ISA Lunch and Learn

Ken Carfagno November 6, 2013

Agenda
Theory & Practice - Basic control (e.g., regulatory control, feedback, etc) - Discrete control (e.g., relay logic, Boolean algebra) - Sequential control (e.g., (e g batch) - Typical Configuration and Programming - Input/output termination and wiring Implementation - HMI (e.g., graphics, alarm management, trending, historical
data) - Network security

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Basic Control

Control Loop Types & Components

Types of Control Loops

Simple Feedback Control Loop Cascade Control Loops

Components of Control Loops

Basic Elements

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Basic Feedback Control Loop

FR

FIC FIC

FY

FV FT

Most commonly used process control loop

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Basic Loop Components

PID Controller

Controller Output (0-100%)

I P

Recorder

Transducer

FR

FIC FIC

FY Pneumatic Signal

Transmission Signal FV Transmitter FT Final Control Element (control valve)

Primary Element

Detailed description of instrument symbols are on the legend

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E Assembly-Double Block/Bleed w Bypass Valve

Bypass Valve

Block Valve

Block Valve

Control Valve I/P Transducer

Bleed Valve

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Cascade Control Loops

Why incorporate a cascade system? To minimize outside load variables resulting in increased process stability Examples Condensate control
FV

TR

Primary Controller

TT

TIC FIC

Secondary Controller
I

FR

FIC FIC

FY

FT

Fuel gas/oil burner pressure control Quick and frequent hydraulic changes

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Cascade Control
TT TIC

Process
I/P

Basic Loop
TY

Steam

Condensate

TT

TIC

Load Variable Changes

(P1 or P 2 is variable)

Process
FIC

Steam, P 1 FY
FT

I/P

P2 Condensate

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Basic Control Implementation Function Blocks

Cascade from Primary

Input from the transmitter

PID Controller

Output to Valve

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Discrete Control

Simple Process
Automate simple process Push a button to start The value should open automatically When the valve is open, the pump should start automatically The operator watches the level indicator. When the tank is full the operator pushes another button The pump should stop and the valve should close. Valve with actuator IN OUT Float level indicator

Water level

Water Pump

Water Tank

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Honeywell Proprietary & Confidential

Since I am using relays and pushbuttons to do my remote control, I need an electrical diagram to use as my guide for connecting all of the electrical wires so I create the following pushbutton / relay wiring schematic diagram. 120 VAC PB-2 (Start)

(Stop) PB-1

(Open Valve) R1

R1 (Valve Opened) (Run Pump) R2 ZSO-2 R1

120 VAC H PB-1 R1 PB-2 N

R1 R2 ZSO-2 R1

Closed

Stopped

Here is how it works: - Press normally open pushbutton PB-2 and relay R1 is energized.

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120 VAC H PB-1 R1 PB-2 N

R1 R2 ZSO-2 R1

Open

Stopped

Here is how it works: - Press normally open pushbutton PB-2 and relay R1 is energized. - R1 seals in PB PB-2 2 so that when I remove my finger from the button button, R1 stays energized energized. - A contact from R1 relay is wired to my valve actuator. A closed R1 contact opens the valve. Note R1 is also close in the second rung.

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120 VAC H PB-1 R1 PB-2 N

R1 R2 ZSO-2 R1

Open

Start

Here is how it works: - Press normally open pushbutton PB-2 and relay R1 is energized. - R1 seals in PB PB-2 2 so that when I remove my finger from the button button, R1 stays energized energized. - A contact from R1 relay is wired to my valve actuator. A closed R1 contact opens the valve. Note R1 is also close in the second rung. - Valve open contact ZSO-2 is wired from the valve (the contact is closed when the valve is fully open). A closed ZSO-2 contact along with the closed R1 contact energizes relay R2. - A contact from R2 relay is wired to the pump. A closed R2 contact starts the pump.
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120 VAC H PB-1 R1 PB-2 N

R1 R2 ZSO-2 R1

Open

Start

Once the tank is full, I can stop the pump and close the valve. Here is how you do it: - Press normally closed PB-1 and relay R1 is de-energized.

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120 VAC H PB-1 R1 PB-2 N

R1 R2 ZSO-2 R1

Closed

Stopped

Once the tank is full, I can stop the pump and close the valve. Here is how you do it: - Press normally closed PB-1 PB 1 and relay R1 is de de-energized. energized - When R1 is de-energized, the contact from R2 stops the pump and the contact from R1 closes the valve. - Valve open contact ZSO-2 returns to the open state as the valve goes to the closed position.

