A Laboratory Manual for

INDUSTRIAL DATA COMMUNICATION

AND
DISTRIBUTED CONTROL SYSTEM
(3161715)
B.E. Semester-6
(Instrumentation and Control Engineering)
Gujarat Technological University

Government Engineering College, Gandhinagar

Directorate of Technical Education, Gandhinagar,

Gujarat

I
 Government Engineering College, Gandhinagar

Certificate

This is to certify that Mr./Ms. ________________________________

Enrollment No. _________________ of B.E. Semester 6 Instrumentation
and Control Engineering of this Institute (GTU Code: _013_) has
satisfactorily completed the Practical work for the subject Industrial Data
Communication and Distributed Control System (3161715) for the
academic year 2023-24 .

Place: __________

Date: __________

Name and Sign of Faculty member

Head of the Department

II
 Preface

Main motto of any laboratory/practical/field work is for enhancing required skills as

well as creating ability amongst students to solve real time problem by developing relevant
competencies in psychomotor domain. By keeping in view, GTU has designed competency
focused outcome-based curriculum for engineering degree programs where sufficient
weightage is given to practical work. It shows importance of enhancement of skills amongst
the students and it pays attention to utilize every second of time allotted for practical
amongst students, instructors and faculty members to achieve relevant outcomes by
performing the experiments rather than having merely study type experiments. It is must for
effective implementation of competency focused outcome-based curriculum that every
practical is keenly designed to serve as a tool to develop and enhance relevant competency
required by the various industry among every student. These psychomotor skills are very
difficult to develop through traditional chalk and board content delivery method in the
classroom. Accordingly, this lab manual is designed to focus on the industry defined
relevant outcomes, rather than old practice of conducting practical to prove concept and
theory.

By using this lab manual students can go through the relevant theory and procedure
in advance before the actual performance which creates an interest and students can have
basic idea prior to performance. This in turn enhances pre-determined outcomes amongst
students. Each experiment in this manual begins with competency, industry relevant skills,
course outcomes as well as practical outcomes (objectives). The students will also achieve
safety and necessary precautions to be taken while performing practical.

This manual also provides guidelines to faculty members to facilitate student centric
lab activities through each experiment by arranging and managing necessary resources in
order that the students follow the procedures with required safety and necessary precautions
to achieve the outcomes. It also gives an idea that how students will be assessed by
providing rubrics.

IDC & DCS is a professional elective subject. InDCS systems are used extensively in
industries. In such computer based automation system;information, communication, and
networking technologies have become integral part. So, it is necessary toknow hardware
interfacing with software driven automation system. This course gives an idea of
generalstructure of DCS and communication protocol system, functional elements, data
links, software andalgorithms, communication and control aspects of modern plant
automation system.

Utmost care has been taken while preparing this lab manual however always there is
chances of improvement. Therefore, we welcome constructive suggestions for improvement
and removal of errors if any.

III
 Practical – Course Outcome matrix
Course Outcomes (COs):
After learning the course the students should be able to:

CO1 :Analyze current philosophy, technology, terminology, and practices used in

automationindustries.
CO2 :Evaluate computer based automation system used in industries ranging from discrete,
continuous process to hybrid processes.
CO3 :Recommend hardware and software for modern automation system required forindustrial
application.
CO4 :Apply relevent concept to configure hardware with software for automation application
CO5 :Understand various communication protocols.
Sr. CO CO CO CO CO
Objective(s) of Experiment
No. 1 2 3 4 5

1.
To Study DCS-Flow-sheet symbol. √ √ √

2.
To study different types of displays in DCS. √ √

3.
To study and prepare cost estimation for DCS. √ √

Tune PID controller for heat exchanger

4. √
usingDCS using VLAB.
To study various hardware and software
5. √
platforms of DCS.
6.
To study programming methods in DCS. √

To study and compare various communication

7. √
protocol.
8.
To study Alarm Management System in DCS. √

To Prepare a case study report on:

9. Application of DCS in Oil Refinery and √
Power Plant.
To perform step by step process of Siemens
10. √
PCS7 DCS hardware configuration.

IV
 Guidelines for Faculty members
1. Teacher should provide the guideline with demonstration of practical to the
students with all features.
2. Teacher shall explain basic concepts/theory related to the experiment to the students
before starting of each practical
3. Involve all the students in performance of each experiment.
4. Teacher is expected to share the skills and competencies to be developed in the
students and ensure that the respective skills and competencies are developed in
the students after the completion of the experimentation.
5. Teachers should give opportunity to students for hands-on experience after the
demonstration.
6. Teacher may provide additional knowledge and skills to the students even though
not covered in the manual but are expected from the students by concerned
industry.
7. Give practical assignment and assess the performance of students based on task
assigned to check whether it is as per the instructions or not.
8. Teacher is expected to refer complete curriculum of the course and follow the
guidelines for implementation.

Instructions for Students

1. Students are expected to carefully listen to all the theory classes delivered by the
faculty members and understand the COs, content of the course, teaching and
examination scheme, skill set to be developed etc.
2. Students shall organize the work in the group and make record of all observations.
3. Students shall develop maintenance skill as expected by industries.
4. Student shall attempt to develop related hand-on skills and build confidence.
5. Student shall develop the habits of evolving more ideas, innovations, skills etc. apart
from those included in scope of manual.
6. Student shall refer technical magazines and data books.
7. Student should develop a habit of submitting the experimentation work as per the
schedule and he/she should be well prepared for the same.

V
 INDEX
(Progressive Assessment Sheet)

Sign. of
Pag Date of Date of Assess
Sr. Teacher
Objective(s) of Experiment e performanc submissio ment Remarks
No. with
No. e n Marks
date
To Study DCS-Flow-sheet
1. 1
symbol.
To study different types of
2.
displays in DCS
To study and prepare cost
3.
estimation for DCS
Tune PID controller for heat
4. exchanger usingDCS using
VLAB.
To study various hardware
5. and software platforms of
DCS
To study programming
6.
methods in DCS
To study and compare
7. various communication
protocol
To study Alarm
8.
Management System in DCS
To Prepare a case study
report on:
9.
Application of DCS in Oil
Refinery and Power Plant.
To perform step by step
process of Siemens PCS7
10.
DCS hardware
configuration.
Total

VI
 Experiment-1

To Study DCS-Flow-sheet symbol.

Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

information about the DCS flow sheet symbols.

Prerequisites: Before proceeding with this tutorial, you must have a understanding of P & I
diagram.

Relevant CO: CO1, CO2, CO4

Objectives: (a) To understand the basics of DCS flow sheet symbol

INTRODUCTION:

DCS flow sheet symbols are specified in standard ISA–5.3–1983. The purpose of this standard is
to establish documentation for that class of instrumentation consisting of computers,
programmable controllers, minicomputers and micro-processor based systems that have shared
control, shared display or other interface features. Symbols are provided for interfacing field
instrumentation, control room instrumentation and other hardware to the above. Terminology is
defined in the broadest generic form to describe the various categories of these devices.

It is not the intent of this standard to mandate the use of each type symbol for each occurrence of
a generic device within the overall control system. Such usage could result in undue complexity
in the case of a Piping and Instrument Drawing (P&ID). If, for example, a computer component
is an integral part of a distributed control system, the use of the computer symbol would normally
be an undesirable redundancy. If, however, a separate general purpose computer is interfaced
with the system, the inclusion of the computer symbol may provide the degree of clarity needed
for control system understanding
This standard attempts to provide the users with defined symbolism and rules for usage, which
may be applied as needed to provide sufficient clarity of intent. The extent to which these
symbols are applied to various types of drawings remains with the users. The symbols may be as
simple or complex as needed to define the process

This standard is intended for use whenever any reference to an instrument is required.

Such references may be required for the following uses as well as others:
• Flow diagrams, process and mechanical;
• Instrumentation system diagrams;
• Specifications, purchase orders, manifests, and other lists;
• Construction drawings;
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 • Technical papers, literature, and discussions;
• Tagging of instruments etc

1. DEFINITIONS AND ABBREVIATIONS

Accessible—A system feature that is viewable by and interactive with the operator, and
allowsthe operator to perform user-permissible control actions, e.g., set point changes, auto-
manualtransfers, or on-off actions.
Assignable—A system feature that permits an operator to channel (or direct) a signal from
onedevice to another, without the need for changes in wiring, either by means of switches or
viakeyboard commands to the system.
Communication link—The physical hardware required to interconnect devices for the
purposeof transmitting and/or receiving data.
Computer control system—A system in which all control action takes place within the
controlcomputer. Single or redundant computers may be used.
Configurable—A system feature that permits selection through entry of keyboard commands
ofthe basic structure and characteristics of a device or system, such as control algorithms,
displayformats, or input/output terminations.
C.R.T.—Cathode Ray Tube
Distributed control system—That class of instrumentation (input/output devices, control
devices and operator interface devices) which in addition to executing the stated control
functions also permits transmission of control, measurement, and operating information to
andfrom a single or a plurality of user-specifiable locations, connected by a communication link.
I/O—Input/Output
Shared controller—A control device that contains a plurality of pre-programmed
algorithmswhich are user retrievable, configurable, and connectable, and allows user defined
controlstrategies or functions to be implemented. Control of multiple process variables can be
implemented by sharing the capabilities of a single device of this kind.
Shared display—The operator interface device used to display signals and/or data on a
timeshared basis. The signals and/or data, i.e., alphanumeric and/or graphic, reside in a data
basefrom where selective accessibility for display is at the command of a user.
Software—Digital programs, procedures, rules, and associated documentation required for
theoperation and/or maintenance of a digital system.
Software link—The interconnection of system components or functions via software or
keyboardinstruction.
Supervisory set point control system—The generation of set point and/or other control
information by a computer control system for use by shared control, shared display or
otherregulatory control devices.

