1

DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institute affiliated to VTU, Belagavi – 590018, Approved by AICTE & ISO
9001:2018 Certified)
Accredited by National Assessment & Accreditation Council (NAAC) with ‘A’ grade

An Internship Report
Submitted in partial fulfilment for the award of degree of

Bachelor of Engineering
In
Electronics & Instrumentation Engineering
Submitted by
Sanjay Pundarekh
1DS16EI038
Internship carried out
at
Yokogawa India Limited
Plot No.96, Electronic City Complex, Hosur Road, Bangalore-560 100, India

Internal Supervisor External Supervisor

Dr. S P Meharunnisa Mrs. Mamtha Rai
Professor DGM Projects
DSCE, Bengaluru - 78 Yokogawa India Limited

DEPARTMENT OF ELECTRONICS & INSTRUMENTATION ENGINEERING

DAYANANDA SAGAR COLLEGE OF ENGINEERING
Shavige Malleshwara Hills, Bangalore-560 078
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DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An Autonomous Institute affiliated to VTU, Belagavi – 590018, Approved by AICTE & ISO 9001:2018
Certified)
Accredited by National Assessment & Accreditation Council (NAAC) with ‘A’ grade
Shavige Malleshwara Hills, Kumaraswamy Layout
Bengaluru-560078

DEPARTMENT OF ELECTRONICS & INSTRUMENTATION ENGINEERING

Accredited by NBA

CERTIFICATE

Certified that an internship report of the internship work carried out by Sanjay Pundarekh bearing a

USN: 1DS16EI038 a bonafide student of DAYANANDA SAGAR COLLEGE OF ENGINEERING,

an autonomous institute affiliated to VTU, Belagavi in partial fulfillment for the award of Bachelor of

Engineering in Electronics & Instrumentation Engineering during the year 2019-2020. It is certified

that all corrections/suggestions indicated for Internal Assessment have been incorporated in the Report

deposited in the departmental library. The Internship report has been approved as it satisfies the

academic requirements in respect of Internship work prescribed for the said Degree.

Signature of the Internal Supervisor and Head of the department

Signature of the Internal Supervisor Signature of the HOD

Dr. S P Meharunnisa Dr. J.S Rajashekar
Professor Professor & Head
Dept. of E&IE Engg. Dept. of E&IE Engg.
DSCE, Bengaluru - 78 DSCE, Bengaluru - 78
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Declaration by the Student

I, Sanjay Pundarekh, hereby declare that the dissertation entitled, “Internship Report”, which has been
submitted by me as partial fulfilment for the final year semester examination of Engineering degree from
Visvesvaraya Technological University, Belgaum, is an authentic record of my own work carried out by me
during final year at Yokogawa India Limited, under the supervision of my internal supervisor Dr. S P
Meharunnisa, DSCE, Bangalore and external supervisor Mrs. Mamtha Rai, Yokogawa India Limited,
Bangalore.

I further undertake that the matter embodied in the dissertation has not been submitted previously for the
award of any degree or diploma by me to any institution.

Sanjay Pundarekh (1DS16EI038)

8th Semester
Department of Electronics & Instrumentation Engineering

Place: Bangalore.
Date: 24-02-2020
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ACKNOWLEDGEMENT

The satisfaction and euphoria that accompanies the successful completion of any task would be
incomplete without mentioning the people who made it possible, whose constant guidance and
encouragement crowned my efforts with success.

I thank our Principal, Dr. C P S PRAKASH and Thank to Head of the Department, Dr. J S
Rajashekhar , Department of Electronics & Instrumentation Engineering who has given us confidence
to believe in ourselves and complete the Internship.

Guidance and deadlines play a very important role in successful completion of the internship report on
time. I convey my gratitude to my internal supervisor, Dr. S P Meharunnisa and external supervisor
Mrs. Mamtha Rai, who helped me carry out my internship work.

Sanjay Pundarekh
(1DS16EI038 )
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EXECUTIVE SUMMARY

This internship work from 12th June 2019 to 28th August 2019 mainly focussed on the design,
development and installation of Distributed Control Systems (DCS) for a wide variety of applications
and processes. My role was primarily concentrated in the Project Software Engineering for two major
projects: 1) Camlin Fine Sciences 2) Catasynth Special Chemicals Private Limited
The job primarily involved loop creation, graphics generation, input-output linking and loop checking.
Loop creation involved the generation and verification of open loops and closed loops using CENTUM
VP. Graphics generation involved generation of process graphics, system graphics and cause & effect
graphics. Input-output linking of various processes within the plant to the generated loops and graphics.
Proper linking of the cause & effect loops with the graphics created. Finally loop check is carried out to
ensure seamless interfacing of all the software engineered components with that of the hardware
components.
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Contents
Page No.

