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Page 1
ISALunch and Learn
Ken CarfagnoNovember 6, 2013
Agenda
Theory & Practice- Basic control (e.g., regulatory control, feedback, etc)- Discrete control (e.g., relay logic, Boolean algebra) - Sequential control (e g batch)Sequential control (e.g., batch)- Typical Configuration and Programming- Input/output termination and wiring
Implementation - HMI (e.g., graphics, alarm management, trending, historical
data)
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- Network security
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Basic Control
Types of Control Loops Simple Feedback Control Loop
Control Loop Types & Components
Cascade Control Loops
Components of Control Loops Basic Elements
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I P
FR FICFIC FY
Basic Feedback Control Loop
E
FT
FV
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E
Most commonly used process control loop
I P
PID Controller
Transducer
Controller Output (0-100%)
Basic Loop Components
PFR FICFIC
E
FY
FT
FV
RecorderTransducer
Primary
Transmitter Final Control Element (control valve)
Pneumatic Signal
Transmission Signal
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Element
Detailed description of instrument symbolsare on the legend
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Bypass Valve
E Assembly-Double Block/Bleed w Bypass Valve
Block Valve
Block Valve
Control Valve
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Bleed Valve
Control Valve
I/P Transducer
TT FICTIC
TRPrimary Controller
Why incorporate a cascade system?
To minimize outside
Cascade Control Loops
I P
FR FICFIC FY
Secondary Controller
To minimize outside load variables resulting in increased process stability
Examples
Condensate control
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E
FT
FV Fuel gas/oil burner pressure control
Quick and frequent hydraulic changes
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Basic LoopTIC
I/P
TY
TT
Process
Steam
Cascade Control
Condensate
FIC
Load Variable Changes(P1 or P2 is variable)
TICTT
Process
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Steam, P1 I/PFY
FT
P2Condensate
Basic Control Implementation Function Blocks
Input from the
Cascade fromPrimary
Input from the transmitter
PID Controller
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Output to Valve
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Discrete Control
Water level
Float level indicator
Simple Process
Automate simple process Push a button to start The value should open automatically When the valve is open, the pump
should start automatically
INOUT
Valve with actuator
Water level The operator watches the level indicator. When the tank is full the operator pushes another button
The pump should stop and the valve should close.
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OUT
Water TankWater Pump
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Honeywell Proprietary & ConfidentialHoneywell Proprietary & Confidential
120 VAC
Since I am using relays and pushbuttons to do my remote control, I need an electrical diagram to use as my guide for connecting all of the electrical wires so I create the following pushbutton / relay wiring schematic diagram.
R1
R1
120 VACH N
PB-1PB-2 (Start)(Stop) (Open Valve)
R2
ZSO-2 R1
(Run Pump)(Valve Opened)
R1
120 VACH N
PB-1PB-2
R2
R1
ZSO-2 R1
Here is how it works:
- Press normally open pushbutton PB-2 and relay R1 is energized.
ClosedStopped
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R1
120 VACH N
PB-1PB-2
R2
R1
ZSO-2 R1
Here is how it works:
- Press normally open pushbutton PB-2 and relay R1 is energized.
R1 seals in PB 2 so that when I remove my finger from the button R1 stays energized
OpenStopped
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- R1 seals in PB-2 so that when I remove my finger from the button, R1 stays energized.
- A contact from R1 relay is wired to my valve actuator. A closed R1 contact opens the valve. Note R1 is also close in the second rung.
R1
120 VACH N
PB-1PB-2
R2
R1
ZSO-2 R1
Here is how it works:
- Press normally open pushbutton PB-2 and relay R1 is energized.
R1 seals in PB 2 so that when I remove my finger from the button R1 stays energized
OpenStart
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- R1 seals in PB-2 so that when I remove my finger from the button, R1 stays energized.
- A contact from R1 relay is wired to my valve actuator. A closed R1 contact opens the valve. Note R1 is also close in the second rung.
- Valve open contact ZSO-2 is wired from the valve (the contact is closed when the valve is fully open). A closed ZSO-2 contact along with the closed R1 contact energizes relay R2.