2. SYMBOLS:
Standard instrumentation symbols as shown in ISA-5.1 are retained as much as possible for flow
diagram use, but are supplemented as necessary by the new symbols. Symbol size should be
consistent with ISA-5.1, Section 3. The symbol descriptions listed tothe right of each symbol are
intended as guidelines for applications, and are not intended to be all inclusive.The symbol may
be used if one or more of the descriptions apply. Shared signal lines can be expressed by the

8
symbol for a system link

3.1 Distributed control/shared display symbols:

Advances in control systems brought about by microprocessor based instrumentation

permit shared functions such as display, control and signal lines. Therefore, the
symbology defined here should be "Shared Instruments," which means shared display
and/or shared control. The square portion of this symbol, as shown in paragraphshas the meaning
of shared type instrument.

3.1.1.) Normally accessible to operator:

Indicator/Controller/Recorder or Alarm Points—usually used to indicate video display.

i) Shared display
ii) Shared display and shared control.
iii) Access limited to communication link.
iv) Operator Interface on communication link.

3.1.2) Auxiliary operator's interface device

i) Panel mounted—normally having an analog faceplate—not normally

mounted on main operator console
ii) Can be a backup controller or manual station.
iii) Access may be limited to communication link.
iv) Operator interface via the communication link.

3.1.3) Not normally accessible to operator

i) Shared blind controller

ii) Shared display installed in field.
iii) Computation, signal conditioning in shared controller.

iv) May be on communication link.

v) Normally blind operation.
vi) May be altered by configuration

3.2) Computer symbols:

The following symbols should be used where systems include components identified as
―computers," as distinct from an integral processor, which drive the various functions of a
"distributed control system." The computer component may be integrated with the system via the
data link, or it may be a stand-alone computer.

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3.2.1) Normally accessible to operator

Indicator/Controller/Recorder or Alarm Point— usually used to indicate

video display.

3.2.2) Not normally accessible to operator

i) Input/output interface
ii) Computation/Signal conditioning within a computer.
iii) May be used as a blind controller or a software calculation module.

3.3) Logic and sequential control symbols:

3.3.1)General symbol— For undefined complex interconnecting logic
or sequence control.

3.3. 2)Distributed control interconnecting logic controller with binary or sequential logic
functions.

i) Packaged programmable logic controller, or digital logic

controls integral to the distributed control equipment.
ii) Not normally accessible by the operator.

3.3.3) Distributed control interconnecting logic controller with binary or sequentiallogic

functions.

1) Packaged programmable logic controller, or digital logic controls integral

to the distributed control equipment
2) Normally accessible to the operator.

3.4) Internal system function symbols:

3.4.1) Computation/Signal conditioning

i) For block identification refer to ISA-5.1, Table 2 "Function

Designations for Relays."
ii) For extensive computational requirements, use designation"C."
Explain on supplementary documentation.
iii) Used in conjunction with function relay bubbles perISA-5.1

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3.5) Common symbols

3.5.1) System link

i) Used to indicate either a software link or manufacturer's system supplied connections between
functions.
ii) Alternatively, link can be implicitly shown by contiguous symbols.
iii) May be used to indicate a communication link at the user's option.

3.6) Recorders and other historical data retention :

Conventional hard-wired recording devices such as strip chart recorders shall be shown in
accordance with ISA-5.1. Long term/mass storage of a process variable by digital memory
means such as tape, disc, etc.,shall be depicted in accordance with 4.2 or 4.3 of this standard,
depending on the location of the device

4) IDENTIFICATIONS:
For purposes of this standard, identification codes shall be consistent withISA-5.1, with the
following additions.

4.1) Software alarms

Software alarms may be identified by placing ISA-5.1, Table 1, letter designators on the input or
output signal lines of the controls, or other specific integral system component.

4.2) Contiguity of symbols :

Two or more symbols can adjoin to express the following means in addition to those shown in
ISA-5.1:

i) Communication among the associated instruments,

e.g., a. Hard wiring b. Internal system link c.Backup
ii) Instrument integrated with multiple functions,
e.g., a. Multipoint recorder b. Control valve with integrally mounted controller. The
application of contiguous symbols is a user option.
If the intent is not absolutely clear, contiguous symbols should not be used.

5) ALARMS:
All hard-wired standard devices and alarms, as distinct from those devices and alarms
specifically covered in this standard, shall be shown in accordance with ISA-5.1, Table.

The examples illustrate principles of the methods of symbolization and identification.

Additional applications that adhere to these principles may be devised as required. The location
of the alarm identifiers is left to the discretion and convenience of the user.

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5.1) Instrument system alarm:

Multiple alarm capability is provided in most systems. Alarms covered by this standard should
be identified as shown by the example5.1.1 and 5.1.2.

Quiz:
 Draw and analyse flow diagram for any two basic loops.
 Draw and understand flow diagram for cascade control loop.

12
Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.

13
 Experiment-2

To study different types of displays in DCS

Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

understanding of various types of DCS displays.

Prerequisites: Basic understanding DCS.

Relevant CO: CO1, CO2

Objectives:To study different types of displays in DCS

INTRODUCTION:

The operation of a distributed control system depends on the displays. There are three
displayscommon to all the suppliers systems, and a number of special displays. The three main
displays are:
 Group displays
 Overview displays
 Detail displays

Group display:

The group displays shows the operating parameters of eight, twelve or sixteen control loops
arranged in rows. Each control loop is shown by rectangular bar graphs to indicate process
variable,output signal & set point value. Engineering values for process variable, set point, and
percentageoutput are printed in or below the rectangular area. The process variable range may be
on right or leftside of bar graph.

14
Overview display:
Overview display shows different groups in separate rectangles. A typical overview
displayshows 12 groups. The set point is shown as straight line reference. Deviation of process
variablefrom set point appears as a vertical bar. If the value of process variable is higher than
referencevalue, vertical line rises up and if the vertical line drops down. If PV is at SP, vertical
line is absent.

If a group display has eight loops in a row, the reference line will have eight segments.
Digital conditions can also be displayed.

15
Detail display:
Detail display is specific to a single loop or control function. The display has bar
graphrepresentation with additional information defining constants, limits & other characteristics
of afunction. The optional displays are: Graphic display & Trend display.

16
Graphic display:
Graphic display allows a picture to be drawn on the screen. Process and control informationis
included in the picture, & it can be made interactive & dynamically changing as real
timeinformation changes. Graphics helps to relate to plant conditions when a number of variables
arechanging at a time. Graphic display can show movements.

Trend display:
Trend displays are a profile of values of a process variable showing changes that have taken
place over a period of time. Some detail displays include trend display. Trend display is
valuableafter an upset. Trend over longer periods can be saved on floppy disk & displayed on
command.Alarm systems alert operators to plant conditions, such as deviation from normal
operating limits andto abnormal events, which require timely action or assessment. Alarms are
thus key sources ofinformation to the operator in maintaining safety. It is important that alarm
systems are well designedand are used correctly.

17
Quiz:
 Compare: Group vs Overview Display
 Compare: Graphic vs Detail Display
 Prepare screenshots of each DCS displays type used in industry.

Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

18
Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.

19
 Experiment-3

To study and prepare cost estimation for DCS

Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

understanding of cost estimation procedure of DCS.

Prerequisites: Basic understanding ofDCS.