1 INTRODUCTION 1

2 PROJECT DESCRIPTION AND GOALS 4

2.1 Project Engineering (Hardware) 5
2.2 Project Engineering (Software) 5
2.3 Factory Acceptance Test (FAT) 6
2.4 Installation & Commissioning 6

3 TECHNICAL SPECIFICATIONS 7
3.1 Distributed Control System 7
3.2 System Configuration 9
3.3 Hardware components of DCS system 11
3.3.1 Design criteria of cabinets 11
3.3.2 System cabinet 11
3.3.3 Field Control Station (FCS) 13
3.3.4 Front loading 13
3.3.5 Input-output (I-O) module 17
3.3.6 Analog / Digital Marshalling cabinet 19
3.3.7 Intrinsic safety barriers 21
3.3.8 Junction box and Terminal Blocks (TBs) 21
3.3.9 Terminal boards 26
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3.3.10 Earthing 28
3.3.11 Power distribution cabinet 30

4 DESIGN APPROACH FOR CONTROL LOOPS 34

4.1 Typical Loops 34
4.1.1 Analog input – output signals 35
4.1.2 Digital input – output signals 38
4.1.3 Resistance Temperature Detector (RTD) 40
4.1.4 Thermocouple 41

5 SOFTWARE COMPONENTS OF DCS 42

5.1 Process Functions 42
5.2 Control logics 43

6 PROJECT DEMONSTRATION & RESULTS 45

6.1 Demonstration of opening & closing of Solenoid valve 45
6.1.1 Opening of XV2009 valve 45
6.1.2 Closing of XV2009 valve 46
6.2 Results 49

7 CONCLUSION 50

8 REFERENCES 51
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List of Abbreviations

DCS Distributed Control Systems

ESD Emergency Shutdown
F&G Fire and Gas
HART Highway Addressable Remote Transducer
HIS Human Interface Station
HMI Human Machine Interface
FAT Factory Acceptance Test
SAT Site Acceptance Test
FCS Field Control Station
FCU Field Control Unit
MCB Miniature Circuit Breaker
PDB Power Distribution Board
ESB Extended Serial Bus
NIU Node Interface Unit
IS Intrinsically Safe
NIS Non-Intrinsically Safe
FFDUN Fan Failure Detection Unit
I-O Input-Output
P&ID Piping & Instrumentation Diagram
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1. COMPANY PROFILE

1.1 Introduction
The Global population will reach nearly up to 10 billion people by 2050, so there will be need
for safe, affordable and reliable energy. With an increase in demand for energy, the industries are
facing new challenges, and this requires new innovative technologies for regulation, generation and
storage of energy. To meet this demand, oil & gas companies focus on innovation for increasing
efficiency.

Shortage of skilled labor is often a problem in oil & gas industries. It has become difficult to
acquire a team of skilled workforce with technical knowledge required to work on reliable energy
sources.

The use of Distributed Control System (DCS) and Automation has now become essential for
these energy companies. With increase in productivity and efficiency, these technologies are helping
industries to maintain high production during shortage. Oil & Gas companies have realized that their
growth and future lie in the field of Automation. Continuous improvements in technology in DCS
and the recent advancements in the field of Automation will help to increase the production &
distribution with higher yield. With the help of DCS it will help the operator to have access to
information about operation and maintenance.

Automation is extremely versatile, making it ideal for daily operation. Oil & Gas companies
spend huge amount of expenses on drilling wells. The cost of drilling is very high and highly
technical which also involves safety of workers. Hence, Automation can be employed in processes
like pipe handling, pressure drilling that can help can reduce safety risks and can speed up overall
drilling processes.

Measurement of flow, temperature and pressure of oil can be easily monitored through DCS
and Automation systems. Installation of transmitters and smart sensors that are connected to the
centralized monitoring unit helps to keep a track of flow, temperature, level and pressure of oil from
the field devices without the need of deploying crew members on-site. In addition to this, some oil &
gas companies have started installing automated weather sensors to predict whether the atmospheric
conditions are suitable for extracting the crude oil from the wells.
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The oil & gas industries have started moving towards digitalization in which more data is
collected by the sensors from the field. The data collected is continuously monitored and controlled
by the DCS system installed on field.
One of the pioneers in the field of Distributed Control Systems (DCS), Automation and field
instruments include YOKOGAWA, SIEMENS, HONEYWELL, ABB, EMERSON AUTOMATION
among others.

1.2. Yokogawa India Limited (YIL)

Yokogawa Electric Corporation is a Japanese electrical engineering and software company,

with businesses based on its measurement, control and information technologies. It has a global
workforce of over 19,000 employees, 84 subsidiary and 3 affiliated companies operating in 55
countries. The company is listed on the Tokyo Stock Exchange and is a constituent of the Nikkei 225
stock index.

