators
 Some examples - TDC 2000, TDC 3000

INDEPENDENT PROCESSING
Multi-processor
architecture provides
guaranteed control
Comm. Control performance.
68040 I/O Link
68040
Common Board
« No I/O capacity
UCN
tradeoffs
I/O Link « No communication
tradeoffs
Intelligent
IOP I/O Processors « Point execution in
(up to 40) configured intervals
« Intelligent I/O
Field Termination Electrical processors
Assembly FTA Conditioning and
Isolation « Extensive diagnostics
Field
Wiring
DISTRIBUTED CONTROL SYSTEM (DCS)
For Process plants.
 What is DCS ?
• DCS is abbreviation for Distributed Control System
• As is apparent from the abbreviation, the word ‘Distributed’ supports
following functionality’s
– Physical Distribution - Nodes or Subsystems can be Distributed i.e
located physically apart
– Functional Distribution - Specific Functionality is imparted for a Node
basing on the combination of hardware and software used. For e.g
Application work-processor with Historian, Application work-processor
with control configuration software
– Structural Distribution - Different Structural hardware platforms
(Application Workstation processor, Workstation processor, Control
processor etc.) are used to achieve the required functionality.
 WHY DCS ?

• For Total Plant Automation

• For Higher Productivity
• For Optimal Process Control
• For Advance Process Control
• For Regulatory Compliance
• For Management Information System
• In Tune With Global Requirement
Information Processing

M anagem ent
In fo r m a tio n &
a p p lic a tio n
P r o d u c tio n r e p o r t,
In v e n to ry re p o rt,
S p e c if ic c o n s u m p t io n
r e p o r t, Y ie ld a n d A c c o u n t in g
E n te r p r is e r e p o r ts a n d V a r ia n c e r e p o r ts
B u s in e s s Q u a lit y in s u r a n c e r e p o r t s ( L I M S ) E n v
a n d p o llu t io n r e la t e d R e p o r t s
In fo r m a tio n M a n a g e m e n t & r e p o r tin g
In fo r m a tio n
H is t o r ia n s - T r e n d s , E v e n t r e c o r d e r s
D is t u r b a n c e r e c o r d e r s
O p tim is a tio n
O p tim is a tio n A d v a n c e P ro c e s s C o n tro l

H a z o p / R is k M a n a g e m e n t
S a fe ty
E m e rg e n c y S h u td o w n S y s te m s
A la r m ,
M o n ito r in g , D is tr ib u te d C o n tr o l S y s te m
C o n tro l C o n tr o l,
R e g u la to r O N -O F F , S u p e r v is o r y C o n tr o l A n d D a ta
S y s te m
In te r lo c k s A c q u is itio n S y s te m
S ta rt-u p
P e r m is s iv e P r o g r a m m a b le L o g ic
T r ip s C o n tr o lle r s
F IE L D : T r a n s m itte r s & fie ld d e v ic e s -
F IE L D F IE L D : S in g le L o o p C o n tr o lle r s
S w itc h e s , C o n tr o l v a lv e s
 The distribution of applications and business logic
across multiple processing platforms

Distributed processing implies that processing will occur on more

than one processor in order for a transaction to be completed.

In other words, processing is distributed across two or more machines

and the processes are most likely not running at the same time, i.e.
each process performs part of an application in a sequence.

Often the data used in a distributed processing environment is also

distributed across platforms.
Basic Building Blocks
• The constitution of DCS can be broadly divided in to three
parts
– Front End presentation or
• MMI - ( Man Machine Interface )
• GUI Graphical User Interface
- Operator Graphics
– Control Algorithms and Logic.
• Add Subtract, PID, ON-OFF, AND, OR , NAND , etc.
– Communication
• Star
• Ring
• Linear Bus
• Star Wired Ring
Basic Building Blocks Platforms

– Hewlett Packard : ABB

– IBM AS 400 : Honeywell, Yokogawa
– Sun Sparc series 30 - 80 : Foxboro
– Digital (VAX ) Fisher Rosemount
Basic Building Blocks Operating Systems

– HP Unix - ABB
– Sun Solaris - Foxboro
– Ultrix/ OS 2 - Honeywell
– VAX VMS - Fisher Rosemount
Types of databases
• Flat file
• Hierarchical data bases
– Parent Child relation ship
• Relational databases
– Oracle
– Ingress
– Informix
– Developer 2000
• Object linked Relational databases
Basic Building Blocks - Control Languages