Relevant CO: CO1, CO2

Objectives:To study and prepare cost estimation for DCS

HARDWARE COMPONENTS

1. Items related to Operator Console and Related Items

A) Operator Console
a) Size of Data Base (type and number of control/monitoring data,
quantifiedusing file orrecord size)
i) Batch Recipes
ii) Standard Operating Procedures
iii) Operational Data
iv) Maintenance Data
b) Basic Features
i) Redundancy Consideration
ii) Software backup Procedure
iii) Data base security and integrity
iv) Access Security
c) Processing Power and Memory
i) Type and number of microprocessors and needed to guarantee
processingpowerand response time
ii) Size of main and cache memory needed to store real time data
base, trends,recipes and reports
iii) Bulk memory devices to store recipes, operating procedures,
maintenance dataetc.
d) Displays
i) Preformatted color graphic displays (overview, group, point,
number)
ii) Custom graphic color displays (type, number)
I ii) DCS status displays (type, number)
iv) Alarm summary Displays (Sequence and number variables)
v) Real Time Trend Displays (Trending interval and number)
vi) Historical trend displays (type, number)

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 vii) Report type displays (number)
viii) Statistical process control displays (type, number)
e) CRT and Keyboard
i) Video Monitors (type, size, number and requirement for special
housing)
ii) Keyboards (type such as operational or engineering, number and
requirements forspecial packaging to meet environmental safety
needs)
B) Archiving Units
i) Type, size and number of bulk memory devices (hard disks
drives, diskette drivers, tape drives, optical disk drives)
ii) Report archiving time interval
iii) Type and number variables (each with archiving times)
iv) Trend archiving
v) Trend and report generation (researching criteria)
C) Printers, Hardcopy Devices
i) Terminals for logging, reporting, graphics, trends, alarms
D) Engineering Station
i) Type of processor
ii) Type, size and number of bulk memory devices (hard disks
drives, diskette drives, tape drives, optical disk drives)
iii) Type of monitor, keyboard and printer
iv) Supporting Software
v) Application libraries cover: spreadsheets, programming
languages, statistical process control analysis, physical properties
libraries, reporting, device monitoring, local area network
monitoring and data base packages
2. Items related to Data Highway

A) Traffic Communications Director

i) Redundancy Requirements
ii) Network Topology (Star, Multidrop, ring)
iii) Transmission Type (Twisted pairs, Coaxial, fiber optic)
iv) Communication Controllers (Type and number of transponders)
B) Interface Units
List manufacturer, model, number, data base structure, configuration and programming
requirements for all microprocessor based equipments including:
i) PLC interfaces
ii) MIS or other computer interfaces
iii) Engineering Workstations
iv) Smart Transmitters or analyzers of other suppliers
v) Digital controllers of other suppliers
vi) Smart Laboratory Equipment
vii) Product identification or inventory equipment
viii) Smart control valves
ix) Stacker cranes or automated guided vehicles
3. Field Mounted Devices
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 A) Control Units (CUs)
a) The type and number of microprocessors should be specified to guarantee the
required processing power within the allowable response time.
b) The physical specifications should state power consumption, heat dissipation,
floor space requirements and equipment weight.
c) The type and size of the memory specified must be able to store all the data and
programs associated with the CU.
d) Power supplies should be sized to meet the load and distribution needs
e) Power supply redundancy should be considered.
f) Fault tolerant architecture should be specified when necessary
g) Control Requirements should be specified including:
i) Type, number and scan time of all PID, cascade or other more complex
loop.
ii) Type, number and scan times for all devices associated with interlock
control
iii) Type, number of operations, steps per operations, and scan times for all
instruments associated with sequential control
h) Inter-processor communications should be specified
i) Mathematical calculations should be listed
j) Monitoring and alarm requirements associated with all motors, valves and other
digital or analog devices should be specified
k) Type and number of data to be uploaded and downloaded via communications
networks should be specified
l) Specifications for fault tolerant operations should be included
m) I/O specifications should be listed, including:
i) Built in or remote I/O
ii) Power supply voltage and power loading requirements
iii) Type and number of I/O (specified to include 20% spares)
 Analog (single ended or isolated 4 to 20mA, thermocouple, RTD,
millivolts, weight scales etc.)
 Discrete (Momentary or latching 120V AC, relay NO or NC)
 Time proportioned
 Pulse Count
 Binary coded decimal (BCD)
 Serial Port
n) Packaging requirements for the particular environment should be specified
o) Internal and external wiring requirements should be specified
B) Multiplexer, Data Acquisition Units
The same requirements apply as for CUs, except for control.

NON - HARDWARE COMPONENTS

Non Hardware components may include following items:

1. Software development costs for configuration, batch sequencing, special displays, etc.
2. System integration, factory acceptance testing (FAT), field installation and checkout,
siteacceptance testing (SAT), documentation, and support services including project
22
management, training and maintenance.

Quiz:

Prepare cost justification sheet for any one of the make and model of the DCSavailable in the
market.

Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.

23
 Experiment-4

Tune PID controller for heat exchanger usingDCS using VLAB.

Date:

Competency and PracticalSkills:This experiment is designed for students to understand the

PID tuning procedure using DCS.

Prerequisites: Basic understanding ofPID controller and DCS.

Relevant CO: CO3

Objectives:
1. To study PID control action and its function block in DCS
2. To understand the application (Heat Exchanger Unit)
3. To tune PID controller for optimum Heat Exchanger performance

INTRODUCTION:
Distributed control systems are used for controlling plants which are physically as
well as functionally distributed. This control system is preferred when number of analog control
loops to be controlled is more than discrete control. One of the analog schemes used as basic
control strategy is PID control. The theory behind PID control is discussed here.

On-Off Control: Discrete Control

As the name suggests this strategy is preferred for on - off type applications. This is a simplest
form of control. Chattering of contacts for final control element is major problem but it can be
avoided by addition of dead zone. Precise control is not possible due to addition of dead zone.
Mostly all domestic applications as Water Geyser, Electric iron, Electric Ovens are controlled
using on-off control strategy.
PID: Continuous Control
There are 3 basic actions in PID.
 Proportional
 Integral
 Derivative
Proportional mode: - In this mode the controller output varies linearly with respect to the error.
The equation for P mode is

m = Kp * e + Po
Where,m is the controller output.
Kp is the gain of controller

24
 e is the error in %
Po is the proportional Bias. (Value of m at e =0)
Due to addition of proportional bias, positive as well as negative errors are handled.
Generally Po is set at 50% to handle equal positive and negative error range. Higher is the
gain lower is the band to control.
Integral mode: - Integral mode is used to remove the offset produced due to P mode. Offset can
either be positive and negative. Equation for Integral mode is

Where, Ti is the integral time setting and t is the time. When this action is used alone due to
integral effect the action becomes too slow. When combined with Proportional, the action may
go into saturation which is called as Reset Windup. To overcome this, controller output is limited
at lower and higher end. This is called as Anti reset windup. But due to addition of Integral
action Offset is nullified.
Derivative mode:- This action is used to increase the speed of response of slow processes. It
anticipates the rate of change of error and takes the control action. Equation for Derivative mode
is

Where, Td is the derivative time .

Set Point can be achieved quickly by using D mode. In noisy environment. this action is not used
as the output goes into saturated condition. Even for constant error D action provides no
correction, hence not preferred alone. It is always combined with P action. Composite controller,
i.e. P, I and D adds advantages of all the three modes. The Equation for the combined controller
is

Loop tuning time can be optimized by using proper combination of PB, Ti and Td One of the
analog control functions available in DCS is 'PID'. Let us look at various configurable parameters
available for this block.

25
The process parameter analog value (PV) is given as input to the block at IN terminal. The
remote analog set point is provided to CAS IN terminal in case of Cascade Control. In case of
feedforward control input is given to FF terminal. In case of manual mode, input value is given to
SIMULATE terminal. For auto/manual bumpless transfer or to avoid rest windup, the FB OUT is
connected back to FB IN of the same or another block. This keeps the track of changes made in
manual mode and adjusts the controller output prior to the control mode is changed from manual
to auto. Let us see how PID function is used for controlling heat exchanger. The piping and
Instrument diagram for the heat exchanger with a boiler unit along with system details are shown
here.

26
This pipe in pipe type heat exchanger uses the steam produced by an electrically fired boiler
which raises water temperature. The feed water pump for boiler is mounted on the base frame of
the unit and pumps water into the boiler. To avoid scale formation and to reduce maintenance
treated water is used. Heat released by operating heaters is utilized for heating water in the shell.
Insulation of shell is done with glass wool to prevent heat losses. The steam pressure is
controlled by means of a pressure switch at 4.5 Kg/cm2. PT-100 sensors used monitor the
temperature at the inlet and outlet . The inlet water flow is measured with a magnetic flow, while
the steam pressure is monitored using HART (Highway Addressable Remote Transducer) based
pressure transmitter. The objective is to maintain water outlet temperature. The variables
associated are

The photograph of the system is show below.

*The Function Block Diagram as per the available Emerson Delta V DCS in College of
Engineering Pune.*

The procedure for using simulator is as follows:

Using PID function block the outlet water temperature is to be maintained as mentioned under
Theory tab. The input to PID block is Measured variable and the Set point is desired value of the
temperature. The manipulated variable is steam flow rate. The implementation is shown here.

27
As per the changes in the process temperature and the settings of P action, D action and I action,
the output of the PID block is calculated and the steam valve opening is varied to maintain the
water temperature. The values for proportional gain, integral time and derivative time are
adujsted to optimize process performance. Make use of simulator to implement the logic. Double
click on PID block to set its properties.

Simulation:

Quiz:
 List parameters to be configured in PID controller.
 Compare action type: Direct versus Reverse action
 Explain PID Tuning methods in brief.

28
Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.

29
 Experiment-5

To study various hardware and softwareplatforms of DCS

Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

information about various hardware and software platfroms of DCS.

Prerequisites: Basic understanding of DCS.