Yokogawa pioneered the development of distributed control systems and introduced its
Centum series DCS in 1975. Some of Yokogawa's most recognizable products are production control
systems, test and measurement instruments, pressure transmitters, flow meters, oxygen analyzers,
fieldbus instruments, Manufacturing Execution Systems and Advanced Process Control.

Fig 1.2 The above figure represents the corporate brand symbol and corporate brand slogan
respectively

From being primarily a provider of Process Automation Systems and Products, Yokogawa India
Limited (YIL) is today positioned as a Comprehensive Solutions Provider of Enterprise Technology
Solutions (ETS). Established in 1987, Yokogawa India has created the state of art global engineering
center and manufacturing centre in Bangalore. We have a strong marketing and service network across
India. We also have a breadth of competencies to meet the technological requirement
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of the Indian Process Industry. Yokogawa India excels in turnkey project execution in
Process Automation and Enterprise Integration with core competencies in:

• Design and Engineering of Process Control Systems

• Implementation of Extended Enterprise Applications

• Web enabling & Enterprise Application Integration

• Manufacturing Execution Systems Software Development

• Project Execution & Management of Process Control systems

Figure 1.2 represents the corporate brand symbol and corporate brand slogan respectively.
The corporate symbol reflects our values and ideals, and is the emblem for all Yokogawa employees.
It symbolizes that we are a dynamic, yet balanced corporation that provides real value. The image is
inspired by the sun, which is the main source of energy for all life on earth, and is an affirmation of
Yokogawa's commitment to benefit humankind through the development of the industrial sector. The
corporate brand slogan passes on the message such as Co-innovating conveys our determination to
continually engage in the co-creation of value with our clients by working with them in long-term
partnerships to develop solutions. Tomorrow expresses our resolve to move steadily into the future,
one step at a time.

1.3 History

Yokogawa traces its roots back to 1915, when Dr. Tamisuke Yokogawa, a renowned
architect, established an electric meter research institute in Shibuya, Tokyo. After pioneering the
development and production of electric meters in Japan, this enterprise was incorporated in 1920 as
Yokogawa Electric Works Ltd.

In 1933 Yokogawa began the research and manufacture of aircraft instruments and flow,
temperature, and pressure controllers. In the years following the war, Yokogawa went public,
developed its first electronic recorders, signed a technical assistance agreement for industrial
instruments with the U.S. firm Foxboro, and opened its first overseas sales office (New York).

In the 1960s the company made a full-scale entry into the industrial analyzer market and
launched the development, manufacturing, and sales of vortex flowmeters, and in the decade
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following established its first manufacturing plant outside Japan (Singapore), opened a sales office in
Europe, and became one of the first companies to bring a distributed process control system to
market. In 1983 Yokogawa merged with Hokushin Electric Works and, towards the end of the
decade, entered the high-frequency measuring instrument business. In the 1990s, Yokogawa
established an office in Bahrain to oversee its business in the Middle East and entered the confocal
scanner and biotechnology businesses.

In 2002 the firm continued its growth with the acquisition of Ando Electric, and in 2005 set
the stage for a new level of globalization in its industrial automation business with the establishment
of Yokogawa Electric International in Singapore. In 2008 the company entered the drug discovery
support market with a new bio test system.

1.4 Businesses and Main Products

 Yokogawa's main businesses are industrial automation and test and measurement
hardware and software.

 Some of Yokogawa's main hardware products are Pressure Transmitters, Flow meters,
controllers, recorders and data acquisition equipment.

 Yokogawa products are used in different industries requiring process control systems.
Depending on the size of the project and the requirements, Yokogawa offers various
control systems: DCS, PLC, SCADA and ESD. In collaboration with Shell Global
Solutions, Yokogawa also offers Advanced Process Control (APC) solutions for
refineries, petrochemical plants, and chemical plants.

 Centum, Yokogawa's flagship DCS, has the largest capacity among DCSs, supporting
up to 1 million device tags.

 Yokogawa manufactures field instruments, test and measurement instruments, and

semi-conductor related products.