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120 VAC H PB-1 R1 PB-2 N

R1 R2 ZSO-2 R1

Closed

Stopped

Once the tank is full, I can stop the pump and close the valve. Here is how you do it: - Press P normally ll closed l d PB PB-1 1 and d relay l R1 i is d de-energized. i d - When R1 is de-energized, the contact from R2 stops the pump and the contact from R1 closes the valve. - Valve open contact ZSO-2 returns to the open state as the valve goes to the closed position. - We are back at the beginning of our sequence when I remove my finger from PB-1.
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Typical Connection and Wiring

120 VAC H PB-1 R1 PB-2 N R1 Contact

Here is how we would wire our control circuit.

120 VAC
R1 R2 R1 R2 Contact

120 VAC

ZSO-2

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Control Via PLC, Ladder Logic

DI DO

Here is how we would wire our devices to the PLC I/O.

DI 1 DI 2 DI 3 DI 4 DI 5

PB-1 PB-2 ZSO 2 ZSO-2

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8

Valve Pump

PB-1 Stop

DI 6 DI 7 DI 8

PB-2 Start

ZSO-2
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120 VAC H PB-1 R1 PB-2 N

DI 1 DI 2 DI 3 DI 4 DI 5

PB-1 PB-2 ZSO-2

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8

Valve Pump

R1 R2 ZSO-2 R1

DI 6 DI 7 DI 8

This is what our PLC programming language looks like. DI 1 DI 2 DO 1 DI 3 DO

( )
1

We take all of our wiring information and I/O module information create this program program.

DO 1

DO

( )
22

Notice the relationship between our I/O point numbers and the programming.
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120 VAC H PB-1 R1 PB-2 N

DI 1 DI 2 DI 3 DI 4 DI 5

PB-1 PB-2 ZSO-2

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8

Valve Pum p

R1 R2 ZSO-2 R1

DI 6 DI 7 DI 8

DI 1

DI 2 DO 1 DI 3

DO

( )
1

Also take note that my DI-1 logic contact is normally open. This is because it will be held close by PB-1 when the PLC power is on.

DO 1

DO

( )
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120 VAC H PB-1 R1 PB-2 N

DI 1 DI 2 DI 3 DI 4 DI 5

PB-1 PB-2 ZSO-2

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8

Valve Pum p

R1 R2 ZSO-2 R1

DI 6 DI 7 DI 8

DI 1

DI 2 DO 1 DI 3

DO

The programming is done on a laptop PC.

( )
1

DO 1

DO

( )
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Control via DCS, Function Blocks

H PB-1 R1
PB-2

120 VAC

R1 R2 ZSO-2 R1

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Sequential Control

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Sequential Control
Time ordered control Series of step to meet control objective - Examples:
Equipment Startup or shutdown Non-continuous (batch) process

Sequential Control follows a common pattern - Take action which will cause a change in the process - Wait for the desired change to complete - Repeat

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SCM Example

Embedded Operator Instructions

Step Blocks

Transition Blocks

Configured Handlers

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Basic Wiring

Analog Inputs

Analog Inputs: Questions

Where does the signal power come from? Where does the transmitter power come from? Where is the signal ground?

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Analog Inputs, 2 wire, System Powered

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AI, Current Signal, Self Power

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Human Machine Interface

HMI

HMI Example of Non-Conforming Graphic

T200 FRAC OVRHD CSR FI226 400.312 MSCFD TI202 281.53 DEGF CW S PI201 18.71 PSI TI201 280.03 F 15% E209 TI203 200.09 DEGF E210 PC105 18.70 PS IG PC106 15 73 15.73 PS IG PI115 10.77 PSIG FI204 000.00 MSCFD FUEL GAS LI224 95 % T203 0% FC234 13.29 KBPD TI223 440.06 F TI213 89.03 F LC204 25 % SOUR W TR 50% SL OP 100% P209 P211 FL ARE

FC201 4608.23 BPD D200

85% LI214 85 %

65%

T200 TEM PS
1-281.53 DEGF 2-280.03 DEGF 3-271.89 DEGF 4-266.00 DEGF 5-255.44 DEGF 6-254.99 DEGF 7-266.92 DEGF

T200

VRU

C205

AI241 320.78 AMPS FC214 1308.29 BPD

NAP HT HA

P210

P212

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HMI Example of ASM Graphic

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Abnormal Situation Management Study