Relevant CO: CO2

Objectives:
 To study evolution of DCS
 To study levels of automation in DCS
 To study working of DCS
 To study various software‘s and hardware‘s used in DCS
 To study advantages and disadvantages of DCS

INTRODUCTION:

Overview:
In any process plant, for production of materials, it is necessary to have the control on the process
to obtain desired quality of material.
Control system whether it is a Programmable Logic Controller (PLC) or a
Distributed Control System (DCS) is required for the same purpose. Here in Industrial
Automation Laboratory we will mainly discuss about DCS, which is not only used for
computerized process control but its function ranges from monitoring, supervising as well as
control of a part or a whole of production plant.

Definition

A Control system which is functionally as well as physically distributed is called Distributed

Control System.

Evolution of DCS

The control system development took place in the following order as the technology as well as
the difficulties faced by each of them was realized.

1. Open Loop : offline

Here digital computers were applied for acquisition and processing of plant, laboratory and test
field data. At this time operator had to read these data and store them, which was an offline
process for acquisition and processing of data. Here optimization and feedback control loop of
the process was open.
30
 2. Closed Loop : offline
Here set point values were calculated but still manually set by plant operator, thus offline closed
loop control was formed. This was only acceptable when timing condition of process control is
not severe as manual intervention leads to introduction of time delay in the control of the process.

3. Open Loop : online

In this era of 50‘s computers were provided for process interface for data acquisition and process
control, by connecting inputs directly to the computer. But still set point values of the controller
were not being done, thus online open loop control.

31
 4. Closed Loop : online
Here in the end of 50‘s era output elements were also connected to the computers for online
process monitoring as well as controlling. Thus there was data transfer in both the direct making
it the first stepping stone towards online closed loop control and advance control strategies
thereby developed.

5. Distributed Dedicated Computers

In the first half of 60‘s computers were used for dedicated functions i.e. their functions were
clearly defined like data processing, data acquisition etc. with no interconnection between them.
Data interexchange was only possible via a transportable medium.

32
 6. Centralized Dedicated Computers
Here the information interexchange which was not possible in the distributed dedicated computer
control was possible by introducing another central computer in which data from all the
dedicated computers come which can be shared later on.

This led to the information exchange but with computational speed and reliability of computer at
stake.

7. Decentralized Computer System

In the beginning of the 70‘s it was accepted that the central computer will be solving central
automation problem only leaving peripheral computers to solve local problems in their close
surrounding, because of which a two stage hierarchical automation system structure called
Decentralized Computer System was introduced .

33
Levels of Automation in DCS

Functionally Decentralized or Distributed Control System is divided into four different levels as
follows performing the said functions as described below;

LEVEL 0: FIELD LEVEL

This level comprises of the basic field instruments like sensors, transmitters etc. which are
directly connected to the process or we can say give the information about the actual process.

LEVEL 1: DIRECT PROCESS CONTROL LEVEL 2: PLANT SUPERVISORY

This level handles the following functions: CONTROL
 Data Acquisition This level handles following functions:
 Data Check  Plant Performance Monitoring
 Plant Monitoring  Plant Coordination
 Open and Closed loop Control  Optimal Process Control
 Reporting  Adaptive Control
 Failure Detections
LEVEL 3: PRODUCTION SCHEDULING LEVEL 4: PLANT MANAGEMENT
AND CONTROL This level handles the following functions:
This level handles the following functions:  Market and Customer Analysis
 Production Dispatching  Orders And Sales Statistics
 Inventory Control  Capacity and Order Balance
 Production Supervision  Order Dispatching
 Production Re-Scheduling  Production Planning
 Production Reporting  Terms Supervision
 Financial Surveys

34
Apart from this general hierarchical structure based on functions performed by each level there is
a specific architecture for used for automation in manufacturing plant having almost the same
structure but yet more bifurcations are done for more simplicity and speed of operations as
shown in figure below:

35
Working of DCS

Its working can be divided into two parts

1. Hardware Flow
In any process the sensory organs of a process are sensors and /or transmitters through which the
status of the process is known. The flow of signal passes from sensors/ transmitters to a local
field junction box where number of wires comes. From field junction box through a multi core
cable it goes to the main junction box. Again from main junction box it comes to a marshalling
cabinet near control room from where the wires enter into the control panel, where in controller
and I/O cards are placed. After signal entering the panel, the signal wire with or without a relay
card goes into the input card connected to the controller. Controller thereby processes the data
according to the logic created and gives output to the Final Control Element through output
cards, and following the same route.

2. Software
There is a scan cycle which needs to be completed for the execution of an instruction needed to
control the process. The scan period is set by the user while configuring DCS and the following
steps occur for each scan period:

 Firstly the inputs from the process through the input cards are checked.
 Then the values are updated in the program and according to the logic
prepared by the programmer output values are decided.
 These outputs then go to the field through output cards.

36
  Moreover the status is updated in the SCADA as well as the changes are
stored for future reference in the historian. Any alarms i.e. deviations in the
process are there, then they are also noted and stored.

Functions of DCS

 I/O signal characterization

 Signal filtering
 Alarming I/O modules
 Ranging and engineering units
 Control logic
 Control interlocks
 Sequencing
 Batch control
 Passing on trending information
 Passing on report information

Performance Evaluation of DCS

 Available memory for configuration,

 Available idle time (based on a given scan rate),
 I/O loading or criticality,
 Number of available software addresses for Input/output blocks, and
 Number of available software addresses for control blocks

Internals of DCS

DCS can be divided into two parts to make its understanding easy:

1. Hardware: It consists of the following

 Controller
 Power supply for controller
 I/O Terminal Block
 DIN Rail
 I/O Interface Carrier
 Bulk Power Supply
 System Power Supply
 Server
 Professional Stations,Operator Stations
 Application Stations
 Remote Workstations
 Relays

37
Apart from these the important ones are the various interfacing cards whose types along with the
classification are depicted here as follows:

4
Based on Channels 8
16
RTD
Based on Sensors
Analog Thermocouple
4-20 mA
Based on Standard 4-20 mA
Signal type HART
1-5V
Input Cards
4
8
Based on Channels
16
32
24V DC
Digital Type of Voltage
120V AC
O/P
230VAC
Pulse Output Card
Isolated output
Dry Contact type Ouput
4
Based on Channels 8
16
Analog
4-20 mA
Based on Standard
4-20 mA
Signal type
HART
4
8
Output Cards Based on Channels
16
32
12V DC
Digital
Type of O/P 24V DC
Voltage 120V AC
230VAC
Isolated
High Side
Foundation Fieldbus
Device Net
Communication
Profibus DP
Interface Cards
Actuator Sensor Interface (AS-i)
Serial Interface

2. Software: It consists of the following

 To view and control the process using mimics same as the real process
(SCADA).
 Programming environment wherein logic can be created.
38
  A hierarchical view of the whole system
 Advance Control Strategy Schemes
 Configuration Suite to configure the hardware attached.
 Diagnostic Suite
 Alarm Module
 History Module
 Trends Module
 Database management module

Advantages
 System implementation can be carried out in a modular fashion due to which system
growth can be easily achieved as each processor has clearly defined set of functions; if
carefully designed.
 System overloading is less in case of DCS.
 In case of failure of a part, DCS doesn't affect the whole system/ process.
 Backup i.e. redundancy feature possible in DCS.
 Reliability of DCS is more than that of Centralized Control.
 Reduction of cost of interfacing to computer due to reduction in wire usage for control
purpose.
 DCS is more flexible in terms of altering configurations within a range so as to conform
to the change requirements if any.
 Duplicate storage of critical data can be done easily.
 Independent or standalone processors communicate with each other which make
management of computers easy.
 Minimization of data loss as well as errors due to placement of controllers in the nearby
vicinity in DCS.
 Advanced control strategies are easy to implement in DCS.

Limitations
 Cost high when compared with PLC/PC Combination.
 Specialized support from engineering personnel required.
 As system configuration is easy, this makes DCS less flexible.
 DCS‘s require a clean control room environment compared to PLC/ PC environment.

Quiz:

 List out major manufacturers of DCS with their models.

 Draw architecture of any one of the make and model of the DCS available in the market.

Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
39
  Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.

40
 Experiment-6

To study programming methods in DCS

Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

information about various programming methods used for DCS.

Prerequisites: Basic understanding DCS and programming language.

Relevant CO: CO3

Objectives:To study and prepare cost estimation for DCS

INTRODUCTION:

DCS can be programmed using 5 different languages as follows:

1. Ladder Diagram(LD)
2. Function Block Diagram(FBD)
3. Structured Text(ST)
4. Instruction List(IL)
5. Sequential Function Chart(SFC)

From all of these five languages mostly ladder diagram and function block diagram are most
popular for the programming of the Controller.

1. Ladder diagram

The ladder diagram is graphical representation of programming language using relay

based logic. To programming a DCS controller in ladder logic follows the same ladder logic as in
the PLC. All the connections and logics are same for both that controllers.

The ladder name is derived from the program‘s resemblance to a ladder with two vertical rails
and a series of horizontal rungs between them. The rails included in the ladder logic are called a
power rails. DCS ladder logic contains all the logics and instructions as the PLC logic contains.