 Yokogawa designs and manufactures the most advanced confocal spinning disks used
in confocal microscopy.
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1.5 Industries, Products and Solutions

Yokogawa caters to a wide range of industries and provides numerous products and
solutions, which are given below:
INDUSTRIES:
 Oil & Gas
 Oil & Gas Downstream
 LNG Supply Chain
 Chemical
 Power
 Water & Wastewater
 Mining & Metal
 Pharmaceutical
 Food & Beverage
 Pulp & Paper
 Iron & Steel

PRODUCTS:
 Control System
 Solution-based Software
 Data Acquisition
 Field Instruments
 Process Analyzers
 Industrial Networking
 Components
 Test & Measurement

SOLUTIONS:
 Synaptic Business Automation
 Profit-driven Operation
 Digital Transformation
 Industrial IoT
 Plant Security
 Operations Management
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 Safe Operations
 Production Management
 Inventory Management
 Quality Management
 Asset Management
 Energy Management
 Analyzer System
 Manufacturing Operations Management
 Life Innovation

2. DEPARTMENT DETAILS:
In any project undertaken by the company, the overall project is designed and monitored using Centum
VP for Distributed Control System (DCS) and ProSafe for Safety Integrated Systems (SIS), which
includes Emergency Shutdown (ESD) system and Fire and Gas (F&G) systems. Additionally, some
international standards for the designing of the System cabinets and Analog & Digital Marshaling
cabinets are followed.

To understand better about the work that has to be carried out, figure 2.1 shows the work flow
of any project in the company.

Fig 1.3 Hierarchy of Distributed Control System (DCS)

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Designing of DCS systems is further broken down into two categories:

 Project Engineering Hardware: Project Engineering Hardware mainly focus on the

design of the System Configuration, Network Architecture, Wiring and Input-Output
Loop Drawings, System cabinet and Analog & Digital cabinets.

 Project Engineering Software: Project Engineering Software mainly focus on the

design of logics, Functional Block diagram, System graphics, Input-Output mapping.
Factory Acceptance Test and Installation & Commissioning of the project at the Final
stage. This is done in presence of the End user consultant and commissioning officer.

PROJECT ENGINEERING (HARDWARE)

1. Overall System Configuration

 This gives the overall layout of the control room in processing plant or
industry.
 Overall view of the position of the System cabinets, Analog & Digital
Marshaling cabinets, Consoles, Human Interface Station (HIS), and printers.

2. Network Architecture
 This gives the overall arrangement of the network switches and network
V-net/IP Ethernet cables.

3. Panel & Cabinet Design

 Design of the DCS System cabinet, Analog & Digital cabinets, Power
distribution cabinets.
 Design of the SIS and F&G System cabinet, Analog & Digital cabinets,
Power distribution cabinets.

4. Wiring & Loop Drawings

 Design of the Analog input, Analog output, open and closed loops.
 Design of the Digital input, Digital output, open and closed loops.
 Design of the Resistance Temperature Detector (RTD) and Thermocouple open
loops.

PROJECT ENGINEERING (SOFTWARE)

1. Graphics Generation
 Overall representation of different sections of the processing plant in the
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Graphics view.
 Overall arrangements and simulation of working of the Control valve, motors,
pumps, Solenoid valve and other field devices in each sections of the
processing plant.

2. Logics Creation
 Creation of the Functional Block Diagram program and the logic gates.

3. Input-Output Mapping
 Design of the cause and effect matrix

4. Loop Checking
 Actual demonstration of the working of the Analog input, analog output, Digital input
and Digital output signals.

FACTORY ACCEPTANCE TEST (FAT)

This test is carried out after all the cabinets have been setup and manufactured according to
the given design. This test includes testing of graphics, logics, typical loop and system redundancy
check.

INSTALLATION & COMMISSIONING

Manufactured Panels are then sent to the Oil & gas industry where the Panels and consoles
will be setup according to the Control room layout, and the field devices are connected to each
terminal block via the Junction box. When all the cabinets are setup, Site Acceptance Test (SAT) is
being carried out to check whether the field devices are connected properly according to the design
of the control loops and the software graphics are checked whether they are configured, controlled
and monitored correctly by the DCS system and the commissioning is done right after the installation
has been done.

2.1 TECHNICAL SPECIFICATION

DISTRIBUTED CONTROL SYSTEM

Distributed control system (DCS) is the control system that is used in process or plant usually
having number of control loops that are controlled by autonomous controllers, and are distributed
throughout the system. DCS is mainly used for monitoring and control of the entire process or plant
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whether they are Oil & gas industries, water pipelines, pigment production plants, oil refineries,
water treatment plant, food and food processing plant. DCS plays an important role in the
manufacturing industries as well. Analog or discrete signals shows that the field devices are
controlled and monitored from the control room in oil & gas industries. With remote monitoring
and supervision, DCS is used for reducing the cost of installation, but localizing control system
functions near processing plant and to enhance reliability.