Comparing ASM designed operator interface (multiwindow) vs standard operator interface (single window)

- 21 Operators - Matching process upsets on

simulator

>38% improvement in recognizing process deviations before an alarm 26% improvement in their ability to successfully resolve problem p 35-48% improvement in overall operator response time to deviations

Source: ASM Meeting report Oct. 2004

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Context-sensitive Access to Information

Context-Sensitive Menus

Alarm help Operating procedures

Trends and analysis tools Alarm management tools Maintenance management tools

Quicker response & Less errors

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Alarm Management
Filtering Sorting Alarm Shelving Alarm Commenting Custom Views Alarm Details Links to Detail & Associated Displays Alarm Help p Dynamic Alarm Suppression

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Trending
Trending - Events Integration - Custom Trend - 32 Pens - Resizable views - Save on demand - Improved User Interface - Easy to use time range
selections

Operators can invoke the Operators can invoke the Location Pane to quickly Location Pane to quickly filter event data to filter event data to specific process areas. specific process areas.

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Trending Examples
Trend Navigation Bar Chart

Trend with Events

Trend with Numerics

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Secure Network Architectures

Manufacturing automation architecture

ISA99 functional hierarchical model
Level 4

Business Planning & Logistics

Plant Production Scheduling, Operational Management, etc

4 - Establishing the basic plant schedule production, material use, delivery, and shipping. Determining inventory levels. Ti Time Frame F Months, weeks, days 3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process. Time Frame Days, Shifts, hours, minutes, seconds

Level 3

Level 2 Batch Control Level 1 Level 0 Continuous Control

2 - Monitoring, supervisory control and automated control of the production process Time Frame Discrete Hours, minutes, seconds, subseconds
Control

1 - Sensing the production process, manipulating the production process 0 - The actual production process

ISA99
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Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...

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PROCES SS CONTROL DOMAIN

Manufacturing Operations Management

OFF FICE DOMAIN

Typical PCS Network Topology

Level 4
Firewall Terminal Patch Anti eServer Server Mgmt Virus Server Server RD 3 Party App Subsystem EAS Interface PHD Shadow Server

L4 to L4 Limited L3.5 to L3.5

Level l 3.5 3 DMZ

Domain Controller ESF PHD Server Experion Server

L3 to L3 Limite d L2 to L3

ESC

ESF

ACE

Experion Server

EST

Level 2 Level 1

Qualified Cisco Switches

L2 to L2

L1 to L1

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Security levels
Level 1 - Controllers and real time control Level 2 Servers, Operator Stations and supervisory control. Level 3 - Historians and Advanced Control and connection to other Level 2 areas or units. Level 3.5 - DMZ accessed from the Business Network and the PCN. Level 4 - Is the business network with clients for Historians or Advanced Control applications. Level 3 and 3.5 utilizes standard open systems Ethernet technology and Level 4 utilizes standard open systems LAN technology.

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No communications betw ween L1 & L3 or L4

File Number File Number

Domain Controller

Limite d L2 to L1

Very Limited L2 to L3.5

Level 3

Router

Optional HSRP Router ESVT Safety Terminal Server Manager

No Direct communications between L4 & L3 or L2

Enterprise Switch

Comm flow

Very Limited L3 to L3.5

Very Limited L3.5 to L4

Level 1 Process Control

Level 4
Firewall Terminal Patch Anti eServer Server Mgmt Virus Server Server RD 3 Party App Subsystem EAS Interface PHD Shadow Server

L4 to L4 Limited L3.5 to L3.5

Level 3.5 DMZ

Domain Controller ESF PHD Server Experion Server

L3 to L3 Limite d L2 to L3

ESC

ESF

ACE

Experion Server

EST

Level 2 Level 1

Qualified Cisco Switches

L2 to L2

L1 to L1

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Level 1 - Process Control

Controllers and real time control Safety Systems Protected by all other levels

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No communications s between L1 & L3 or L4

File Number File Number

Domain Controller

Limite 2 to d L2 L1

Very Limited L2 to L3.5

Level 3

Router

Optional HSRP Router ESVT Safety Terminal Server Manager

No Direct communica ations between L4 & L3 or L2

Enterprise Switch

Comm flow

Very L3 Limited L to L3.5

Very Limited L3.5 to L4

Level 2 Supervisory Control

Level 4
Firewall Terminal Patch Anti eServer Server Mgmt Virus Server Server RD 3 Party App Subsystem EAS Interface PHD Shadow Server