- A contact from R2 relay is wired to the pump. A closed R2 contact starts the pump.
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R1
120 VACH N
PB-1PB-2
R2
R1
ZSO-2 R1
Once the tank is full, I can stop the pump and close the valve.
Here is how you do it:
OpenStart
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- Press normally closed PB-1 and relay R1 is de-energized.
R1
120 VACH N
PB-1PB-2
R2
R1
ZSO-2 R1
Once the tank is full, I can stop the pump and close the valve.
Here is how you do it:
Press normally closed PB 1 and relay R1 is de energized
ClosedStopped
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- Press normally closed PB-1 and relay R1 is de-energized.
- When R1 is de-energized, the contact from R2 stops the pump and the contact from R1 closes the valve.
- Valve open contact ZSO-2 returns to the open state as the valve goes to the closed position.
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R1
120 VACH N
PB-1PB-2
R2
R1
ZSO-2 R1
Once the tank is full, I can stop the pump and close the valve.
Here is how you do it:
P ll l d PB 1 d l R1 i d i d
ClosedStopped
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- Press normally closed PB-1 and relay R1 is de-energized.
- When R1 is de-energized, the contact from R2 stops the pump and the contact from R1 closes the valve.
- Valve open contact ZSO-2 returns to the open state as the valve goes to the closed position.
- We are back at the beginning of our sequence when I remove my finger from PB-1.
R1
120 VACH N
PB-1PB-2 R1 Contact
120 VAC
Here is how we would wire our control circuit.
Typical Connection and Wiring
R2
R1
R1
R2 Contact
120 VAC
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ZSO-2
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Control Via PLC, Ladder Logic
Here is how we would wire our devices to the PLC I/O.
DI DO
DI 1
DI 2
DI 3
DO 1
DO 2
DO 3
PB-1PB-2ZSO 2
PumpValve
PB-1 Stop
DI 3
DI 4
DI 5
DI 6
DI 7
DI 8
DO 3
DO 4
DO 5
DO 6
DO 7
DO 8
ZSO-2
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ZSO-2
PB-2 Start
R1
R1
120 VACH N
PB-1PB-2
DI 1
DI 2
DI 3
DI 4
DI 5
DO 1
DO 2
DO 3
DO 4
DO 5
PB-1PB-2ZSO-2
PumpValve
R2
R1 DI 6
DI 7
DI 8
DO 6
DO 7
DO 8
( )DODIDI
ZSO-2 R1
We take all of our wiring information and I/O module information create this program
This is what our PLC programming language looks like.
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( )
( )
1
DO
2
DO
1
DI
3
2DO
1
1information create this program.
Notice the relationship between our I/O point numbers and the programming.
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R1
R1
120 VACH N
PB-1PB-2
DI 1
DI 2
DI 3
DI 4
DI 5
DO 1
DO 2
DO 3
DO 4
DO 5
PB-1PB-2ZSO-2
Pump
Valve
R2
R1 DI 6
DI 7
DI 8
DO 6
DO 7
DO 8
( )DODIDI
ZSO-2 R1
Also take note that my DI-1 logic contact is normally open. This is because it will be held close by PB-1 when the PLC power is on.
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( )
( )
1
DO
2
DO
1
DI
3
2DO
1
1
DI 1
DI 2
DI 3
DI 4
DI 5
DO 1
DO 2
DO 3
DO 4
DO 5
PB-1PB-2ZSO-2
Pump
Valve
R1
R1
120 VACH N
PB-1PB-2
DI 6
DI 7
DI 8
DO 6
DO 7
DO 8
( )DODIDI
R2
R1
ZSO-2 R1
The programming is done on a laptop PC.
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( )
( )
1
DO
2
DO
1
DI
3
2DO
1
1
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Control via DCS, Function Blocks
R1
R1
120 VACH N
PB-1PB-2
R2
ZSO-2 R1
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Sequential Control
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Sequential Control
Time ordered control Series of step to meet control objective
- Examples: Equipment Startup or shutdown Equipment Startup or shutdownNon-continuous (batch) process
Sequential Control follows a common pattern- Take action which will cause a change in the process- Wait for the desired change to complete- Repeat
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SCM ExampleEmbedded Operator
Instructions
Transition Blocks
Step Blocks
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Configured Handlers
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Basic Wiring
Analog Inputs
Analog Inputs: Questions
Where does the signal power come from?