Figure 2.1: Signal Flow diagram of Distributed Control System (DCS) from HIS to field instruments

Figure 3.1 shows the signal flow diagram from the field instrument to control room and vice-
versa. Field instruments i.e. Sensors, valves, actuators and transmitters send the signal to the Field
Control Station (FCS), which is the controller of DCS system. FCS is loaded with the functional
block diagram and logic blocks, which does signal processing. In control room, there is Human
Machine Interface (HMI) or the operator station where the Engineer or the operator can monitor and
control the field instruments. Ethernet cables and Vnet / IP cables are connected from the HIS to the
FCS to communicate between the Operator station and the controller. When the signal is sent from
the HIS, it first goes to the Input-Output (I-O) modules. Then, signal conversion takes place
according to the type of the signal and the type of the I-O module i.e. Digital or Analog according to
respective I-O card module. Then the signal travels through the Pre-Fab cables from the system
cabinet to the marshaling cabinets. The Pre-Fab cable gets terminated in marshaling cabinet. It is
connected to the terminals boards which are mounted on the marshaling cabinets. The terminal
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boards are designed according to the Analog/Digital input/output signals. When the Analog I-O card
is connected to the Analog marshaling cabinet in Analog terminal board via the specified Pre-Fab
cable, then only the communication takes place with the connected field instruments. Same happens
with the Digital I-O card and Digital marshaling cabinets also. There are intrinsic safety barriers
mounted in the marshaling cabinets to provide safety to the Control unit.

There are two types of signals i.e. Intrinsically Safe (IS) and Non-Intrinsically Safe (NIS). IS
signals are connected via the analog input and output barriers to provide safety to the controller if
any hazardous situation occurs in the processing plant. These barriers limit the signal in the specified
range and then allow the signal to direct towards the controller. These barriers are specially used in
case of Emergency Shutdown (ESD) and F&G (Fire & Gas) systems. NIS signals are directly
terminated at the terminal block. These signals are non-hazardous signals. These signals are used in
plant where there are no chances of any hazardous situation. Also, the marshaling cabinets has
components like Relays, isolators to provide protection to the controller. The signals then go to the
field instruments via the junction boxes, which are placed in the field.

The system cabinet consists of the controller, Ethernet switch, Network switches, IO module
card and power supply module. Various electrical components like MCBs, bus-bars, switches, Fan
failure detection unit (FFDUN), earthing plates are mounted on the cabinets. Marshaling cabinets
holds terminal boards, barriers, relays, isolators, and terminal block. All hardware components are
redundant i.e. if one fails other take over the control of the entire system. This is done to avoid
complete system failure of the DCS. 4-20mA is normally the range for analog signals while Binary
digits, 0 or 1 is for digital signals.

Advantages of DCS:

1. They are redundant in nature. i.e. if one unit fails, other unit takes over the control avoiding the
failure of the entire system.
2. At various levels, Redundancy is available.

3. Interlocks and logic blocks, functional block diagrams are created using software.

4. Flexibility in modification and updating the logic blocks and interlocks.

5. Entire process information and monitoring of the field is available to the operator with easy
access.
6. Troubleshooting and maintenance requirement is very less.
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2.2 SYSTEM CONFIGURATION

Figure 2.2 depicts the overall system configuration with connection between the controllers,
network switches, controllers and I-O modules present. Along with 24 port network switches,
Ethernet switch, routers, HIS, server station, operator station, Global positioning system (GPS) are
also connected in the system. The connections of the HIS to the system & marshaling cabinets with
the printers, consoles are shown in the system configuration plan.

The cabinets are then setup according to the system configuration plan in the control room.
The Engineering station or the operator control station are numbered as per the domain and station
number. This numbers are unique and control the portion of the processing plant. If more than one
section is present in the processing plant, they are numbered accordingly to control the process.

The main operating station is the Engineering station where the operator or an engineer can
monitor and control the processing plant. Vnet / IP is the communication protocol used to
communicate between the HIS and controllers. Here, two communication bus are provided as the
controllers are redundant in nature. Network switches are connected through bus 1 while the Ethernet
switches are connected through bus 2. To achieve time synchronization, GPS is configured to the
network.

The connection between the operator station (HIS) and Hardwired consoles is through
Ethernet cables. The 55’ LED display used in this project is to have overall representation of the
process control in the processing plant.
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Figure 2.2: Overall system configuration of control room of the processing plant
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2.3 HARDWARE COMPONENTS OF DCS SYSTEM

2.3.1 Design Criteria of Cabinets

- International standards are followed while designing the system cabinets and marshaling
cabinets. Power supply modules, CPU modules, ESB coupler units and I-O module card
are mounted on the 19-inch rack according to the design provided to the manufacturer.
- Certain exhaust fans are mounted on the door of the cabinets to provide proper ventilation
and to reduce the heat dissipation and temperature inside the cabinets.
- MCBs, Fuse ratings, cable wiring size and number of hardware components like Terminal
boards, terminal blocks, relays, isolators, barriers are mounted perfectly in the marshaling
cabinets. Fan-Failure detection unit (FFDUN) is used to detect and control the
temperature inside the cabinets.

