ExperionPKS Training Module Overview

Prepared By: Viswanathan Raju Product & Process Excellence, HTSL-Bangalore Version: Initial Draft Date: 25Jan06
(For Internal use within HTSL)

ExperionPKS Overview
Training Agenda: -Evolution (TDC2000 / TDC3000 / TPS / PlantScape / ExperionPKS)

Honeywell Confidential

File Number- 2

Evolution TDC2000
Honeywell introduced the worlds first DCS system in 1970s called TDC2000 system
EOS BOS

Data Hiway

CB

EC

AMC

TDC2000 comprised of a variety of Process Controllers/Devices called as below: CB Basic Controller EC Extended Controller AMC Advanced Multifunction Controller DHP Data Hiway Port (to connect 3rd Party PLCs) RCD Reserve Controller Director (for CB and AMC) HLPIU High Level Process Interface Unit LLPIU Low Level Process Interface Unit LEPIU Low Energy Process Interface Unit EOS Enhanced Operator Station BOS Basic Operator Station All these Controllers (also called as Boxes) / Devices were connected to a common Process control Network called as Data Hiway on the one side and the Field Terminations on the other side (Analog Inputs / Outputs and Digital Inputs / Outputs). Data Hiway is a proprietary Process Control Network of Honeywell Each of the Controller / Device has its own Configuration specification that allows the user to Configure / Download / Monitor the Control Strategies. For e.g., a CB would allow to configure a maximum of 8 Analog Inputs (Open Loops) and 8 Regulatory Loops (Closed loops) There exist a variety of Control Algorithms and specific features that meets the Process Automation needs and demands.
Honeywell Confidential
File Number- 3

DHP

RCD

HLPIU

LLPIU

LEPIU

Evolution TDC3000
In 1980s, TDC3000 system was introduced as shown in the figure. EOS and BOS capabilities were carried out by US with Local ENGR / SUP / OPER Access level personalities. Control HM was introduced to function as the Memory module Network (LCN) both for System and User data. Hiway Network AM was introduced to carry out Supervisory functions / Gateway Interface (HG) Module Complex algorithms and Peer to Peer connections between (NIM) multiple Process Control Networks (Data Hiways / UCNs) A proprietary Supervisory Network was introduced as LCN. HG and NIM served as the Gateways for Data Hiway and CB UCN connectivity to LCN. Data Hiway Universal PM Control In UCN, three Controllers were introduced as follows with Network AMC specific improvements to their processing capabilities: (UCN) PM Process Manager PIU APM Advanced Process Manager APM HPM High Performance Process Manager DHP PM Family has its own Control Processor and IOs. PM Control Processing capability was defined by PU s HPM called Processing Units. For. e.g., 1 Regulatory loop running RCD at 1 sec would consume 1 PU. Difference between Data Hiway and UCN control networks PM 80 PU s; APM 160 PU s; HPM 800 PU s. is that DH allowed Fixed configuration and UCN allowed PM Control Processor gets connected to its IOs (PM IOPs) Variable Configuration limited by PU s. through IOLINK communication. The end users / Project engineers could customize the Control Data per their needs in PM family limited by PU s.
Universal Station (US) History Module (HM) Application Module (AM) 4 Honeywell Confidential
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Evolution - TPS
Ethernet Universal Station (US) Local Control Network (LCN) Hiway Gateway (HG) Network Interface Module (NIM) History Module (HM) Application Module (AM) Global User Station (GUS) Plant History Database (PHD) Application Platform Processor (APP

CB Data Hiway AMC Universal Control Network (UCN)

PM

PIU APM DHP

In 1990s, Honeywell introduced TPS (Total Plant Solution) System that made them enter into the Open Systems environment GUS node provided the US features with Ethernet connectivity and in turn operated on Windows OS. PHD with HM capability and APP with AM capability resulted in a Windows environment provided the other Applications that sit on Ethernet to access the Process Control Network Systems data seamlessly. With TDC2000 / TDC3000 / TPS Systems, Honeywell had an enormous number of Customer bases particularly in the Oil & Gas / Petrochemicals / Refining / Chemicals sector.