Where does the transmitter power come from?
Where is the signal ground?
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Analog Inputs, 2 wire, System Powered
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AI, Current Signal, Self Power
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Human Machine Interface
HMI
HMI Example of Non-Conforming Graphic
PC10615 73
PC10518.70PSIGE209 E210
TI202281.53DEGF TI203
200.09DEGF
FL ARECSR
CW SFUELGAS
FI226400.312MSCFD
PI11510.77PSIG
FI204000.00
MSCFD
T200 FRAC OVRHD
15%
PI20118.71
PSI
TI201280.03
FFC201
4608.23BPD
LC20425%
LI21485%
FC214
FC23413.29KBPD
15.73PSIG
TI21389.03
F
TI223440.06
F
AI241320.78AMPS
D200
T203
T200
C205
LI22495%
VRU
SOUR
CW S
T200 TEMPS1-281.53 DEGF2-280.03 DEGF3-271.89 DEGF4-266.00 DEGF5-255.44 DEGF6-254.99 DEGF7-266.92 DEGF
0%85%
65%
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FC2141308.29
BPD
P211
P212P210
P209
NAPHT HA
WTR
SL OP
50%
100%
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HMI Example of ASM Graphic
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Abnormal Situation Management Study
Comparing ASM designed operator interface (multi-window) vs standard operator interface (single window)- 21 Operators- Matching process upsets on
simulator
>38% improvement in recognizing process deviations before an alarm
26% improvement in their ability to successfully resolveproblem
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p 35-48% improvement in overall
operator response time to deviations
Source: ASM Meeting report Oct. 2004
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Context-sensitive Access to Information
Context-Sensitive Menus
Alarm helpOperating procedures
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Trends and analysis toolsAlarm management toolsMaintenance management tools
Quicker response & Less errors
Alarm Management
Filtering Sorting Alarm Shelving Alarm
CommentingCommenting Custom
Views Alarm Details Links to Detail
& Associated Displays
Alarm Help
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p Dynamic Alarm
Suppression
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Trending Trending
- Events Integration - Custom Trend - 32 Pens- Resizable views- Save on demand- Improved User Interface- Easy to use time range
selections
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Operators can invoke the Location Pane to quickly filter event data to specific process areas.
Operators can invoke the Location Pane to quickly filter event data to specific process areas.
Trending ExamplesTrend Navigation Bar Chart
Trend with Events Trend with Numerics
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Secure Network Architectures
Level 4Business Planning
& LogisticsPlant Production Scheduling,
4 - Establishing the basic plant schedule -production, material use, delivery, and shipping. Determining inventory levels.
Ti F
Manufacturing automation architecture
ISA99 functional hierarchical model
FIC
E D
OM
AIN
Level 2
Level 3
Plant Production Scheduling,Operational Management, etc
Manufacturing Operations Management
Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...
2 - Monitoring, supervisory control and automated control of the production process
Time Frame
3 - Work flow / recipe control to produce the desired end products. Maintaining records and optimizing the production process.
Time FrameDays, Shifts, hours, minutes, seconds
Time FrameMonths, weeks, days O
FFSS
CO
NTR
OL
DO
MAI
N
ISA9
9
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Level 1
BatchControl
DiscreteControl
ContinuousControl
1 - Sensing the production process, manipulating the production process
Time FrameHours, minutes, seconds, subseconds
Level 0 0 - The actual production process
PRO
CES
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Typical PCS Network Topology
Firewall
Enterprise Switch
l 3 DMZ
Level 4
Terminal Patch Anti eServer PHD Limited
Comm flow
L4 to L4
Very
Li
mite
d
L3.5
to L
4be
twee
n L4
& L
3
Router
ESC ESF ESTACE ExperionServer
ESVT SafetyManager
TerminalServer
Qualified Cisco Switches
Optional HSRPRouter
Domain Controller
ESF EASPHDServer ExperionServer
3RD Party App SubsystemInterface
Level 3
Level 3.5 DMZ Server MgmtServer
VirusServer
eServerShadowServer
Level 2
Domain Controller
L2 to L2
L3 to L3
Lim
ited
L2 to
L3
Limited L3.5 to L3.5
Very
Li
mite
d L
3 to
L3.