– Basic
– Pascal
– C, C++
– Fortran 77
Basic Building Blocks - Control algorithms
– Analog Input / Output Block
– PID Block / Auto tune PID block
– Digital Input/Output Block
– Calculation Block / Advance Calculation Block
– Characterizer Block
– Comparison blocks - Less than.More than, Equal to.
– Switch blocks
– Data blocks / memory blocks
– Sequence blocks
– Mathematical block
– General Device Block
– Programmable Logic Block
– Motor Operator Valve, Pneumatic Valve control block
 Communication

Network
Topologies

Physical Logical

Linear
Star Tree Ethernet FDDI
Bus

Star
Token
Ring Wired ATM
Ring
Ring
Communication
Communication
802.3: Established the new standard for a LAN that features a
Carrier Sense, Multiple Access with Collision Detection
(CSMA/CD). This "new" LAN is properly referred to as
CSMA/CD, but is more commonly known as "Ethernet."

802.4: Defined a physical layer standard for a bus topology LAN

with a token-passing media access method. This LAN is called
Token Bus and can operate at 1, 2, 5, or 10Mbps.

802.5: Established the standards for Token Ring's access methods

and physical signaling techniques.
DISTRIBUTED CONTROL SYSTEM (DCS)
Design Basis
DCS Design Basis
 The entire design has followed the federal constitution of
our country with nominal head and small assisting team
like core group at the top.
 Network architecture design is such that, it is functionally,
geographically and administratively well distributed to
have total stability at any point of time.
 The DCS design architecture is distributed for:
 Different business processes.
 Work Breakdown Structure
 Maintenance & operation organogram of RPL.
DCS Design Basis
 Modular design
 Ease of erection, commissioning and distributed operation
independent of the Refinery wide LAN.

 Extensive use of Fiber Optic:

 Since the entire network is distributed over 50 Sq. Km of area
having different earthing resistance for different soils (Rocky to
Marine ), Fiber Optic cable external to the building is used
extensively to facilitate distributed and local grounding of
equipments to..
 Avoid loop currents
 Ground currents
 Parasitic effect of noises like RFI, EMI and cross talks.
DCS Design Basis
 Taking care of limitations of hardware, network and software.
 All the six systems are connected through PIN for site wide integration
of information.
 Real- time data exchange among all the systems using Modbus device
integrators.
 Minimum communication load on LAN.
 Each plant can be started and shutdown independently.
 Expandability of the System at every level .
DCS Design Basis
 Ease of Software upgradation at node level without
disturbing complex wide operation.
 Control I/Os, respective control processor and respective
operator stations are on the same node, thereby minimizing
the traffic on LAN and maximizing the availability of the
system for operation.
 RTF, RRTF and Marine Terminal systems are kept on the
same LAN for the purpose of ease of data transfer for
TIS/OMIS/BOSS applications.
 Redundancy at all level - be it processors, communication
or power supplies.
DCS Design Basis
 Emergency Shutdown Systems are integrated with DCS
and Human Interface from DCS.
 All third party packages are integrated with the system
through redundant serial link to achieve a single point
operation from DCS i.e 100% measurements parameters
are monitored and controlled from single point.
 Remote diagnosis from Foxboro, USA, Holland or
Singapore using dial-up networking / ISDN.
DCS Design Basis
 Building Block Technology:
 The processing is confined within at cell (CP) level so as peer to
peer communication between the processors within the node bus
and across nodebus is minimized. This is achieved by means of:
 Proper distribution of the tags in the FBMs.
 Allocations of loops within CPs.
 Allocation of units at the nodebus level.
 Allocation of Operator stations for specific nodebuses.
 Provision of hook up for APC application, Optimizer and any third
party application software at any stage of time.
DCS Design Basis
 Plant Information Network is used for integrating information from
Refinery, Aromatics, MTF, CPP, PP and Port Operations.
 PIN is implemented using fast Ethernet 10/100 mbps Cisco switches
and routers.
 PIN is used for following.
 INI51 for connecting two systems.
 X-Window for interplant graphics transfer among all six systems.
 X-Window anywhere on PCs connected to Reliance WAN.
 Integration with third party application like Infoplus.21.
 To access historian data from system to Window applications.
DISTRIBUTED CONTROL SYSTEM (DCS)
Large Industrial Systems
 DCS MANUFACTURERS