RCD

HPM

Honeywell Confidential

File Number- 5

Evolution - PlantScape
PlantScape Vista
SCAN3000 Honeywell UDC5000 SPP Controller

In 1990s, Honeywell acquired a company called SCAN3000, who were specialists in MMI (Man Machine Interface) or HMI (Human Machine Interface). PlantScape Vista was introduced with SCAN3000 as MMI that connected Honeywells UDC5000 Set Point Programming (SPP) Controller. This product was targeted for Batch Industries. PlantScape SCADA was introduced with SCAN3000 as MMI that connected Allen Bradleys SLC500 PLC. This product was targeted for Batch Industries and other medium scale Industries who wanted a capable SCADA system for their Automation needs.

PlantScape SCADA
SCAN3000 AB SLC500 PLC

PlantScape Process

PlantScape Process was introduced with SCAN3000 as MMI that connected to a Hybrid Controller (CPM or C200). This product was introduced with Honeywell and Allen Bradley entering into an agreement that Controller would be from Honeywell and IOs would be from AB.
Hybrid Controller (Regulatory / Logic / Sequential Control)

SCAN3000

C200 controller could do Regulatory / Logic and Sequential control and it was named as Hybrid Controller. Controller Redundancy was provided but, IOs were Non Redundant. This product was targeted for medium scale industries who wanted to go for an intermediate version between DCS and PLC capabilities.
Honeywell Confidential
File Number- 6

Architecture Overview Experion R300

Unlimited Secure Access
www eServer

State-of the Art Operation and Engineering Tools Advanced Applications and Integration
Application Control Environment Experion Stations Remote Engineering Tools PHD Historian

Casual Users

Wireless Devices
(Operations and Maintenance)

FTE Network C200 C300 PMD

ESVT Safety Manager

Redundant Servers

NIM
Allen-Bradley ControlLogix PLC

IO Link
TPS, TDC2000, TDC3000 PM I/O SCADA Devices (OPC, Modbus DH+, and many more!)

Digital Video Manager

Investment Protection Complete Integration

Ethernet

Comprehensive Support for Smart Field Devices

Video as a Process Input!

Honeywell Confidential

File Number- 7

Evolution - ExperionPKS
As there was a need to provide Open System (since all DCS competitors were venturing), Honeywell came out with an Open system called ExperionPKS DCS. This system aimed at providing a Common Platform for all the Legacy Systems introduced by Honeywell earlier and also with some key features like Fault Tolerant Ethernet (FTE) / HMI Web Displays / New Controllers / IOs etc., Experion PKS unified architecture combines DCS functionality and a plant-wide infrastructure that unifies business, process, and asset management to: Facilitate knowledge capture Promote knowledge sharing Optimize work processes Accelerate improvement and innovation. Refer the ExperionPKS Architecture for R300 in the previous slide further. Various Levels of Experion PKS system: L1 Embedded Nodes like Controllers / Interface Modules (C200 / C300 / FIM4 / FTEBs etc.,) L2 Non Embedded Nodes like Servers / Stations / Supervisory Control nodes (EPKS Server / Console Station / ACE / SCE / Flex Stations / EST / ESVT etc.,) L3 Application Nodes like Uniformance / PHD / DSA Servers L4 Management Information Systems / Remote Servers access through Firewall
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Evolution - ExperionPKS
While approaching the ExperionPKS design, the following approaches were taken: EHG Integration A node called EHG (EHG Node plus Data Hiway Ethernet Bridge) was introduced. DHEB interfaced Data Hiway and FTE. This Integration targeted all the Data Hiway Boxes to be configured from ExperionPKS Server. This approach eliminated the configuration through legacy Hiway Gateway.

PMIO Integration In the Hybrid Controller (C200) configuration, a new Interface Module was introduced as IOLIM (I/O Link Interface Module) that allowed integration of PM Family IOPs to C200. The existing role of Controllers like PM/APM/HPM was replaced by C200 by retaining the PM IOPs.