5Ve
ry
Lim
ited
L2
to L
3.5 N
o D
irect
com
mun
icat
ions
or
L2
wee
n L1
& L
3
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Qualified Cisco SwitchesLevel 2
Level 1
L1 to L1
Lim
ited
L2 to
L1
No
com
mun
icat
ions
bet
wor
L4
Security levels Level 1 - Controllers and real time control
Level 2 Servers, Operator Stations and supervisory control.
Level 3 - Historians and Advanced Control and connection to other Level 2 areas or units.
Level 3.5 - DMZ accessed from the Business Network and the PCN.
Level 4 - Is the business network with clients for Historians or Advanced Control applications.
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Level 3 and 3.5 utilizes standard open systems Ethernet technology and Level 4 utilizes standard open systems LAN technology.
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Level 1 Process Control
Domain ESF EASPHD Experion
Firewall
3RD Party App Subsystem
Enterprise Switch
Level 3.5 DMZ
Level 4
TerminalServer
PatchMgmtServer
AntiVirusServer
eServer PHD ShadowServer
Limited L3.5 to L3.5 L3
Comm flow
L4 to L4
Very
Li
mite
d
L3.5
to L
4at
ions
bet
wee
n L4
& L
3
Router
ESC ESF ESTACE ExperionServer
ESVT SafetyManager
TerminalServer
Qualified Cisco Switches
Optional HSRPRouter
Domain Controller
ESF EASServer ExperionServer3RD Party App Subsystem
Interface
Level 3
Level 2
Domain Controller
Level 1 ite
2 to
L2 to L2
L3 to L3
Lim
ited
L2 to
L3
Very
Li
mite
d L
to L
3.5
Very
Li
mite
d L2
to
L3.
5 No
Dire
ct c
omm
unic
aor
L2
s be
twee
n L1
& L
3
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Level 1
L1 to L1
Lim
d L2
L1N
o co
mm
unic
atio
nsor
L4
Level 1 - Process Control
Controllers and real time control
Safety Systems Safety Systems
Protected by all other levels
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Level 2 Supervisory Control
Firewall
Enterprise Switch
l 3 DMZ
Level 4
Terminal Patch Anti eServer PHD Limited
Comm flow
L4 to L4
Very
Li
mite
d
L3.5
to L
4be
twee
n L4
& L
3
Router
ESC ESF ESTACE ExperionServer
ESVT SafetyManager
TerminalServer
Qualified Cisco Switches
Optional HSRPRouter
Domain Controller
ESF EASPHDServer ExperionServer
3RD Party App SubsystemInterface
Level 3
Level 3.5 DMZ Server MgmtServer
VirusServer
eServerShadowServer
Level 2
Domain Controller
L2 to L2
L3 to L3
Lim
ited
L2 to
L3
Limited L3.5 to L3.5
Very
Li
mite
d L
3 to
L3.
5Ve
ry
Lim
ited
L2
to L
3.5 N
o D
irect
com
mun
icat
ions
or
L2
wee
n L1
& L
3
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Qualified Cisco SwitchesLevel 2
Level 1
L1 to L1
Lim
ited
L2 to
L1
No
com
mun
icat
ions
bet
wor
L4
Level 2 - Supervisory Control
Connections for Servers and Operator Stations
Supervisory control
Connection to Level 1
Protection for Level 1 with access lists
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FTE capable
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Level 3 Advanced Control
Firewall
Enterprise Switch
l 3 DMZ
Level 4
Terminal Patch Anti eServer PHD Limited
Comm flow
L4 to L4
Very
Li
mite
d
L3.5
to L
4be
twee
n L4
& L
3
Router
ESC ESF ESTACE ExperionServer
ESVT SafetyManager
TerminalServer
Qualified Cisco Switches
Optional HSRPRouter
Domain Controller
ESF EASPHDServer ExperionServer
3RD Party App SubsystemInterface
Level 3
Level 3.5 DMZ Server MgmtServer
VirusServer
eServerShadowServer
Level 2
Domain Controller
L2 to L2
L3 to L3
Lim
ited
L2 to
L3
Limited L3.5 to L3.5
Very
Li
mite
d L
3 to
L3.