L4 to L4 Limited L3.5 to L3.5

Level l 3.5 3 DMZ

Domain Controller ESF PHD Server Experion Server

L3 to L3 Limite d L2 to L3

ESC

ESF

ACE

Experion Server

EST

Level 2 Level 1

Qualified Cisco Switches

L2 to L2

L1 to L1

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Level 2 - Supervisory Control

Connections for Servers and Operator Stations Supervisory control Connection to Level 1 Protection for Level 1 with access lists FTE capable

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No communications betw ween L1 & L3 or L4

File Number File Number

Domain Controller

Limite d L2 to L1

Very Limited L2 to L3.5

Level 3

Router

Optional HSRP Router ESVT Safety Terminal Server Manager

No Direct communications between L4 & L3 or L2

Enterprise Switch

Comm flow

Very Limited L3 to L3.5

Very Limited L3.5 to L4

Level 3 Advanced Control

Level 4
Firewall Terminal Patch Anti eServer Server Mgmt Virus Server Server RD 3 Party App Subsystem EAS Interface PHD Shadow Server

L4 to L4 Limited L3.5 to L3.5

Level l 3.5 3 DMZ

Domain Controller ESF PHD Server Experion Server

L3 to L3 Limite d L2 to L3

ESC

ESF

ACE

Experion Server

EST

Level 2 Level 1

Qualified Cisco Switches

L2 to L2

L1 to L1

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Level 3 - Advanced Control

Connections for Historians and Advanced Control g Routing Access List control Connect other Level 2 areas or units Can be redundant, but not FTE capable HSRP

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No communications betw ween L1 & L3 or L4

File Number File Number

Domain Controller

Limite d L2 to L1

Very Limited L2 to L3.5

Level 3

Router

Optional HSRP Router ESVT Safety Terminal Server Manager

No Direct communications between L4 & L3 or L2

Enterprise Switch

Comm flow

Very Limited L3 to L3.5

Very Limited L3.5 to L4

Level 3.5 Demilitarized Zone (DMZ)

Level 4
Firewall Terminal Patch Anti eServer Server Mgmt Virus Server Server RD 3 Party App Subsystem EAS Interface PHD Shadow Server

L4 to L4 Limited L3.5 to L3.5

Level l 3.5 3 DMZ

Domain Controller ESF PHD Server Experion Server

L3 to L3 Limite d L2 to L3

ESC

ESF

ACE

Experion Server

EST

Level 2 Level 1

Qualified Cisco Switches

L2 to L2

L1 to L1

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Level 3.5 - Demilitarized Zone (DMZ)

Is commonly called the DMZ Typical nodes WSUS, Anti-Virus Server, etc. Provides connectivity for devices that are to be accessed from the Business Network and the PCN. Security zone between the PCN and outside networks Can be redundant, but not FTE capable

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No communications betw ween L1 & L3 or L4

File Number File Number

Domain Controller

Limite d L2 to L1

Very Limited L2 to L3.5

Level 3

Router

Optional HSRP Router ESVT Safety Terminal Server Manager

No Direct communications between L4 & L3 or L2

Enterprise Switch

Comm flow

Very Limited L3 to L3.5

Very Limited L3.5 to L4

Level 4 - Business Network

Level 4
Firewall Terminal Patch Anti eServer Mgmt Server Virus Server Server RD 3 Party App Subsystem EAS Interface PHD Shadow Server

L4 to L4 Limited L3.5 to L3.5

Level l 3.5 3 DMZ

Domain Controller ESF PHD Server Experion Server

L3 to L3 Limite d L2 to L3

ESC

ESF

ACE

Experion Server

EST

Level 2 Level 1

Qualified Cisco Switches

L2 to L2

L1 to L1

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Level 4 Business Network

Is the business network with clients for Historians or Advanced Control applications. Untrusted Network Separated by a firewall No direct connection to Level 3 or below Managed by Business IT department Level 4 utilizes standard open systems LAN technology.

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No communications betw ween L1 & L3 or L4

File Number File Number

Domain Controller

Limite d L2 to L1

Very Limited L2 to L3.5

Level 3

Router

Optional HSRP Router ESVT Safety Terminal Server Manager

No Direct communications between L4 & L3 or L2

Enterprise Switch

Comm flow

Very Limited L3 to L3.5

Very Limited L3.5 to L4

Questions?

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Thank You

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