Honeywell Confidential

File Number- 9

Evolution ExperionPKS Level 1

Fieldbus Integration A new Interface Module called FIM (Fieldbus Interface Module was introduced within C200 family that allowed Fieldbus Devices to be integrated into ExperionPKS family. FIM is a double wide module that occupied 2 slots in the chassis. Each FIM could support 2 FF Links and in turn 16 Devices per Link. Profibus Integration Another Interface module called Profibus Interface Module (PBIM) was introduced with a tie up between Honeywell and Woodhead Connectivity (SST). PBIM is a single slot module that could sit along with a C200 configuration. DeviceNet Integration An interface module called DeviceNet Interface Module (DNET_IM) was introduced that allowed DeviceNet protocol devices to be integrated with C200 family. HART Integration First attempt was made with 1756 HART modules between Honeywell and Spectrum Controls company in coming out with 1756 wide HART Analog Input and Analog Output modules. These modules were Non Redundant and could accommodate 8 Input or Output channels. HART Software Multiplexer was introduced and HART digital data was made available.

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Honeywell Confidential

File Number- 10

Evolution ExperionPKS Level 1

PMIO HART Integration PMIO HART was introduced to address Redundant HART IOPs and increased channel capacity of 16 per IOP. These IOPs were added to PMIO Family within ExperionPKS and support was not provided for TPS PMIO Family. C300 Controller A new Embedded Ethernet based controller called C300 was introduced with increased Form factor and Green Hills Integrity OS. This Controller could accommodate one CEE environment and two IO Links. User could configure PMIO / Series C IOs or both of the same IO family in each of these links. C300 controller offers Module wide Redundancy unlike C200s concept of Chassis wide Redundancy. C300 controller also falls under Series C HW. Series C HW consists of IOM (IO Module) and IOTA (IO Termination Assembly) Series C IO - A new range of IO family with an 18 degree slant design enables more heat dissipation. IO Modules include AI (HART enabled) / AO (HART enabled) / DI / DO / LLMUX during R300 release. FIM4 Module Another HW in Series C family is FIM4 module for Fieldbus Integration with 4 FF links. Could accommodate 16 Devices per link and totaling 64 Devices per FIM4.
11 Honeywell Confidential
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Evolution ExperionPKS Level 1

CF9 Module Control Firewall switches were introduced exclusively for Series C HW in R300 release to provide more security for the C300 Controllers and IOs. These switches could be compared with a Cisco L1 Switch for FTEB based C200 Controller topology.

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Honeywell Confidential

File Number- 12

Evolution ExperionPKS Level 2

ExperionPKS Servers EPKS Servers could be configured as either Redundant or Non Redundant ones. These nodes act as the centralized data storage and pass the control / monitoring data to and from Operator Stations and Control Networks. Flex Stations Flex Stations are Operator Interfaces (HMI / MMI) for operating upon Point Detail / Group Detail displays / Alarms / Trends / History / Events etc., There are two Security levels one Operator based security and another Station based security. Normally, Flex Stations access data from EPKS Servers and display it for Operators. Console Stations Console Stations are also Operator Interfaces. Difference between Flex and Console stations is that in case of failure of both EPKS Servers, Flex stations will have loss of view, but Console stations access data directly from Control Networks. ACE Application Control Environment (ACE) Node will allow users to perform Supervisory Control Functions, Peer to Peer between different Control Networks, host complex Custom Control Algorithms etc., It could be considered as a Controller running on Windows OS.
13 Honeywell Confidential
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Evolution ExperionPKS Level 2

SIM-C200 Simulation Control Environment (SCE) Node will allow users to perform Simulation of C200 controller. SIM-IOLIM Simulation of IOLIM environment is achieved using this. It simulates PM IOPs and hosts IOLINKs in IOLIM. SIM-C300 / SIM-FIM development is in progress. eServer A node that allows Plant data to be sent to the Internet as a Read only data. There are two licenses available called Regular Snapshot data is provided and Premium Real Time data is provided. EST ExperionPKS Station TPS Node acts as an Operator interface for TPS network in EPKS HMI environment.

ESVT ExperionPKS Server TPS Node acts as a Server interface for TPS networks in EPKS environment.

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Honeywell Confidential

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