( IDC AND DCS NOTES )

(Ch-5)
1. Industrial Communication System. (Map and Top protocol)
Ans : An industrial communication network is a backbone for any automation
system architecture as it has been providing a powerful means of data exchange,
data controllability, and flexibility to connect various devices.
These networks, which can be either LAN (Local Area Network, which is used in a
limited area) or WAN (Wide Area Network which is used as global system)
enabled to communicate vast amounts of data using a limited number of
channels.
As the industrial automation systems become complex and large with more
number of automation devices on control floor, today, the trend is toward Open
Systems Interconnection (OSI) standards that permits to interconnect and
communicate any pair of automation devices reliably irrespective of the
manufacturer.
Data communication refers to the transformation of information or data, mostly
in digital format from a transmitter to a receiver through a link (which can be
copper wire, coaxial cable, optical fiber, or any other medium) connecting these
two.
Industrial communication network is a special type of network made to handle
real-time control and data integrity in harsh environments over large installations.
The examples of industrial communication networks include Ethernet, DeviceNet,
Modbus, ControlNet, and so on.
Industrial networking also led to the implementation of various communication
protocols between digital controllers, field devices, various automation related
software tools and also to external systems.
The Various Protocol including in Industrial communication are , (MAP AND TOP).
MAP is a hardware/software protocol developed jointly by a group of industries
and vendors of computers and PLC 20s. It follows the ISO OSI model.
Manufacturing Automation Protocol (MAP) interface unit couples a local area
network (LAN) to a MAP network. The LAN
Includes a plurality of industrial programmable logic controllers (PLCs) and the
MAP network includes a plurality of MAP devices.
The MAP interface unit comprises a CPU for performing a plurality of routines. A
first routine controls the coupling of the MAP
Interface unit to the MAP network and a second routine controls the coupling of
the MAP interface unit to the LAN. A further routine disposed between the first
coupling routine and the second coupling routine converts messages from the
MAP devices on the MAP network to messages to the PLCs on the LAN and
converts messages from the PLCs to messages to the MAP devices.
MAP specifications were “intended to define a Local Area Network for terminals,
computing resources, and programmable devices within a plant or complex,”
while allowing for the interconnection “of multiple LAN’s and for connection to
Wide Area Networks or digital PBXs for long distance communications.
TOP is a widely used communication protocol developed by Boeing Computer
Services. TOP is the initiative of a group of computer system purchasers.
Thus TOP is an application-oriented OSI protocol application. Like MAP , TOP is
focused on the OSI model of seven layers.The major difference between the MAP
& TOP is occurring in the first and seventh layers.
MAP/TOP architecture
2) OSI MODEL.
ANS : The OSI Model (Open Systems Interconnection Model) is a conceptual
framework used to describe the functions of a networking system. The OSI model
characterizes computing functions into a universal set of rules and requirements
in order to support interoperability between different products and software

Physical Layer
The lowest layer of the OSI Model is concerned with electrically or optically
transmitting raw unstructured data bits across the network from the physical
layer of the sending device to the physical layer of the receiving device. It can
include specifications such as voltages, pin layout, cabling, and radio frequencies.
At the physical layer, one might find “physical” resources such as network hubs,
cabling, repeaters, network adapters or modems.

Data Link Layer

At the data link layer, directly connected nodes are used to perform node-to-node
data transfer where data is packaged into frames. The data link layer also corrects
errors that may have occurred at the physical layer.
The data link layer encompasses two sub-layers of its own. The first, media access
control (MAC), provides flow control and multiplexing for device transmissions
over a network. The second, the logical link control (LLC), provides flow and error
control over the physical medium as well as identifies line protocols.
Network Layer
The network layer is responsible for receiving frames from the data link layer, and
delivering them to their intended destinations among based on the addresses
contained inside the frame. The network layer finds the destination by using
logical addresses, such as IP (internet protocol). At this layer, routers are a crucial
component used to quite literally route information where it needs to go
between networks.
Transport Layer
The transport layer manages the delivery and error checking of data packets. It
regulates the size, sequencing, and ultimately the transfer of data between
systems and hosts. One of the most common examples of the transport layer is
TCP or the Transmission Control Protocol.

Session Layer
The session layer controls the conversations between different computers. A
session or connection between machines is set up, managed, and termined at
layer 5. Session layer services also include authentication and reconnections.

Presentation Layer
The presentation layer formats or translates data for the application layer based
on the syntax or semantics that the application accepts. Because of this, it at
times also called the syntax layer. This layer can also handle the encryption and
decryption required by the application layer.

Application Layer
At this layer, both the end user and the application layer interact directly with the
software application. This layer sees network services provided to end-user
applications such as a web browser or Office 365. The application layer identifies
communication partners, resource availability, and synchronizes communication.