DCS ladder logic is used for the higher level application. All the logics and instructions in both
the controllers are same as each other.

There are many types of instructions in ladder logic as shown below.

1. Basic instructions- NO -||- , NC -|/|- and output relay logic.

2. Arithmetic instructions- in which all the addition, subtraction, multiplication and dividing
functions contains.
41
3. Timer & Counter instructions- from which we can set the timers to automatically on-off the
process after some time.
So there are so many instruction format contains in the ladder logic. And it is also a simplest
level language format among all the other formats and also mostly used format for programming
also.

2. Functional Block Diagram (FBD)

A functional block diagram, also a graphical representation of various mathematical and logical
functions, is primarily developed for programming continuous process automation, even though
it also supports discrete process automation.

FBD has also some rules and it based on the following:

 Graphical representation of programming elements, which are modular, repetable, and

reusable in different parts of the program.
 It represents functional relation between I/O.
 Different blocks of this language are connected together to make whole logic structure
 In this type of programming structure the logic will flow through the different logic
blocks. And it will be flow through the input to output.
 Primary concept behind FBD is data flow. The connecting lines have data types that must
be compatible on both the ends.
 Its main advantage is that it will supports programming of binary numbers to deal with bit
logic
For the FBD logic all the process can be done only by the different blocks. For example: If we
want to multiply Sine and Cosine functions then we have to take two blocks of Sine and Cosine
and then we have provide their output to the input of multiplication block. So that‘s how we can
do the different functions.

In FBD for all the functions there are so many blocks from which we can do all the tasks easily
and can set the logics so much easily.

There are five types of logic instructions in FBD

1. Logic instructions- in which it interpret signal states of 1 & 0 and combine them
according to Boolean logic.
2. Compare instructions- in which it will compare two functions and give the according
output to the system.
3. Flip-flop instructions- in which we can check out the different logics.
4. Timer and counter instructions- in which we can set timing and counters by the different
timer and counter blocks.
5. Arithmetic instructions- in which we can add, multiply, subtract and divide the two values
directly come from the different processes.

3. Structured Text (SL)

42
Structured text is a high level language that is block structured and has syntax that resembles to
the syntax of the languages like Pascal, Basic and C. The language is composed of written
statements separated by semicolons. The statements use predefined statements and program
subroutines to change variables. The variables can be explicitly defined values, internally stored
variables, or inputs and outputs. Spaces can be used to separate statements and variables,
although they are not often necessary.

Structured text is not case sensitive, but it can be useful to make variables lower case, and make
statements upper case. Indenting and comments should also be used to increase readability and
documents the program.

ST programs allow named variables to be defined. Variable names must begin with a letter, but
after that they can include combinations of letters, numbers, and some symbols such as ‘_‘.
Variable names are not case sensitive and can include any combination of upper and lower case
letters. Variable name must not have the same name as predefined functions, or user defined
functions.

When defining variables one of the declarations shown below can be used:

DECLARATION DESCRIPTION

VAR The general variable declaration

VAR_INPUT Defines a variable list for a function

VAR_OUTPUT Defined output variable from a function

VAR_IN_OUT defines variable that are both inputs and

outputs from a function

VAR_GLOBAL Global variable

RETAIN Value is retained when the power is lost

CONSTANT a value that cannot be changed

END_VAR marks the end of a variable declaration

Number types includes: Integers, Real numbers, Real with exponents, Binary numbers, Octal
numbers, Hexadecimal numbers & Boolean numbers. Almost all Mathematical, Logical and
Conditional operators used in C are available in ST also.

Control programs can become very large. When written in a single program these become
confusing, and hard to write/debug. The best way to avoid the endless main program is to use
43
subroutines to divide the main program. The IEC61131 standard allows the definition of
subroutines/functions. The function will accept up to three inputs and perform a simple
calculation. It then returns only one value.

4. Instruction List (IL)

Instruction List is a low level language and resembles assembly language of programming
controllers. It uses very simple instructions similar to the original mnemonic programming
languages developed for PLCs. It is the most fundamental level of programming language - all
other programming languages can be converted to IL programs. Most programmers do not use IL
programming on a daily basis, unless they are using hand held programmers.

Program control (control flow) is achieved by jump instructions, function calls and subroutines.
A rung of ladder logic contains four inputs, and one output. It can be expressed in a Boolean
equation using parentheses and in turn the Boolean equation can then be directly converted to
instructions of Instruction List.

The beginning of the program begins at the START: label. At this point the first value is loaded,
and the rest of the expression is broken up into small segments. The only significant change is
that AND NOT becomes AND.

All instructions are to be enclosed in a parenthesis. An important concept in this programming

language is the stack. The instruction values are pushed on the stack until the most deeply nested
term is found. The LD instruction pushes the first value on the stack. The end of a parenthesis
sends the stack downwards and the value of stack is incremented.

Allen Bradley and Siemens both have their own version of IL programming. Allen Bradley only
supports IL programming on the Micrologix 1000, and does not plan to support it in the future.

5. Sequential Function Chart (SFC)

All of the previous methods are well suited to processes that have a single state active at any one
time. This is adequate for simpler machines and processes, but more complex machines are
designed perform simultaneous operations. This requires a controller that is capable of
concurrent processing - this means more than one state will be active at any one time. This could
be achieved with multiple state diagrams, or with more mature techniques such as Sequential
Function Charts.

Sequential Function Chart (SFC) is a graphical technique for writing concurrent control
programs. It can be used to program processes that can be split into steps.

Main components of SFC are:

 Steps with associated actions

 Transitions with associated logic conditions
 Directed links between steps and transitions

44
Steps in an SFC diagram can be active or inactive. Actions are only executed for active steps. A
step can be active for one of two motives:

 It is an initial step as specified by the programmer

 It was activated during a scan cycle and not deactivated since

Steps are activated when all steps above it are active and the connecting transition (its associated
condition) is true. When a transition is passed, all steps above are deactivated at once and after all
steps below are activated at once. Actions associated with steps can be of several types, the most
relevant ones being Continuous (N), Set (S) and Reset (R). Apart from the obvious meaning of
Set and Reset, an N action ensures that its target variable is set to 1 as long as the step is active.

An SFC rule states that if two steps have an N action on the same target, the variable must never
be reset to 0. It is also possible to insert LD (Ladder Diagram) actions inside an SFC program.

SFC is an inherently parallel language in that multiple control flows can be active at once. Non-
standard extensions to the language include actions inside a program unit that influence the state
of another program unit. The most relevant such action is "forcing", in which a functional block
can decide the active steps of another functional block.

SFC diagrams can be converted to ladder logic using MCR blocks. The sequence of operations is
important when converting SFCs to ladder logic.

Quiz:
 Which programming languages are supported by the any one DCS available in the
market?
 What are the tasks involved in Production monitoring and control for a given operation?
 What is Real time operating system? Discuss its various types with an example.

Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

45
References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.

46
 Experiment-7

To study and compare various communication Protocol

Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

understanding about various communication protocol used in industry.

Prerequisites: Basuc understanding of common standard protocol.

Relevant CO: CO5

Objectives:
 To study basics of protocol
 To study data communication in DCS

INTRODUCTION:

DCS Network Topology:-

In today‘s competitive production environment, process industries demand a totally

integrated control and optimization solution that can increase productivity, reliability, and
quality while minimizing cost. DCS is designed to meet these above needs.

The architecture of the DCS is designed in such a way that it reduces downtime, improve system
availability, enhance control reliability, and uninterrupted system access. The architecture
distributes risk so the loss of any one component does not affect the rest of the system. For
example, if a single controller fails, operation in other areas of the plant will be uninterrupted.

DCS Typical Topology:

47
Plant Data Highway connects Operator Management stations for fast and effective data

transfer of non-real-time files and print sharing. This improves overall network performance
by offloading non-critical communication from Unit Data Highway. This part of the architecture
consist of ring topology type network for data communication. Mostly Ethernet, TCP/IP
protocols are used to communicate in this level.

Unit Data Highway connects the Operating and Control levels of the system. UDH provides
superior reliability and availability between the operator and control layers through its double-
ring high-speed Ethernet backbone, allowing uninterrupted access to real-time process
information, alarms, and events. This level uses bus type topology to communicate with the field
devices in such a manner that the failure of particular device will not affect the whole system.

The redundant Process I/O Network establishes a high-speed data transmission between DCS and

Remote I/O stations over a distance of up to two kilometers. It uses a Ethernet, foundation
fieldbus, profibus, modbus, and many other protocols which are compatible with field
instruments.

DCS Network Security:-

Over the past few years, most companies with Critical Infrastructure controlled by SCADA,
DCS, PCN or Process Control Network, and try to keep that environment as separate and isolated
as possible from the IT and Corporate Networks. While this concept is a move in the right
48
direction, treating the PCN environment like a black box and trying to manage one firewall or
cyber defense solution at the border with IT is not adequate to protect from changing external
and internal threats. The sensitive nature of the PLC and DCS devices controlling the Critical
Infrastructure assets require a higher level of network segmentation and advanced defense.

