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Introduction to

Control Engineering

at Power Plants

Lesson 2


6 – Distributed Control Systems (DCS)Architecture

User Interfaces

Server

Process Interfaces

Thin Clients

I/O Devices

Application Server

Automation Server

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6 – Distributed Control Systems (DCS)Configuration

Application Highway

Automation Highway

Thin Clients

Application Server

Automation Server

I/O systems and Intelligent field devices

CommunicationServer

Time Server

Security Server

Terminal Server

Intranet / Internet

Automation Server


6 – Distributed Control Systems (DCS)Features

Reliable

Easy to use

Cyber secure

Scalable

Platform for more


6 – Distributed Control Systems (DCS)Features - Reliable

Application Highway

Automation Highway

Thin Clients

Application Server

Automation Server

I/O systems and Intelligent field devices

CommunicationServer

Time Server

Security Server

Terminal Server

Intranet / Internet

Automation Server

Process Interfaces

I/O system with redundant

interface module and I/O modules

Networks

Fault tolerant Ethernet NetworkRedundant PROFIBUS DP and PROFINET field bus

User Interfaces

Multiple Thin Clients, parallel operation

Servers

Redundant Application Server

Redundant Automation Servers


6 – Distributed Control Systems (DCS)Features - Easy to use

All tasks available in the same window

All information is available at a glance

Quick and easy navigation between all views

Diagnostic View

Project ViewOperation

Trends

Reports

Engineering

All data and information available from a single source


6 – Distributed Control Systems (DCS)Features – Cyber secure

Configuration Change Monitoring –

detects security gaps and provides

transparency

Security Event Monitoring –

comprehensive information about

the security status

Application Whitelisting –

protection of secure plant operation

+

+

Malware Protection – protects

Windows-based computers against

malware

+

Siemens Remote Services

Firewall

PublicNetwork

Firewall

VPNRouter Terminal-

Server

VPNTunnel

IT OfficeInfrast.

ServiceInfrast.

DMZ

IntranetInternet

Customer Office Network

Application Highway

Automation Highway

Thin Clients

Application-Server

Automation-Server

Security Server

SPPA-T3000

Secure Remote Access –

separated by two firewalls

Hardening – enhanced system

protection for components

Account Management –

enforcement of password policy

Security Patch Management –

maintain the highest security level

Network Intrusion Detection

System (NIDS) – identification and

localization of potential attackers

+

+

+

+

+

+


6 – Distributed Control Systems (DCS)Features – Scalable

red

un

dan

t

no

n-r

ed

un

da

nt

Redundant

Application

Server

Thin Client:

up to 35

Automation

Server: up to 60

I/O Signals: max.

40.000

Non-redundant

Application

Server

Thin Client: 5

Automation Server:

up to 3

I/O-Signals: 5.000

local compact

Application Server

Thin Client:

1 integrated + 4 ext.

Automation Server:

up to 4

I/O-Signals:

max. 4.000

Compact Automation and

Application Server

Thin Client:

1 integrated + 1 ext.

Automation Server:

1 integr.

I/O-Signals:

max. 800

AS3000

lcApS3000

cAApS3000


6 – Distributed Control Systems (DCS)Features – Platform for more

Data Sources

DCS in the

Power Plant

Data &

Security

Gateway

Firewall

Application

Servers

Terminal Server VPN

Router

Data

Agent

Digitalization

Analytics Platform

Data

Management

Data

Analytics

Result

Data Base

Analytics

Data Center (in

the cloud)

Automatic

Transfer

Manual

Upload

Raw Data

Lake

Benefits

Availability increase

Profitability

optimization

Compliance assurance

Results

visualization

Customer Portal

Digitalization with

secure transfer of

all relevant data


6 – Distributed Control Systems (DCS)Workbench


6 – Distributed Control Systems (DCS)Servers and Clients

Non - Redundant

Application Server

Local compact Application Server

+ Automation Server

(integrated Thin Client,

Terminal Server and Time

Server)