DCS / ESD / F&G system use three types of cabinets:

1. System cabinet
2. Analog / Digital Marshaling Cabinet
3. Power Distribution (PDB) Cabinet

2.3.2 System Cabinet

The following components are mounted in the system cabinet:
 Field Control Station (FCS)
 Input-Output (I-O) module card
 Power distribution board
 Network switches
 Ethernet switches
 Power Supply module
 Extended Serial Bus (ESB) coupler unit

Figure 2.3 represents the internal hardware design of the system cabinet for DCS. The DCS
controller is mounted in the node 1 of the 19-inch standard size mountable rack. Along with
controller, there is CPU, Power Supply Module, ESB coupler unit and I-O module card. The
subsequent nodes have only I-O module card and power supply modules. Subsequent nodes are
connected via the ESB cables, and so the communication takes place between the HIS and different
nodes.
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Figure 2.3 Internal hardware design of the System cabinet for DCS

There are standard dimensionsto be followed. Height should be 2000mm, length and breadth should be
800mm.

2.3.3 Field Control Station (FCS)

The Field Control Station is known to be controller of the DCS. Ethernet cables and Network
switches are used to connected the controller to the Human Interface System (HIS) system. Since,
there are redundancy to be followed, 2 quantities of controllers are present to avoid any failure.
FCS is of following types:
1. Field Control Unit (FCU)
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2. Node Interface Unit (NIU)

3. I-O modules
FCU and NIU are interconnected by ESB bus. Each NIU rack consists of ESB interface
cards, I-O modules and Power supply Modules. Up to 8 I-O modules can be mounted in one NIU
rack. The work of the I-O module is to transfer data from the FCS to the field instruments and vice-
versa.
There are certain limitations and precautions to be taken while designing the front loading for the
system cabinets.

There are limitations for installation of modules imposed by capacity of power supply to
transmitters.
Installation of modules in any one of node units and FCU impose limitation on total number of I-O
module card considering the power supply.
For the application to non-hazardous area, the sum of the factor for each module to be installed
should be less than or equal to 100.
For the application to hazardous area, the sum of the factor for each module to be installed should be
less than or equal to 80.

For the FCU unit, the sum of factor of each module should be less than or equal to 65 for non-
hazardous area also for the hazardous areas, the sum of factor of each module should be less than or
equal to 65.
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Specifications of the Field Control Station

 Model : AFV30D
 CPU : CP461 has two processor units – VR5532 and has speed of 350 MHz
 Main memory capacity : 128 MB
 Battery backup : 72 hours during power failure condition
 Speed of Vnet / IP : 1 GBps for full duplex mode
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2.3.4 Input – Output (I-O) Modules

The I-O module card are mounted in the system cabinet in the NIU depending on the number of the
Analog input/output and Digital input/output tags. The tags are number according to the field
instruments available in the field or in the processing plant. The module can read the signal in between
the current range of 4 – 20 mA or the voltage range of 1 – 5 V DC. Highway Addressable Remote
Transducer (HART) communication protocol is most commonly used in process & instrumentation
systems. It is an open protocol and is used in analog & digital industrial automation. Its advantage is
that it can communicate over a specified range of 4 – 20 mA analog control loops using a pair of wires.

Hart communication Protocol

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HART protocol communicates at speed of 1200 bps without interrupting the 4 – 20 mA

signal. It allows master to receive two or more digital updates per second from field device. This
protocol gives two simultaneous communication channels: 4 – 20 mA analog & digital signal. This is
fastest and most reliable industry standard. This communication provides low-cost and robust
solution that is easy to use and configure.

2.3.5 Analog / Digital Marshalling Cabinets

This cabinet provides a gateway for the signal to pass from the System cabinet to the field
devices or instruments via the junction box which is present near the field. The junction box is
connected to the Analog / Digital marshalling cabinets depending on the type of the signal and the
field devices via cables. All the field device cables are terminated in Junction box, and then the
multi-core or multi-pair cables are connected to the marshalling cabinets. These multi-pair cables are
terminated in the terminal blocks in the marshalling cabinets. There are components like Terminal
boards, Terminal blocks, Relays, and Safety barriers as shown in Figure 2.3.