An assembly line shutdown at a Diamler-Chrysler plant (August 2005) due to the Zotob worm,
and the Slammer worm infestation at First Energy‘s nuclear power plant (January 2003) present
clear evidence of such issues.

Safety v/s Security:-

49
It is important to realize the distinction between safety and security. While machines are built
with several fail-safes to ensure safety, these fail-safes are designed against circumstances
that have realistic probabilities of occurrence under normal operation. A cyber attack
can skew the probabilities severely or mislead the operator into taking inappropriate actions by
presenting false information.

To understand the vulnerabilities associated with control systems (CS), you must first know all of
the possible communications paths into and out of the Control system. Above figure presents
various devices, communications paths, and methods that can be used for communicating
with typical process system components.

As illustrated in above figure there are many ways to communicate with a control system
network. A person having knowledge in process equipment, networks, operating software can
easily gain access to the control system. Wireless access points that allow unauthorized
connection to the system component and networks makes system insecure.

In a typical large-scale production system utilizing SCADA or DCS configuration there are many
computer, controller and network communications components integrated to provide the
operational needs of the system. Typical network architecture is shown below.

In the world of network system firewall refers to a network device which blocks certain kind of
network traffic, forming a barrier between trusted and untrusted network. It is analogous
to a physical firewall in the sense that firewall security attempts to block the spread of computer
attacks.

MODBUS in Distributed Control System :-

50
• Developed by Modicon (now Schneider Electric) in 1979.

• Can run over RS232, but was adapted to run on RS485.

• It can run over virtually all communication media, including twisted pair wires,
wireless, fiber optics, Ethernet, telephone modems, cell phones and microwave.

• MODBUS provides digital communications in older plants, using existing twisted

pair wiring.

• Master-slave configuration

A MODBUS network consists of one ―master,‖ such as a PLC or DCS, and up to 247 ―slave‖

devices connected in a multi-drop configuration

The three most common MODBUS versions popular today are:

• MODBUS ASCII

• MODBUS RTU

• MODBUS/TCP

MODBUS ASCII- All messages are coded in hexadecimal, using 4-bit ASCII characters. For
every byte of information, two communication bytes are needed, and twice as many as with
MODBUS RTU or MODBUS/TCP. Therefore, MODBUS ASCII is the slowest of the three
protocols, but is suitable when telephone modem or radio (RF) links is used.

MODBUS RTU-Data is coded in binary, and requires only one communication byte per data
byte. This is ideal for use over RS232 or multi-drop RS485 networks, at speeds from 1,200 to
115Kbaud. The most common speeds are 9,600 and 19,200 baud. MODBUS RTU is the most
widely used industrial protocol.

51
MODBUS/TCP: Is simply MODBUS over Ethernet. Instead of using device addresses
to communicate with slave devices, IP addresses are used. With MODBUS/TCP, the MODBUS
data is simply encapsulated inside a TCP/IP packet. Hence, any Ethernet network that supports
TCP/ IP should immediately support MODBUS/TCP.

MODBUS DEVICE CONNECTION

The easiest ways to bring field devices into a process control system, PLC or industrial computer
is to simply connect digital and analog I/O into a distributed I/O system that has MODBUS
communication capability. This solution works for both new and existing plants. In many
existing plants, field instruments typically connect to the DCS or PLC via ―home run wiring,‖
where each device is connected with individual twisted pairs that carry analog signals

With the NCS (NET connector system), one of those twisted pairs can be used for the MODBUS
signal. This is particularly useful if the plant wants to add additional field instruments, but does
not want to run more wiring. A distributed I/O system can accommodate all of the existing I/O,
or it can be used just to send data from all the new field instruments.

In some cases, the control system is not able to deal with a MODBUS signal. In that case, a peer-
to peer solution with two NCS systems simply replaces all the home run wiring with a single
MODBUS cable. Analog outputs from the control room NCS are then wired directly into the host
system‘s I/O card.

52
PROFIBUS :- (PROcess Field BUS)

PROFIBUS provide absolute consistency and are highly application-oriented. With its standard
protocol, PROFIBUS takes in all subprocesses found in production and process
automation, including safety related communication and drive applications, thereby providing the
ideal basis for ensuring horizontal consistency within an automation system.

PROFIBUS is open standard ,instead of proprietary solutions, ensures long term compatibility
and expandability.

PROFIBUS contributed considerably to the development of fieldbus technology. It links

controllers and control systems with sensors and actuators on the field level (field devices) and
also enables simultaneous consistent data exchange with superordinate systems(management
system).

Specification:-
• Max. number of nodes 127
• Distance supported up to 24 km (with repeater and fiber optics transmission)
• Speed varying from 9600 bps to 12 Mbps
• Master-slave configuration (RS-485)
The three most common PROFIBUS versions popular today are:-
1. Profibus DP(Decentralized Peripherals), (master/slave)
2. Profibus FMS(fieldbus message specification)(master/slave, peer to peer)
3. Profibus PA(process automation)(intrinsically safe)

53
PROFIBUS-DP is optimized for high speed and inexpensive hookup. This PROFIBUS version is
designed especially for communication between automation control systems and distributed I/Os
at the device level. PROFIBUS-DP can be used to replace parallel signal transmission with 24 V
or 0 to20 mA.

PROFIBUS-PA is designed especially for process automation. It permits sensors and actuators to
be connected on one common bus line even in intrinsically-safe areas. PROFIBUS-PA permits
data communication and power over the bus using 2-wire technology according to the
international standard IEC 1158-2.

PROFIBUS-FMS is the general-purpose solution for communication tasks at the cell

level. Powerful FMS services open up a wide range of applications and provide great
flexibility. PROFIBUS-FMS can also be used for extensive and complex communication tasks.

The protocol architecture is oriented to the OSI (Open System Interconnection) reference model
All three PROFIBUS versions (DP, FMS and PA) use a uniform bus access protocol.
PROFIBUS is said to be a multi-master bus. Note that this multi-master bus access protocol is
different from that of CAN in which every node is able to request access to the bus. In
PROFIBUS the masters are predefined and have assigned slaves to control. The PROFIBUS
bus access protocol includes the token passing procedure which is used by masters to
communicate with each other.

Comparison of Different Type of Network Communication Protocol and their Characteristic

Numbe
Developed r Bus
Interface Topolog OfDevi DataRate TypicalUse
By y ces Length

54
4-20mA Point-to- Dedicated 600m Comm.
point link Between
between 2 transmitters
devices &control
HART HCF Point-to- In 2000m Comm.
system.
point, multidrop Between
multidr mode 15 transmitters
op slaves &control
MODBUS Modicon Bus, 250 1200m 9.6-115.2 Industrial
daisy system.
kbps manufacturin
MODBUS/ Schneider chainin
Bus,star Unlimited >1kbps g network
PLC, HMI,
g,
TCP multipo field I/O
int devices to
communicate
PROFI- SIEMENS Line, 32,or127 100- 1.5-12 Factory and
overEthernet
stat,
BUS-DP with 1200m Mbps process-
PROFI- SIEMENS ring
Bus, repeater
32 1900m 31.25kbps automation In
Comm.
tree, s
BUS-PA exploration
RS-485 hazardous
PROFINE SIEMENS Ethernet Unlimited 10/100 area.
Factory and
T
Mbps process auto,
motion-
DeviceNet Allan- Trunkline 64 100- control.
125,250,50 Low-cost
, 0
Bradley 500m comm.
Dropline kbps between
sensors and
ControlNet Allan- Trunkline 99 1000m 5Mbps Real-time
controllers.
,
Bradley high-speed
Tree,star comm.
complex
control
Ethernet/IP Allan- Ethernet- Unlimited 100m 10/100 Integrated
system.
Bradley Bus, Mbps sensor-
star, actuator
daisychai network
n
FF- Fieldbus Multidro 2to32 1900m, 31.25kbps Manufacturing
p,
H1(Low- Foundation spur and process
Speed star. lengt automation
Fieldbus) h

55 120m
 FF-H2 Fieldbus Bus Vary 1.0, 2.5 Advance
(High- Foundation based on Mbps Process
Speed cable, control,
Fieldbus) repeater,
etc remote I/O,
FF-HSE Fieldbus Star Unlimited 100m 10/100 Basic and
Factory
(High- Foundation Mbps automation
advance
Speed Process
Ethernet) control

Quiz:
 Which are the communication protocols supported by any one of the DCS available in
the market?
 Give the difference between: a) OSI model and TCP/IP model, b) Ethernet and
Industrial Ethernet
 What are the benefits of utilizing advanced fieldbus technologies, such as Profibus or
Foundation Fieldbus, in a DCS architecture?

Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.
56
 Experiment-8

To study Alarm Management System in DCS

Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

information about the alarm management system used in DCS.

Prerequisites: Basic understanding ofDCS .

Relevant CO: CO3

Objectives:To study and prepare cost estimation for DCS

INTRODUCTION:
Alarm systems alert operators to plant conditions, such as deviation from normal operating
limits and to abnormal events, which require timely action or assessment. Alarms are
thus key sources of information to the operator in maintaining safety. It is important that
alarm systems are well designed and are used correctly.