• ASEA BROWN BOWERI - ABB

• TATA HONEYWEL
• FOXBORO - INVENSYS
• YOKOGOWA BLUE STAR - YBL
• ALLEN BRADLEY
• GE FANUC
• FISHER ROSEMOUNT
• TOSHIBA
 DCS INSTALLATIONS AT RELIANCE
SITE
MANUFACTURER
JG HZ PG BARODA NC GANDHAR
ASEA BROWN BOWERI - ABB √ √
TATA HONEYWEL √ √ √
FOXBORO - INVENSYS √ √ √
YOKOGAWA BLUE STAR - YBL √ √ √
SIEMENS
GE FANUC
FISHER PROVOX √ √
TOSHIBA √
Honeywell DCS System Architecture

TPS Uniformance Uniformance Remote GUS

Builder Desktop Applications Display
Server
Fisher Provox DCS System Architecture
Yokogawa Centum DCS System Architecture
 ABB DCS System Architecture
Information Network TCP/IP

OPERATOR
STATION ( OS )
INFORMATION
ENGINEERING MANAGEMENT
STATION ( ES ) SYSTEM (IMS)
DUAL DCN
RING
RING 0

RING 1

C Controller

Advant
Controller 460

SC Controller
ABB DCS System Architecture
Distributed Communication Network (DCN)

 Total Nodes per Ring 29

 Total Nodes/Network 255
 Total Rings/Network 85
 Maximum end-to-end length/Ring 14 miles/ring
 Maximum distance between two active nodes 5280 ft* wire
 Fiber-optic 10,000 ft
*recommend 1 mile (5280 ft, 1600 M) between 3 nodes
ABB DCS System Architecture
Typical Schematic Diagram For Information Flow
From TX
JB TB B/R TRIO CSS

FIELD CONTROL ROOM OS

JB TB B/R TRIO CSS

To O/P

JB = JUNCTION BOX TRIO = TAYLOR REMOTE I/O

TB = TERMINATION BOX CSS = CONTROL SUB SYSTEM
B/R = BYPASS RELAY OS = OPERATOR STATION
FOXBORO I/A Series DCS System Architecture
A brief Introduction

I/A Series FieldbusIEEE 1118

Digital Field Link

Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro
LBUG

LBUG

Intelligent &
XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

Conventional
Fieldbus Module Fieldbus Cards
Field Devices
 FOXBORO I/A Series DCS System Architecture

I/A Series Nodebus

IEEE 802.3

Control Application Device

Communications Integrator
Workstation Processor Processor Processor COM 10 ( DI,MG 30 )
Processor (CP - 40) (AW - 51)
(WP - 51)
I/A Series Fieldbus
IEEE 1118

Peripherals
3rd Party Devices e.g.
Digital Field Link ; PLC’s, ESD’s RTU’s
B/W & Scanners Power Plant
Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro

Color Scales Tank Farms

Printers,Analyzers Spectrum
LBUG

LBUG

Intelligent & XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

Conventional Terminals;
FoxWatch
Fieldbus Module Fieldbus Cards
Field Devices
 FOXBORO I/A Series DCS System Architecture

I/A Series LAN

I/A Series Nodebus

IEEE 802.3

Control Application Device

Communications Integrator
Workstation Processor Processor Processor COM 10 ( DI,MG 30 )
Processor (CP - 40) (AW - 51)
(WP - 51)
I/A Series Fieldbus
IEEE 1118

Peripherals
3rd Party Devices e.g.
Digital Field Link ; PLC’s, ESD’s RTU’s
B/W & Scanners Power Plant
Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro

Color Scales Tank Farms

Printers,Analyzers Spectrum
LBUG

LBUG

Intelligent & XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

Conventional Terminals;
FoxWatch
Fieldbus Module Fieldbus Cards
Field Devices
 FOXBORO I/A Series DCS System Architecture
Information Network TCP/IP
IEEE 802.3

Computers,
Workstations,
X-Terminals, I/A Series LAN IEEE 802.4
PC’s etc

I/A Series NodebusIEEE 802.3

Control Application Device

Communications Integrator
Workstation Processor Processor Processor COM 10 ( DI,MG 30 )
Processor (CP - 40) (AW - 51)
(WP - 51)
I/A Series Fieldbus
IEEE 1118
RS - 232 RS - 232

Peripherals
3rd Party Devices e.g.
Digital Field Link ; PLC’s, ESD’s RTU’s
B/W & Scanners Power Plant
Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro Foxboro