3) Communication Hierarchy.
Ans : Device Level:
This lowest level consists of field devices such as sensors and actuators of
processes and machines. The task of this level is to transfer the information
between these devices and technical process elements such as PLCs.
 The information transfer can be digital, analog or hybrid. The measured values
may stay for longer periods or over a short period.In order to provide field level
communication, 4-20 mA current loop, serial point-to-point communication
methods are widely used.
These networks consist of parallel, multiwire cables as transmission medium. The
common serial communication protocol standards used in this level include
RS232, RS422 and RS485. There are many other field level communication
networks available which are characterized different factors such as response
time, message size, etc.
Nowadays, fieldbus technology is the most sophisticated communication network
used in field level as it facilitates distributed control among various smart field
devices and controller. This is a bidirectional communication system in which
many variables are taken care by single transmission. Different types of fieldbuses
include HART, ControlNet, DeviceNet, CAN Bus, Profibus, and Foundation Field
Bus.
Control Level:
This level consists of industrial controllers such as PLCs, distributed control units,
and computer systems. The tasks of this level include configuring automation
devices, loading of program data and process variables data, adjusting set
variables, supervising control, displaying variables data on HMIs, historical
archiving, etc. So this level requires characteristics like short response time, high
speed transmission, short data lengths, machine synchronization, constant use of
critical data, etc.

Local Area Networks (LANs) are widely used as communication networks in this
level to achieve desired characteristics. The Ethernet with TCP/IP protocol is
mostly used as control level network to connect control units with computers. In
addition, this network acts as a control bus to coordinate and synchronize
between various controller units. Some fieldbuses are also used in this level as
control buses such as Profibus and ControlNet.
Information Level:
This is the top level of the industrial automation system which gathers the
information from its lower level i.e., control level. It deals with large volumes of
data that are neither in constant use or time critical. Large scale networks are
exists in this level.
So Ethernet WANs are commonly used as information level networks for factory
planning and management information exchange. Sometimes these networks
may connect to other industrial networks via gateways.
4) What is a Fieldbus?
Ans : It is a digital two-way multidrop communication link between intelligent
field devices. It is a local area network dedicated to industrial automation.
It replaces centralized control networks with distributed control networks and
links the isolated field devices such as smart sensors/
transducers/actuators/controllers.
Foundation Fieldbus H1 and PROFIBUS-PA are the two fieldbus technologies used
in process control. In this two-way communication, it is possible to read data from
the smart sensor and also write data into it. The multidrop communication facility
in fieldbus results in enormous cable savings and resultant cost reduction.
Primary benefit of Fieldbus is for field connected devices. For instance, consider
you have several field devices that are quite a distance from your controller.
With Fieldbus devices such as sensors, motors, lamps, switches, these devices are
connected to an “I/O data block”, which is then connected to a “field distribution
device”, which is connected to a Fieldbus power supply, then finally connected
back to the Programmable Logic controller.
The connections to the Fieldbus components, with the exception of the field
devices themselves, are single cable connections. This connection scheme may
vary depending on the Fieldbus protocol that you are using.
This type of field device connection saves on wiring runs that would have to go all
the way back to the controller.
5) Smart Transmitter.
Ans : SMART transmitter stands for Single Modular Auto-ranging Remote
Transducer.
It is an intelligent transmitter that has an analog output and simultaneously
provides digital communication signal based on HART protocol or FOUNDATION
FIELDBUS or PROFIBUS.

The output from the smart transmitter no longer just the primary process
variable, but also includes secondary process variables, sensor health, sensor
performance characteristics, calibration information, and real-time diagnostics.
(These data can be accessed through HART protocol or via fieldbus
communication)
The most common digital communication protocols is HART protocol, which
stands for Highway Addressable Remote Transducer.
A HART transmitter contains both a conventional analogue mA signal and a digital
signal superimposed on top of the analogue signal. Since it also has the analogue
signal, it is compatible with conventional installations. Field bus and Profibus
contain only a digital output, with no analogue signal.
Advantages of SMART Transmitters:
Smart transmitters consist of microprocessors and have bi-directional
communication.
Smart transmitters include secondary sensors, that can measure and compensate
for environmental disturbance.
Signal conditioning will be done and also analog to digital conversion.
Smart Transmitters consists of multiple sensors and covering various
measurement ranges and allow automatic selection of the required range.
Disadvantages of SMART Transmitters
As a part of preventive maintenance, calibration or validation can not be avoided,
though the transmitters are SMART.

