DeltaV Process Control

System
CM4120
Unit Operations Lab
January 2011

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Outline
Evolution of Process Control

Layout and Architecture of the DeltaV system in

the PSCC

Physical connections between process

instrumentation and the DCS

What the engineers and operators see

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Evolution of Controllers
1930’s – Pneumatic Controllers
• air pressure w/ flappers, bellows, and valves
adjust valve position based on measured
process variable for P, PI, later PID control
1950’s – Electronic Controllers
• transistors, resistors, and capacitors for P, PI,
PID control
• capable of remote installation
1960’s – Mainframe Computer Control
• Refineries were typical users
• Alarming capability and supervisory control
• Single point of failure, no user-friendly
graphical interface

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Evolution of Controllers
Late 1970’s – Distributed Control Systems
(DCS)
• Networked computers distributed thru plant
• Pre-configured controllers
• Data archival capabilities
• Included an operator console
• Hardware was proprietary
Late 1990’s – DSC’s built on commodity
hardware platforms (COTS)
• Better scalability
• Affordable

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Distributed Control System (DCS)
Functionality
y Continuous control of processing equipment
y Pre-programmed control software – needs
only to be configured
y Control functions are distributed throughout
redundant, deterministic networked computer
architecture
◦ I/O interface and level 1 (basic) control
functions
◦ advanced control functions
◦ interactive graphical interface (HMI)

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 DeltaV Architecture: ProPlus server

Plant Area – valves, xmitters

MD Controller
and I/O Cards

ProPlus
Server

PSCC_DeltaV
Redundant Hub

•Stores/serves configuration
•Archives data
•Displays information
•Allows control of process
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 DeltaV Architecture: Operator Stations

Plant Area – valves, xmitters

MD Controller
and I/O Cards

ProPlus
Server

PSCC_DeltaV
Redundant Hub

•Archive data
•Display information (HMI)
•Allows process changes Operator Stations

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 Communication paths…

Redundant Control network

MD Controller
Windows XP Workgroup –
PSCC_DeltaV
PSCC_DeltaV
Windows Networking and Redundant Hub
ProPlus
TCP/IP protocol Server

Operator Stations

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DeltaV’s MD Controller and I/O –
How it connects to the process…
Plant Area – valves, xmitters

MD Controller
and I/O Cards

ƒI/O cards are specific to device requirements

•4-20 mA input, 4-20 mA output
•24 VDC input, 24 VDC output, etc.
•Foundation Fieldbus Interface

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 Emerson’s DeltaV System –
Current State of the Technology
PID control
Discrete logic control
Signal conversions
Alarming
Fuzzy control, etc.
are continuously executed
by the “MD” controller

10
Wiring Systems Connect Transmitters
to DCS – at the Instrument End:

Wiring to field
Level transmitter junction cabinet

RTD or T/C head

Wiring from
transmitter to temp
measuring element

Temperature
transmitters
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Wiring Systems Connect Transmitters
to DCS – at a Marshalling Cabinet:

Single pairs
from field
devices

8 pr. Cables to
controller
cabinet

8-pr. cables run from Field Junction Box (Marshalling

Cabinet) to Distributed Control System
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Wiring Systems Connect Transmitters
to DCS – in the Controller Cabinet:
DeltaV “MD” controller

I/O cards
Power-limiting
Zener barriers

8 pr. cables from

field junction cabinet

2nd I/O chassis w/4-20

mA Output cards

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Wiring Systems Connect DCS to
Transducers – at Marshalling Cabinet:
8-pr. cable from
controller cabinet

Current to pneumatic
transducers

Air lines to Wire prs. to transducers

control valves

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Regulatory Control Valve

Air line from I/P transducer

Actuator w/ positioner

Control valve

Block valves

Bypass valve

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Output Signals from Control System
to Control Solenoids
Solenoids for 2-position 8-pr. cable from
air-actuated ball valves controller cabinet

Air lines to
ball valves

Wire prs. to solenoids

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Installed Field Devices:
Ball Valve w/ Actuator

Air line from

solenoid
Ball valve body

Actuator

Process line

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 DeltaV & Foundation Fieldbus
(4) mass flows, (4) densities,
and (4) RTD temps
(3) 8-multiplexed RTD temps
(2) temp-only transmitters
(1) wire

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 The directory tree for our DeltaV
system…

Control modules

ProPlus server
MD controller w/ I/O
cards and controllers

Fieldbus I/O card

w/instruments

Operator Stations

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A typical PID Control Module…

Analog Input
function block

PID function block

Analog Output
function block

20
Configuring a PID Control Module…

Alarm
configuration
PID tuning
configuration

Configuration for
I/O signals

Configuration of
operating
parameters

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What an operator might see…

22
References
www.emersonprocess.com/rosemount/,
Rosemount, Inc., Oct. 2006.
www.emersonprocess.com/micromotion/, Micro
Motion, Inc., Oct. 2006.

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