Color Scales Tank Farms

Printers,Analyzers Spectrum
LBUG

LBUG

Intelligent & XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX

Conventional Terminals;
FoxWatch
Fieldbus Module Fieldbus Cards
Field Devices
FOXBORO I/A Series DCS System Architecture
Reliance Jamnagar DCS Architecture

Functions of Equipment installed in PCC’s

System administration and System management (AW51)
File server (AW51)
Human Interface for Plant Operations (WP51)
Alarm management (AW51, WP51)
Interface as Engineering station (AW51)
Information management - Historian and Reports (AW51)
Interface for System Maintenance (AW51, WP51)

Functions of Equipment installed in PIB’s

Interface for process inputs and outputs (FBMs and FBCs)
Process Control (CP40)
Interface for third party systems via serial links (INT30)
DISTRIBUTED CONTROL SYSTEM
Jamnagar
 DCS SYSTEM RELIANCE JAMNAGAR
Highlights:
 Total nodes across the complex - 41 No.
 LAN Length - 19.6 Km
 Total panels - 1102nos.
 Total I/Os - 182,375 No.
 Total Stations - 1367 No.
 Total FBMs - 3307 No.
 Total Serial Links - 270
 Total cost of DCS within complex - 300 crore (approx
$60m)plus.
 Fiber Optic cable used - 242 KMs
Reliance Jamnagar DCS Architecture

World’s Longest ever Real-Time Control Network for TMS.

World’s Largest System with more then 257 stations in ROS.

The DCS is configured as 6 systems as listed below.

 Refinery ( ROS )
 Tank farms ( TMS )
 Captive Power Plant
 Aromatics Plant
 Poly Propylene Plant
 Port Operations

Within each system the I/A series node buses are interconnected by Fiber
Optic LAN Interface modules.
Reliance Jamnagar DCS Architecture
Refinery
15 Node System
Refinery PCC, PIB’s 6, 7, 8, 9, 10, 11, 13, 14, 15, 16, 17, 18
Tank Farms
11 Node System
Marine PCC and PIB’s 19, 20, 21, 23, 27, 28, 29

Captive Power Plant

3 Node System
CPP PCC, and MRS 1, 2
Aromatics Plant
6 Node System
ARO PCC, and PIB’s 1, 2, 3, 4, 5
Poly Propylene Plant
5 Node System
PPP PCC A&B, and PIB’s 24, 25, 34
Port Operations
Single Node System
Port PCC
 OPTION -1
SPLITTING IN TWO NETWORK - AS PER BUSINESS

R1 R2 R3 R4 R5 R6 R7 F1 F2 F3 F4 U2 13 23

REFINERY OPERATIONS SYSTEM

ISSUES:
E1 INI51/HOST
AW 1. INI51 IS NOT REDUNDANT
F5
2. SEPERATE AWS ARE TO BE PROVIDED ON EITHER SIDE

3. MOVED STATIONES ARE TO BE DELETED FROM SYSDEF AND AWS

TCP/IP
4. ADDITIONAL LAN LOADING ON TANK FARM MANAGEMENT SYSTEM
DUE TO EXAPNSION OF 70 TANKS.

INI51/HOST
AW

22 19A U1 19 M1 27 28 29 21 R8 E1

TANK FARM MANAGEMENT SYSTEM

 Integration of Applications: Overview
IP.21
LIMS
MODEBUS Plant
Open YIELD ACC.
RTU Industrial Information
DATA RECONS
MODEBUS Standard Integration
X-Window
ASCII AIM*Historian
RIMS
AB DH +
INI51

IMAC

Integrated
Industry Solutions

TIS OMIS BOSS TAS APC

Software Overview

Operating System: Sun OS 5.5.1 based on Unix IV

Human Interface: Foxdraw for Graphics Building & Configuration and Foxview for
display of graphics
Alarm Manager – For Current Alarm Summary, Alarm History Display.
ICC – Integrated Control Configurator, provides software blocks for continuos,
sequence and lader logic control.
System Configurator – For system configuration of the hardware and software
Historian – For collecting sample data for history and trends
Report Writer – For daily, weekly, monthly reports
SMDH – System Management and monitoring
Functionality

Engineering Station (Application Workstation AW51B) :

Operating system Sun OS runs on AW51B, that is main server for the system
and seat on the Nodbus.
All other configuration software likes Historian, ICC, and all advance
applications also run on AW51B.
Mainly used for Configuration, System Diagnostic and downloading
configuration to all stations configured.
Can be used as Operator station.
Functionality
Integrated Control Configuartion:
The Integrated Control Configurator database is the backbone of the I/A Series
control subsystem and is the primary means by which real-time process
variables are translated to the DCS environment
The software structure of the Control and I/O (CIO) functions revolve around
the "COMPOUND:BLOCK.PARAMETER" concept.