Figure 2.4 Design of Marshalling cabinet

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2.3.6 Intrinsic Safety Barriers

Intrinsic safety avoids releasing of sufficient energy which ignites the volatile gases and other
low-voltages circuits in hazardous areas. If any fault condition occurs, excess current or voltage can
damage the controller and I-O module card. This can heat up or create the spark and can ignite the
gases in hazardous areas.
This Intrinsic safety barrier has a resistor, a fuse and two Zener diodes. The short circuit
current is limited by the resistor. The voltage is limited by the Zener diode. The fuse will blow when
the diode conducts. This interrupts circuit, preventing the diode from burning and allowing excess
voltage or current to reach hazardous area.
The two Zener diodes are used because if one fails, the other operates providing complete
protection. If the input voltage exceeds the allowable limit, the diode shorts input voltage to ground
and fuse blows, turning off power to hazardous area.
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Figure 2.6 Internal Barrier circuit

2.3.7 Junction box and Terminal blocks (TBs)

There are large number of field devices and instruments that has to be operated from HIS that
is present in control room. The number of cables connected to these devices are terminated to the
Junction box which is present in the near the field areas.From the junction box, cables are terminated
to the terminal blocks which is present in the marshalling cabinets. These are connected to the
terminal boards, where another cable from the system cabinet is connected here.Terminal blocks are
used to terminate the wiring connected to the field devices.They are connective blocks which binds
two different wires.

Figure 2.7 Sample image of Field Junction Box with wiring

terminations

There are different types of the Terminal blocks that mounted on the marshaling cabinets. They are,

1. Knife Disconnect type terminals

These connective blocks with disconnect option binds two different wires. They are mainly
 30

useful for maintenance purpose.

Figure 2.8 Sample image of Knife disconnect type terminal block

Figure 2.9 Sample image of Knife Disconnect TBs when mounted in the marshalling cabinets

2. Feed through type terminals

These connective blocks without disconnect option binds two different wires. They are
generally used for power distribution.
 31

Figure 2.10 Sample image of Feed through type terminal block

3. Fuse type terminals

This type of connective block binds two different wires through a fuse. This type of terminal
is mostly used in case of output signals to protect the IO module to which the signal is connected

Figure 2.11 Sample image of Fuse type terminal block

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Figure 2.12 Sample image of Feed through TBs and Fuse TBs
when mounted in the marshalling cabinets

2.3.8 Terminal Boards

Terminal Boards are mounted in Analog / Digital Marshalling cabinets. One end of the Pre-
Fab cable is connected to the I-O module card and other end is connected to the terminal board,
depending upon the type of the signal or the field instrument tags.

There are different types of Terminal boards – Analog Input / Output, Digital Input and
 33

Digital Output boards.Analog input and analog output boards have 16 channels respectively, while
digital input and output boards have 32 channels respectively.

Figure 2.13 Sample image of input – output

terminal board
 34

2.3.9 Earthing
It is the process of connecting electrical components and equipment to earth by wire having
zero resistance is called earthing. Immediate discharge of current or voltage is done without any
harm or danger, thus avoiding electrocution to a person or technician.

It provides an alternative path for electrical system to reduce damage cause by overcurrent,
lightning, and line surge.

For the protection of the components that are mounted, earthing has to be done. There are 3
types of earthing, that is:

1. Panel Earth
This type of earthing is present in all cabinets. It is used for all AC components. The ground
resistance must be 100 ohms or less.

Figure 2.14 Sample image of Panel Earthing

2. System Earth
This type of earthing is present in system cabinets. It is used for all DC components. The ground
resistance must be 10 ohms or less.

Figure 2.15 Sample image of System Earthing

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3. Shield Earth
This type of earthing is present in intrinsically safe (IS) cabinets. It is used for all IS components and
IS field cable shields. The ground resistance must be 10 ohms or less.

Figure 2.16 Line diagram for Earthing of IO modules in System

cabinet

2.3.10 Power Distribution (PDB) cabinet

Power Distribution Board consists of MCBs, Power supply unit, diode block unit, bus bars
and Terminal blocks. This cabinet provides power to all the System cabinet, Analog & Digital
marshaling cabinets. The Line diagram for the 230V AC supply for UPS and Non-UPS is as shown
in figure 2.17.
 36

Figure 2.17 Line diagram for Power distribution in cabinets

Figure 2.18 Internal Arrangement of PDB cabinet

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Figure 2.18 shows the internal arrangement of PDB cabinet showing the arrangement of MCBs,
Terminal blocks, busbars and shield earth.

