DeltaV Process Control System

CM4120Unit Operations Lab

January 2011

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OutlineEvolution of Process Control

Layout and Architecture of the DeltaV system in the PSCC

Physical connections between process instrumentation and the DCS

What the engineers and operators see

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Evolution of Controllers1930’s – Pneumatic Controllers• air pressure w/ flappers, bellows, and valves

adjust valve position based on measured process variable for P, PI, later PID control

1950’s – Electronic Controllers• transistors, resistors, and capacitors for P, PI,

PID control• capable of remote installation1960’s – Mainframe Computer Control• Refineries were typical users• Alarming capability and supervisory control• Single point of failure, no user-friendly

graphical interface

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Evolution of ControllersLate 1970’s – Distributed Control Systems

(DCS)• Networked computers distributed thru plant• Pre-configured controllers• Data archival capabilities• Included an operator console• Hardware was proprietaryLate 1990’s – DSC’s built on commodity

hardware platforms (COTS)• Better scalability• Affordable

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Distributed Control System (DCS) Functionality

Continuous control of processing equipmentPre-programmed control software – needs only to be configuredControl functions are distributed throughout redundant, deterministic networked computer architecture◦ I/O interface and level 1 (basic) control functions◦ advanced control functions◦ interactive graphical interface (HMI)

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DeltaV Architecture: ProPlus server

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•Stores/serves configuration

•Archives data

•Displays information

•Allows control of process

PSCC_DeltaVRedundant Hub

ProPlusServer

MD Controllerand I/O Cards

Plant Area – valves, xmitters

DeltaV Architecture: Operator Stations

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•Archive data

•Display information (HMI)

•Allows process changes

PSCC_DeltaVRedundant Hub

ProPlusServer

MD Controllerand I/O Cards

Plant Area – valves, xmitters

Operator Stations

Communication paths…

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Redundant Control network

Windows XP Workgroup –PSCC_DeltaV

Windows Networking and TCP/IP protocol

Operator Stations

PSCC_DeltaVRedundant Hub

ProPlusServer

MD Controller

DeltaV’s MD Controller and I/O –How it connects to the process…

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MD Controllerand I/O Cards

Plant Area – valves, xmitters

I/O cards are specific to device requirements•4-20 mA input, 4-20 mA output

•24 VDC input, 24 VDC output, etc.

•Foundation Fieldbus Interface

Emerson’s DeltaV System –Current State of the Technology

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PID control

Discrete logic control

Signal conversions

Alarming

Fuzzy control, etc.

are continuously executed by the “MD” controller

Wiring Systems Connect Transmittersto DCS – at the Instrument End:

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Wiring to field junction cabinet

RTD or T/C head

Temperature transmitters

Wiring from transmitter to temp measuring element

Level transmitter

Wiring Systems Connect Transmittersto DCS – at a Marshalling Cabinet:

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Single pairs from field devices

8 pr. Cables to controller cabinet

8-pr. cables run from Field Junction Box (Marshalling Cabinet) to Distributed Control System

Wiring Systems Connect Transmittersto DCS – in the Controller Cabinet:

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DeltaV “MD” controller

8 pr. cables from field junction cabinet

Power-limiting Zener barriers

I/O cards

2nd I/O chassis w/4-20 mA Output cards

Wiring Systems Connect DCS to Transducers – at Marshalling Cabinet:

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Wire prs. to transducers

Current to pneumatic transducers

Air lines to control valves

8-pr. cable from controller cabinet

Regulatory Control Valve

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Air line from I/P transducer

Actuator w/ positioner

Control valve

Block valves

Bypass valve

Output Signals from Control Systemto Control Solenoids

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8-pr. cable from controller cabinet

Solenoids for 2-position air-actuated ball valves

Air lines to ball valves

Wire prs. to solenoids

Installed Field Devices: Ball Valve w/ Actuator

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Air line from solenoid

Actuator

Ball valve body

Process line

DeltaV & Foundation Fieldbus

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(4) mass flows, (4) densities,

and (4) RTD temps

(3) 8-multiplexed RTD temps

(2) temp-only transmitters

(1) wire

The directory tree for our DeltaVsystem…

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Control modules

ProPlus server

MD controller w/ I/O cards and controllers

Fieldbus I/O card w/instruments

Operator Stations

A typical PID Control Module…

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Analog Input function block

PID function block

Analog Output function block

Configuring a PID Control Module…

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PID tuning configuration

Configuration for I/O signals

Configuration of operating

parameters

Alarm configuration

What an operator might see…

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Referenceswww.emersonprocess.com/rosemount/,

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

Motion, Inc., Oct. 2006.

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