A compound as a group of blocks related to a particular Plant Unit, Equipment,

Subsystem etc.

A block is a member of a set of predefined algorithms designed to perform

mathematical, logical or boolean operations on one or more values.

Both blocks and compounds have PARAMETERS. Parameters include real-

time values and may be used for display, trending and other processing
requirements.
Integrated Control Configuartor
Functionality
Human Interface (Operator Work Station):
Operator Work station processor with single or dual CRT, Annunciator Key
Board, Trackball and touch screen provide human interface.

The Concept of efficient process control using an operator interface is with the
following basic utilities:

Process Graphics
ESD Graphics
Group / Trend Displays
Face Plate Overlays
Alarm Manager
Process Graphics
Functionality

Process Graphics:
There are four levels of graphics used in Project.
Level –1: Complex Overview
Level – 2: Plant wide Overview
Level –3: Based on PFDs
Level – 4: Based on P&Ids

In addition to above following are other graphics used for the Project.
Group Display: Group of eight Face plate or four Face plate and four treads.
Overlay: Faceplates, Pump START/STOP etc.
Functionality

Work Station Access:

Environments

Workstation Processors provide security through access levels for different

categories of system users. Password protection can be configured for each
environment.

The environments configured for this project are defined in next slide.
Functionality
Environment Access Level Authorisation
Field_Op_Env 1 Can view displays, Cannot change values
(SP, Output, Auto-Manual etc.),
Cannot acknowledge alarms

Ctrl_Rm_Op_Env 2 All Field_Op_Env access, Can change values

(SP, Output, Auto-Manual etc.), only for WPs
Can acknowledge alarms, Cannot change alarm limits

Supervisor_Env 3 All Ctrl_Rm_Op_Env access, only for WPs

Can change alarm limits, Can tune controllers,
Cannot access configurators or maintenance functions

Maint_Engr_Env 4 All Supervisor_Env access, Can tune controllers,

Can access configurators and make configuration changes,
Cannot access software management

Soft_Engr_Env 5 All Maint_Engr_Env access,

Can access software management to write programs,
Can access Password configurator and change environment
menus
Environment
Functionality

ESD Graphics:
There are two levels of ESD system graphics:

•ESD Overview (Level 1)

•ESD Detail (Level 2)

Facilities are provided to move from one level to the other and also sideways within
level 2 graphics.

The ESD Overview Level graphic lists all ESD's in the area and summarises their
statuses. Each plant area has a level 1 ESD graphic.

In ESD Detail Level graphics, dynamic Cause and Effect information is depicted.
This includes status of the cause and the commanded and actual statuses of the effect
(e.g., valve position, pump status etc.).
Functionality
FoxAnalyst

A separate application for viewing trends is is available in all Operator

workstation.

Operator can assign a group of 16 trends in one page and save as a

scratch pad.

This application can be opened from pull down menu in operator

environment
Functionality
Alarm manager
Alarm manager can display alarm information in up to six distinct display
windows.

•Current Alarm Display ( CAD )

•Most Recent Alarm Display ( MRA )
•Alarm History Display ( AHD )
•Alarm Summary
•New Alarm Display ( NEWALM )
•Acknowledged Alarm Display ( ACKED )
•Unacknowledged / Return-to-normal Alarm Display ( UNACK)
Alarm manager
Functionality

Historian & Reports:

The Historian collects, stores, processes, and archives process data
from the control system to provide data for trends, Statistical Process
Control charts, logs, reports, spreadsheets, and application programs.

The Historian is a tool for collecting, organizing, and storing data

for later retrieval. It contains built-in algorithms for reducing data
and provides workstation displays to retrieve and display data .
Typical data are process analog and/or digital points.

Historian Functions
 Collect process control point samples
 Reduced point samples
 Application-generated alarms & messages
Trends
Functionality

Advance Applications:
TIS : Tank Inventory System for Tank Farm Management

BOSS : Blending & Optimisation Supervisory System

OMIS : Oil Movement & Information System

Information Management:
IP.21 is interface with DCS for integration with SAP to form
Refinery Information Management System.

Foxhistory : Plantwide Consolidated history for generating

reports.

X-window configuration for remote monitoring.