Indeed, all DCSs have a sophisticated alarm and HMI system for operators to monitor and
control plant status. The DCS alarm system can be a vital, productive tool for managing
industrial process control plants, and can be configured to identify and notify personnel of a
wide variety of abnormal conditions in a manufacturing process.
Philosophy of Alarm Management
Alarm Management is imperative to assessing, improving and optimizing plant alarms,
thereby increasing the effectiveness of plant operators by only notifying them of a need for
their intervention. A poor alarm system results in billions of dollars lost every year to
accidents, equipment damage, unplanned plant or unit outages, off-spec production,
regulatory fines and huge intangible costs related to environmental and safety infractions.
Alarm Management is about safety, the environment, optimizing operations and increasing
corporate profits.

One important philosophy is that the operator must have some action for any specific alarm.
If the action is not required, the alarm should be removed. Further, reducing or eliminating
alarm floods liberates an operator to respond to plant demands, enabling them to avoid
shutdowns and keep the plant running at optimal performance. In addition, the advanced
alarming -- like alarm shelving -- can dramatically reduce alarms temporarily during a
specific period so the operators can focus on important alarms and reduce startup/shutdown
time.‘

57
The relationship between a DCS alarm system and an Alarm Management System is
shown inFigure1.

Fig.1

The alarm system of the DCS is the executer of all alarm functions. However, the
Alarm Management System is the monitor and optimizer for the DCS alarm system, which is
used to reduce nuisance alarms, rationalize related alarms, and avoid alarm floods and so on.
In addition, some advanced alarm functions like alarm shelving and alarm suppression can
be added to existing DCS alarm system to make it more effective.
As a result, it is possible to reduce unscheduled plant shutdowns, improve performance and
mitigate the risk of incidents and excursions and hence to enhance reliability and profitability
by improving the performance of the existing alarm system.

How does an Alarm Management System work?

The DCS alarm system can be optimized and enhanced by an Alarm Management System.
An Alarm Management System and service attempt to identify unnecessary alarms, improper
alarm set values and where improvements can be made to the current procedures for dealing
with alarms, which can be demonstrated in Figure 2.

58
As shown, Alarm Management System and service is not a one-time project; it is
aredesign/re- engineering and a life-long process. Therefore the performance of the alarm
system is continuously being improved and optimized.
Alarm Philosophy Development
The Modern Alarm Philosophy is introduced to plant operations. The alarmphilosophy
is the collection of guiding principles and targets by which users configure alarms and
measure alarm performance. Most philosophies cover the following criteria at a minimum:
1. What is an alarm?
2. How are priorities set based on criticality and time to respond?
3. General alarm considerations, e.g., how to deal with BAD I/O alarms?
4. Alarm performance criteria and resolution activities?
Most plants do not have a robust Alarm Philosophy. All alarms are defined on an ad hoc
basis. This is the root cause of most alarm problems. An effective Alarm Philosophy outlines
key concepts and governing rules for alarm strategy, e.g., what constitutes an alarm and what

59
risk categories pertain to your site operations. It outlines roles and responsibilities,
change management procedures and project goals, such as target alarm rates.
Alarm Analysis
The Alarm Analysis module identifies potential areas for alarm system performance
improvement. This module automatically collects configuration data, alarm messages
and the operator action journal from the DCS. The data can be automatically captured and
imported without any manual intervention. Main Analysis includes:

1. Alarm System Performance (Alarms per Time Period, Frequent Alarms, Chattering
Alarms, Priority Distribution, Alarm Summary, etc.)
2. Alarm System Settings (Alarms Set by Priority, Disabled/Inhibited Alarms, etc.)
3. Process Changes (Alarm Enable States, Alarm Priorities, etc.)
The results of the analysis reports can be used to improve and monitor alarm system
performance.

Performance Metrics Manager

This module enables business personnel at all levels to make informed and timely
decisions by providing timely and accurate access to Key Performance Indicators (KPIs).
The Performance Metrics Manager provides comparable metrics through benchmarking and
normalization for alarms and operator interactions independent of control systems and
database formats.

Report Manager
This module is a report mechanism. Report sections may be created from specific
components and then included in a report that may be scheduled for automatic execution and
publishing. In addition, each report execution may trigger an e-mail notification that can be
customized to any number of e- mail recipients.

Real-Time Alarm Viewer

This module provides real-time viewing of alarm messages from the alarm system on any
authorized client PC connected to the Alarm Management Server. For Foxboro I/A Series
systems, the alarms are collected from one or more printer ports on a Foxboro I/A
workstation. A serial to Ethernet converter is used to send the alarm messages on a LAN to
the Alarm Management Server. This is the same LAN used for transferring data for statistical
analysis.
60
The alarm messages can be sorted and filtered in any column to facilitate analysis and make
the elimination of alarm printers possible.

Advanced Alarm Management

This module provides more enhanced alarm functions for the DCS alarm system to reduce
Alarm
Floods:
1. Alarm Shelving
2. Grouped Alarms
3. AlarmPriority Reduction
4. Alarm Load Shedding
5. Pattern Recognition
6. Alarm Suppression (Redundant Voted Alarms, Eclipsing Alarms, etc.)
Alarm Suppression provides significant benefits in removing standing alarms when a plant
unit is shut down, provided that the meaning of ‗shut down‘ is clearly understood. If
inventory has been removed as part of the shutdown process and the equipment is fully
isolated, then suppression of all the alarms is likely to be appropriate.
However, if the plant may restart on short notice, with key inventories in place, then there
will be a number of alarms that should not be suppressed during a plant shut down. In
addition, in batch industries like pharmaceutical plants, alarm setpoints or whether an alarm
is configured typically change depending on the batch phase. If it is not part of the
automation, it may generate alarm floods. Similarly, alarm conditions may change during
different recipes, which may also result in alarm floods. State-based alarm techniques are
used in these situations to suppress those alarm floods.
Safety - - Safety shower Potential fatality

outofservice orworse
Environment - Minor release Significant Notifiable

insideboundary release inside release

Productionloss Lower Non-spared boundary
Non-spared Downtime more

efficiency equipmenttrip equipment will than

increased trip
Equipmentdamage fouling
Pump damage Pump damage Damage to Critical

(spareonhand) (nospare) majorequipment equipment

Inefficient <$50k $50 to100k likely
>$100k destroy
-

operation
61
Consequence Minor Moderate Major Extreme
urgency
Now(<5min) High High Emergancy Critical
Next(5to5min) Critical
Latter(>5min) Low High Emergancy Critical

Low Low High

Here the colour of the LED indicates the stage of criticalness. These critical conditions are
divided into four parts: Minor, Moderate, Major and Extreme.

The colour coding is described below:

1) Magenta – it is indicate the extreme critical condition and its alarm system is designed in
a such way that though one have pass the acknowledge signal it will continuously giving
audio alarm and when the required action is take place after that it will goes in the relax
mode.
2) Red – it is indicate the Major critical condition and its acknowledgement system designed
in such a way that there is some time duration after the acknowledgement signal passed so
that one can take action within that time if the action could not take place in given time its
start the alarm again.
3) Yellow – it is indicate the moderate critical condition and show the little bit high
condition.
4) Crayn – it is indicate the minor critical condition and when the minor situation is occurred
at that time this LED will glow.
Human and Ergonomic factor
The study of people and their relationship with the environment around them is called
ergonomics. The application of measurement to products, in order to improve their
human use, is called ergonomic.
Alarm systems alert operators to plant conditions, such as deviation from normal operating
limits and to abnormal events, which require timely action or assessment. Alarms are
thus key sources of information to the operator in maintaining safety. It is important that
alarm systems are well designed and should be used correctly.
Alarm handling (or alarm management) is an issue for any site or process where there is
claimed reliance on human response to an alarm in order to control major accident hazards. If
there are too many safety critical alarms (i.e. more than 20) then the balance is likely to be
too far towards reliance on the operators.

62
• There should be a clear link from the site alarm philosophy to major accident hazard risk
assessments.
• Alarm systems need continuous management and improvement – in particular, there
should be a good link between modification/change processes and alarms.
• Alarm management is primarily a design issue; trying to put matters right later is much
more difficult.
• Alarms should direct the operator‘s attention towards plant conditions requiring
timely assessment or action
• Every alarm should be useful and relevant to the operator, and have a defined response
• The alarm system to accommodate human capabilities and limitations.

The performance of the alarm system should be assessed during design and commissioning to
ensure that it is usable and effective under all operation conditions. Regular auditing should
be continued throughout plant life to confirm that good performance is maintained.
The following steps should be considered for good alarm system:
• Rate of incoming alarms (with priority distribution)
• Number of alarms in main list (with priority distribution)
• Frequency distribution of alarms: For identifying any "bad actors" that
contribute significantly to the overall alarm load
• Operator response times (time before acceptance): Too long or too short response
times indicate that the system is not being used as intended
Benefits
Well-designed alarm systems can help an operator prevent an abnormal situation from
escalating or an upset from occurring. Benefits include:
63
• Increased safety
• Reduced environmental incidents
• Increased production
• Improved quality
• Decreased costs

Distributed Control System Reporting

When the plant is located only into the physically small area there are two kind of control
system exist:
1) Centralized Control system :
In which the controller into the field communicate with one or many operator station, each
for different levels, but the disadvantage is that by failure of the controller, by any fail into
the plant, whole plant fail.
Because of that the use of this kind of control system is limited to only small plants.