6) MODBUS

ANS: Modbus is a simple master-slave protocol. The master has full

control of communication on the bus, whereas a slave will only
respond when spoken to. The master will record outputs and read in
inputs from each of its slaves, during every cycle.
The slave devices do not “join” the network. They simply respond
whenever a master talks to them. If the master never talks to them,
then they are idle.
There is also no requirement for diagnostics related to the slave’s
health. If the master requests data that does not make sense to the
slave, then the slave can send an exception response.
The physical layer
Modbus ASCII and RTU both typically use either the RS-232 or RS-485 physical
layer, but can also use other physical layers such as phone lines or wireless.

Typical applications
1. Controller/monitor to a smart device – In this application, there is one
smart device from which data needs to be pulled.
2. Controller/monitor to many smart devices from the same vendor – Like the
first application, this is very easy to implement. The variations in the
protocol are generally not a problem.
3. Remote monitoring of information from a smart device – Since the Modbus
protocol is modem-friendly.

7) How does Profibus work?

Profibus is also a master-slave type protocol like Modbus but with an additional
token ring protocol to allow for multiple masters. Also, unlike Modbus, all devices
go through a startup sequence during which they “join” the network. Each slave
maintains a failsafe timer.
If the master does not talk to it within a certain time limit, the slave goes into a
safe state; the master must then go through the startup sequence again before
further data exchange can occur. This, in combination with a watchdog timer in
the master, ensures that all communication occurs every bus cycle with a certain
time value.
The general bus scan would happen as shown in Figure 2. Master A receives the
token, which gives it control of the bus. It will then exchange data with each of its
slaves, and when complete, pass on the token to the next master (if there is one).
The requirement for detailed diagnostics from each slave is also built into the
protocol. During normal data exchange, a slave can alert the master that it has
diagnostics, which the master will then read during the next bus scan.
The main physical layer for Profibus DP is based on RS-485, which Modbus uses.
Both of Profibus’ main physical layers (modified RS-485 and MBP-IS) are highly
detailed and have excellent noise immunity, proven over and over again at
countless sites.
Typical applications
Profibus was designed to automate an entire plant, regardless of its size or
whether the plant is factory automation (composed of discrete input/output) or
process automation (made up of analog input/output). It also does not matter if
all the sections are local or remote: Profibus can handle it all well
Profibus Types
The Profibus family consists of three compatible versions: Profibus-DP, Profibus-
PA and Profibus-FMS.
(CH-2)
1) Local Control Unit.
Ans : Local Control System Architecture
 The above Figure describes a system architecture in which sensors,
controller, and controlled equipment are within close proximity and scope
of each controller is limited to a specific system or subsystem.
Local controllers are typically capable of accepting inputs from a supervisory
controller to initiate or terminate locally-controlled automatic sequences, or to
adjust control setpoints, but the control action itself is determined in the local
controller.
Required operator interfaces and displays are also local. This provides a significant
advantage for an operator troubleshooting a problem with the system, but
requires the operator to move around the facility to monitor systems or respond
to system contingencies.
Examples of local control are the packaged control panels furnished with chillers
or skid-mounted pump packages.
2) Centralized Control System
Centralized control describes a system in which all sensors, actuators, and other
equipment within the facility are connected to a single controller or group of
controllers located in a common control room.
Locating all controls, operator interfaces and indicators in a single control room
improves operator knowledge of system conditions and speeds response to
contingencies.
This type of system architecture was common for power plants and other facilities
using single-loop controllers or early digital controls in the past, but it has now
been largely supplanted by distributed control because of the high cost associated
with routing and installing all control system wiring to a central location.
Centralized Control Systems
Centralized control systems should only be considered for small industrial
facilities and if used, must have fully redundant processors. Where redundancy is
provided in a centralized control system segregated wiring pathways must be
provided to assure that control signals to and from equipment or systems that are
redundant are not subject to common failure from electrical fault, physical or
environmental threats.
3) Distributed Control System
Distributed control system architecture offers the best features of both local
control and centralized control. In a distributed control system, controllers are
provided locally to systems or groups of equipment, but networked to one or
more operator stations in a central location through a digital communication
circuit.
Distributed Control System AArchitectur
Control action for each system or subsystem takes place in the local controller,
but the central operator station has complete visibility of the status of all systems
and the input and output data in each controller, as well as the ability to
intervene in the control logic of the local controllers if necessary.
Advantages of Distributed Control Systems
There are a number of characteristics of distributed control architecture which
enhance reliability:

Input and output wiring runs are short and less vulnerable to physical disruption
or electromagnetic interference.
A catastrophic environmental failure in one area of the facility will not affect
controllers or wiring located in another area.
Each local controller can function on its own upon loss of communication with the
central controller.
Limitations of Distributed Control Systems
There are also specific threats introduced by distributed control architecture that
must be addressed in the design of the system:

Networks used for communication may become electronically compromised from

outside the facility.
Interconnection of controllers in different locations can produce ground loop and
surge voltage problems.