Compact Automation,

Application and Terminal Server

(integrated Thin Client,

Terminal Server and

Automation Server)Thin Clientand Monitors


6 – Distributed Control Systems (DCS)Automation Servers and Time Servers

Time Server and Antenna Automation Server

Automation Serveror

Communication Server

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6 – Distributed Control Systems (DCS)I/O Racks

Mounting Rail

Bus

Adapter

Interface

Module

Carrier

module for IM

Plug-in connector

for Power supply

Carrier module

for I/O module

(behind I/O and

Terminal Block)

Server module

I/O module

Terminal Blocks

Powerbus cover

I/O Rack


6 – Distributed Control Systems (DCS)Switches and Routers

100 Mbit/s network switches

1 Gbit/s network switches

Media modules

Multi unit routers

Service router


6 – Distributed Control Systems (DCS)Multi unit configuration

unit 2 unit 10unit 1

Mulit Unit Routers

Uniform HMI over the units

....


6 – Distributed Control Systems (DCS)Configuration with 3rd party communication interfaces

Application Highway

Automation Highway

Thin Clients

Application Server

Automation Server

I/O systems and Intelligent field devicesGE GSM

DNP 3.0

TCP / serial

IEC

60870-5-101/104

IEC 61850

Modbus

TCP / serial

OPC Connect

SPPA-T2000

TELEPERM ME

CS275

S7

PCS7

Allen

Bradley

3rd party

S5 / S7

OPC

CommunicationServer

Time Server

Security Server

Terminal Server

Intranet / Internet

Black Box

S7

Automation Server


7 - Cabinet StructureFrame (Overview)

Automation servers

Power supplies

Fuses (Circuit breakers)

Distribution terminals

Relays and others

I/O modules

I/O modules

Marshalling terminals

(For field cables)


7 - Cabinet StructureFrame (Screen connection)


7 - Cabinet StructureFrame (Seismic design)


7 - Cabinet StructureEnclosure (Overview)


7 - Cabinet StructureEnclosure (Ingress Protection)


7 - Cabinet StructureEnclosure (Cooling, heating and other peripherals)

1- Fan&filter (cooling)

2- Air conditioning (cooling)

3-Convection heater

4-Fan heater

5-Thermostat

1

2

3 4

5


7 - Cabinet StructurePower supply (24VDC & 230VAC)


7 - Cabinet StructurePower supply (24VDC & 230VAC)

Diode Module (Redundancy Module)24VDC Power SupplyCircuit Breaker

Infeed Terminals

Distribution

Terminals


7 - Cabinet StructureCabinet monitoring

Circuit Breaker Thermostat (left) & Hygrostat (right)

Door Limit Switch Cabinet Fault Indicator Emergency Stop Button


7 - Cabinet StructureI/O rack & Modules


7 - Cabinet Structure

I/O field interfaces (Terminals)

Terminals Support Plate


7 - Cabinet StructureAutomation servers (S7-400 Series)

1- Backplane rack

2- Power supply

3- Synchronization Modules

4- Fiber optic cables (for item-3)

5- CPU

6- Memory card

7- Communication processor

1

2 2

3 3

3 3

5 5 77

6 6


7 - Cabinet StructureAutomation servers (AS3000 & CS3000)

1- Backplane rack

2- Power supply connectors

3- CPU

4- Communicaton processor (PB)

5- LAN connectors

1

2

2

3 3 4 4

5

5

AS3000: Automation server

CS3000: Communication server for 3rd party communication

Both of them has similar structure as shown above.


7 - Cabinet StructureNetwork components (Ethernet)


7 - Cabinet StructureNetwork components (Profibus)


7 - Cabinet StructureColor code and labeling


8 - Cabinet TypesServer & LAN


8 - Cabinet TypesI/O Cabinet


8 - Cabinet TypesRelay & Interface


8 - Cabinet TypesControl desk (Obsolete system)


8 - Cabinet TypesJunction box


Thank you

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