2) Distributed Control System :

To overcome the major disadvantage of CCS a network of many distributed
communicable controllers is formed. For each controller use in different level of plant have
individual operator station and they can share the information to each other through the
network. This arrangement is call distributed control system.

In DCS reporting play very important roll to understand the performance & monitoring of the
whole plant.
1) Alarm Reporting, Type Of Alarm Generated & Acceptance Of Alarm
With data reporting another reporting is very important is alarm reporting. Data reporting
only give
the information about the past and current values of parameters into the plant but with this it
is very important to ensure that there is nothing going wrong into the plant or the plant is not
about to fall in any undesired or hazardous condition. So to ensure the plant working into
the safe zone alarm reporting is necessary into most of plants.
Types of the alarm system are as following:

64
Process Alarms:
These alarms may be to do with efficiency of the process or indicate defects in the
equipment. This type of alarm is normally incorporated into the plant control system
(typically a DCS) and shares the same sensors as the control system.
Machinery or Equipment Alarms:
These alarms assist with detection of problems with equipment and do not directly
affect the operation of the process.
Safety Related Alarms:
These alarms are used to alert operators to a condition that may be potentially
dangerous or damaging for the plant. Such alarms should normally have a high priority
and where they are involved in protecting against mal-operation by the control system they
should be independent of the devices they are monitoring. In many cases these alarms are
generated by the safety shutdown system itself.
Shutdown Alarms:
This type of alarm tells the operator that an automatic shutdown event has been reached and
has been initiated by the SIS.
• Fire (e.g. Satellite Instrument House)
• Spill or toxic release
• Safety shower
• Power system fault
• Electrical room or Substation smoke detector
2) Different Type Of Logs& Report Which Can Be Configured On DCS
The ability of DCS to generate logs & reports is nearly unlimited. Any data input to DCS and
any data processed by DCS can be put in a programmed format and printed out on
demand , automatically on the occurrence of a predetermined event or periodically at a time
designated by the operator.
Types of Logs:
Periodic Log:
• Automatic printed out daily or at fixed interval.
• Contains data consenting the performnce of unit in the recent period.

65
 • Data may be instantaneous, averaged or value accumulated in period.

Figure2.1Example of Periodic logs

TrendLog:

Printselectedgroupofdataatpredeterminedinterval.

Usedtofollowthetrendofsetofrelatedoperatingparameters.

Itisusedintheplacetoreplaceof thetraditionalmultipointrecorders.

66
SequenceofEventLog:

 Givetheinformationofstateofinputandoutputtrip.
 Isusedinbystationoperatingpersonnelview.

Figure2.3ExampleofSequentiallog
PostTripReviewLog:

67
  Continuouslycollectselectedanalogpointsfortheperiodimmediatelybeforeandafteraunit
triporasimilaractionoccurs.
EventLog:

 Isdefinesthestepbystepactiontakenbyoperator.
 DataHistoryUseInLogs,Reporting&TrendDisplay

Thislogs,reports& trendareveryimportantinDCSfor:
 Properunderstandingofplantaswellasthesystem.
 Toimprovetheplant&thesystemandtomakethesystem&plantstabilize.
 Tooptimizetherawmaterial.
 Somekindofproblemthatwecan‘trecognizeatthetimeithappensweclearlyunderstood
fromthehistory.

Quiz:
 How are alarms handled in a DCS?
 What is IOP alarm in DCS?
 What is the purpose of Alarm Management System in DCS?

Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.
 Experiment-9

To Prepare a case study report on: Application of DCS in Oil Refinery and
Power Plant
Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

information about the DCS flow sheet symbols.

Prerequisites: Before proceeding with this tutorial, you must have a understanding of P & I
diagram.

Relevant CO: CO4

Objectives:To study and prepare cost estimation for DCS

Suggested Reference :<to be provided by the faculty member>

 Students in a group of two or three should prepare a case study report on Application
of DCS in power plant and oil refinery
 Faculty can also ask the students to prepare a case study on any other application area
 Student should prepare a report mentioning the application of DCS along with role of
instrumentation in that specific field.

Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.
 Experiment-10

To perform step by step process of SiemensPCS7 DCS hardware

configuration
Date:

Competency and PracticalSkills:This experiment is designed for students to get basic

information about the DCS flow sheet symbols.

Prerequisites: Before proceeding with this tutorial, you must have a understanding of P & I
diagram.

Relevant CO: CO1, CO2, CO3

Objectives:To study and prepare cost estimation for DCS

Suggested Reference :<to be provided by the faculty member>

1. INTRODUCTION:

Automation Station (AS) Hardware Configuration Siemens PCS7

1. From file New Multiprojects Give name
(Save the project at particular location)
2. Right Click on multiprojectsCreate In multiprojects (Save As same Path) User
projects Right click on multiproject Create in multiproject Libraries
3. Use existing library or give (create) a new library
Define create library as master data library
4. Right click on that library multiprojectdefine maths data library
Now add AS & ES
5. Simatic PC station (rename it as ES_OS)
6. Again add simatic pc station (rename it as AS)
Now do Hardware Configuration
Click on AS Configuration If Open HW configuration window
Form right panel (Window) Add IE General SE V7.1 (As per available
automation status)
Drag and dorp into [0] PC Window
If Opens properties – ―Ethernet Interface IE general‖ window Give IP
address
Find the IP address from command window CMD And than type ― arp-a ‖
-First IP is system IP add
-Second IP is As IP add ― use this ‖

-Type this address in IP address:

Create New Subnet ―plantbys ‖
New Add CPU

-Select from simatic PC station Controller

-WinLcRT6E57611-45B00-OYB7 V4.6(select as per port)

-Drag and drop in IE general (0) PC

 -Next Add COMMUNICATION PROCESSOR

-From select simatic PC station Controller WinLcRTx6E57611-45B00-

OYB7 V.4.6. Add
CP5611/CP5621/CP5612/CP5622

-Drag and drop in IE general (0) PC opens properties- Profibus interface

address 2 As it is

-Create new subnet as ―field bus‖ and click ok

Then field bus: DP master system (1) link will be
added to IE general

Configuration of ES_OS

-Open configuration for ES_OS

-Add simatic pc station IE general SW V8.2 Drag

& drop
Assign IP address same as PCIP address
Same subnet plantbusClick ok

-Add wincc application from HMI

Windows control centre

-Select HMI Wincc App. In IE general

Now, Save and Complie
Now, configure Plc in Operating system

-In simatic manager window

Right click on ES_OS Select PLC Uncheck [] use
configured computer name

-click on DT_COE_DWS078 (system name)

-click on configure
-then press ok
Final message "congratulations completed" then Close

- Open configuration

-Open network view

We can see
 Now Add distributed I/O (ET200) Module
-select profibus ET200M IM153.2 ( select as per available serial or data or model No.)

-drag and drop on ―fieldbus dp master system (1)‖ line

Select address as 3 (as per d/p switch)

Subnet is fieldbus 1.5 mbps

Click ok

-now in this distributed I/O module add different analog &

digital I/O

-identify order number of DI,DO,AI and AO module

-search these module add order no, in find Section

Search only in selectd distributed IO module section

-Drag and drop all I/Os in

Right button Im153.2 window

-Possible to copy & paste similar modules

-Now click on save and compile

-Then , download this to hardware

Click OK OKOK(Ignore Warning)

Now, Estalbish a connection between ES & AS Click on

Click ON Wincc Application

ES_OS
Click on Downside window

Click Insert new Connection Apply

New window ―Properties_S7 Connections‖

Open with communication path

-If shows S7 connection Between ES & AS

-download hardware into station from download in netpro window click ok

Start the as

-save and compile

Now open Wincc application

From project window select Wincc application select (OS) open project

In Wincc application we can make graphics / animation

Quiz:

 What is the meaning of DCS hardware configuration?

 Enlist steps of operating system configuration in DCS.

Suggested Reference:
 http://ial-coep.vlabs.ac.in/
 http://www.idc-online.com
 Process Control- Instrument Engineers Handbook by Bela G. Liptak, Chilton book co.
 Overview of Industrial Process Automation by KLS Sharma, Elsevier pub.
 Practical Distributed Control Systems (DCS) for engineers and technicians by
IDCTechnologiesDistributed Computer Control Systems in Industrial Autoation by
D.Popovic and V. Bhatkar,Marcel Dekker

References used by the students:

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Rubrics:
1. Group work while performing experiment.
2. Understand the concept while performing.
3. Individual work done.
4. Participation in lab work.
5. Quiz answers and submission in time.