5Ve
ry
Lim
ited
L2
to L
3.5 N
o D
irect
com
mun
icat
ions
or
L2
wee
n L1
& L
3
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Qualified Cisco SwitchesLevel 2
Level 1
L1 to L1
Lim
ited
L2 to
L1
No
com
mun
icat
ions
bet
wor
L4
Level 3 - Advanced Control
Connections for Historians and Advanced Control
Routingg
Access List control
Connect other Level 2 areas or units
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Can be redundant, but not FTE capable
HSRP
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Level 3.5 Demilitarized Zone (DMZ)
Firewall
Enterprise Switch
l 3 DMZ
Level 4
Terminal Patch Anti eServer PHD Limited
Comm flow
L4 to L4
Very
Li
mite
d
L3.5
to L
4be
twee
n L4
& L
3
Router
ESC ESF ESTACE ExperionServer
ESVT SafetyManager
TerminalServer
Qualified Cisco Switches
Optional HSRPRouter
Domain Controller
ESF EASPHDServer ExperionServer
3RD Party App SubsystemInterface
Level 3
Level 3.5 DMZ Server MgmtServer
VirusServer
eServerShadowServer
Level 2
Domain Controller
L2 to L2
L3 to L3
Lim
ited
L2 to
L3
Limited L3.5 to L3.5
Very
Li
mite
d L
3 to
L3.
5Ve
ry
Lim
ited
L2
to L
3.5 N
o D
irect
com
mun
icat
ions
or
L2
wee
n L1
& L
3
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Qualified Cisco SwitchesLevel 2
Level 1
L1 to L1
Lim
ited
L2 to
L1
No
com
mun
icat
ions
bet
wor
L4
Level 3.5 - Demilitarized Zone (DMZ)
Is commonly called the DMZ
Typical nodes WSUS, Anti-Virus Server, etc.
Provides connectivity for devices that are to be accessed from the Business Network and the PCN.
Security zone between the PCN and outside networks
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Can be redundant, but not FTE capable
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Page 27
Level 4 - Business Network
Firewall
Enterprise Switch
l 3 DMZ
Level 4
Terminal Patch Anti eServer PHD Limited
Comm flow
L4 to L4
Very
Li
mite
d
L3.5
to L
4be
twee
n L4
& L
3
Router
ESC ESF ESTACE ExperionServer
ESVT SafetyManager
TerminalServer
Qualified Cisco Switches
Optional HSRPRouter
Domain Controller
ESF EASPHDServer ExperionServer
3RD Party App SubsystemInterface
Level 3
Level 3.5 DMZ Server MgmtServer
VirusServer
eServerShadowServer
Level 2
Domain Controller
L2 to L2
L3 to L3
Lim
ited
L2 to
L3
Limited L3.5 to L3.5
Very
Li
mite
d L
3 to
L3.
5Ve
ry
Lim
ited
L2
to L
3.5 N
o D
irect
com
mun
icat
ions
or
L2
wee
n L1
& L
3
55 HONEYWELL - CONFIDENTIAL File Number
Qualified Cisco SwitchesLevel 2
Level 1
L1 to L1
Lim
ited
L2 to
L1
No
com
mun
icat
ions
bet
wor
L4
Level 4 Business Network Is the business network with clients for
Historians or Advanced Control applications.
Untrusted Network
Separated by a firewall
No direct connection to Level 3 or below
Managed by Business IT department
Level 4 utilizes standard open systems LAN
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Level 4 utilizes standard open systems LAN technology.
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Page 28
Questions?
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Thank You
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