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DeltaV Process Control System

CM4120 Unit Operations Lab January 2011

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

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

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

Distributed Control System (DCS) Functionality


y y y

Continuous control of processing equipment Pre-programmed control software needs only to be configured 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)

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

Communication paths
Redundant Control network Windows XP Workgroup PSCC_DeltaV Windows Networking and TCP/IP protocol
MD Controller

PSCC_DeltaV Redundant Hub

ProPlus Server

Operator Stations

DeltaVs MD Controller and I/O How it connects to the process


Plant Area valves, xmitters

MD Controller and I/O Cards

I/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

Emersons 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

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Wiring Systems Connect Transmitters to DCS at the Instrument End:

Level transmitter

Wiring to field 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 control valves Wire prs. to transducers

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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 air-actuated ball valves Air lines to ball valves 8-pr. cable from controller cabinet

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

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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

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

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