Figure 2.19 Sample image of PDB cabinet

4. DESIGN APPROACH FOR CONTROL LOOPS

4.1 TYPICAL LOOPS

Signal from field instruments to the DCS controller is referred to as ‘input’ signal while the
signal from the DCS controller to the field instruments is referred to as ‘output’ signal. The signal
which is coming from field instruments is in the range of 4 – 20 mA current signals. The reason it is
not taken from 0 mA is that to detect the faulty condition whether the cable or wire is broken or cut,
when line or connected field instrument is healthy, it will show minimum of 4 mA. Our human heart
can withstand current up to 30 mA, so to prevent human from being electrocuted, the higher range is
20 mA. 4 mA shows 0% reading while 20 mA shows 100% reading. All the Analog input – output
signals are in the range of 4 – 20 mA current signals while all the digital input signals in the form of
voltage. Digital signals have the output 0 or 1.
 38

There are two types of signals: Intrinsic safety (IS) and Non – intrinsic safety (NIS) signals.
Intrinsic safety signals are used in hazardous areas. These signals will not be able to produce any
spark and will not be able to ignite any volatile gases present in the field. These signals are mainly
used in Oil & Gas industries, petroleum industries; where the air carries harmful inert gases. Non –
intrinsic safety signals are used in non-hazardous areas.

In case of digital output signals, the relays are used to energize the solenoid valve or any
other field instruments. The line contains active 24V DC supply from the marshaling cabinets to the
field instruments. This is known as Wet contact or potential contact. The field instrument has power
supply from field itself, relays energize and de-energize depending on the ON – OFF signal from the
controller and according to the control system logics. The voltage or the potential in the circuit can
be 24V DC, 110V AC supply. The line which has no 24V DC power supply in it is called as Dry
contact or potential free contact.

There are different types of typical loops.

1. Analog input – output
2. Digital input – output
3. RTD and Thermocouple
4. Analog Input – Output Signals

Figure 4.1 Analog input – output (2-wire) closed loop with barrier
 39

Analog Input:
Analog input meaning the signal comes from the field instruments transmitters to the DCS controller.
Transmitter is used to convert the measure signal from the device in the form of 4 – 20 mA electrical
current signal which can be read by the DCS controller.
The field devices for analog input are listed below:
• Pressure Transmitter
• Differential Pressure Transmitter
• Flow Transmitter
• Level Transmitter
• Temperature Transmitter

There are 3 types of Analog inputs:

1. Analog 2-wire (2W)
When the power and signal is fed from the same pair of cables, the signal is termed as Analog
2-wire signal. Transmitters like Pressure, flow, temperature are Analog 2-wire types.

2. Analog 3-wire (3W)

The signal is transmitted through the pair of cables and the third wire is powered from the
power source in marshaling cabinets. Fire and Gas detectors are Analog 3-wire type which is used to
detect the toxic gases present in field.

3. Analog 4-wire (4W)

The signal is transmitted through the pair of cables from the field device to the control system
and other pair of cable is used to supply power to the field device. Magnetic Flow meter is one such
example of 4-wire analog signal.

Analog Output:
Analog output meaning the signal is driven from the DCS controller to the field instruments such as
control valves. Control valve controls the flow, pressure by opening or closing fully or partially, in
response to control signal received form controller.
The field devices for analog output are listed below:
 Pressure control valve
 Flow control valve
 Level control valve
 Temperature Transmitter
 40

Figure 4.2 Sample images of various control valves and a temperature transmitter respectively

Figure 4.3 Analog input – output (3-wire) open loop

Figure 4.4 Analog input – output (4-wire) closed loop with barrier
 41

Digital Input – Output Signals

Digital Input:

These signals are discrete received from contacts or switches of field devices to control
system. When the switch is closed, input obtained is in the binary number 1 or else 0 if open.

The field devices for digital input are listed below:

• Pressure Switch
• Level switch

Figure 4.5 Digital input loop

Digital Output:
These signals are discrete signals to turn ON or OFF the solenoid valve from the DCS
controller. This signal uses 24V DC or 110V AC supply from the field to energize the solenoid valve
via the relays.
The field devices for digital output are listed below:
• Emergency start / stop
• Pump start / stop
• Motor start / stop
• Resistance temperature Detector (RTD)
• Thermocouple
Thermocouple works on the Seebeck effect i.e. When two dissimilar metals are in contact at
one end, the temperature difference between the heated end and the reference point is observed, the
voltage is produced on difference of the junction to other part of circuit. Thermocouple inputs are the
voltage signals from field thermocouples wired to the control system.
 42

Figure 4.6: Wet contact (24V DC) Digital Output loop

Figure 4.7: Wet contact (110V AC) Digital Output loop

Figure 4.8: Dry contact of Digital Output loop

 43

Figure 4.9: RTD input (3-wire) open loop

Figure 4.11: Thermocouple input (2-wire) open loop

 44

5. SOFTWARE COMPONENTS OF DCS SYSTEM

The software being used is Centum VP (Vigilant Plant). This software has pre-defined functional
block interconnected according to control logic scheme for creating logic structure.

Figure 5.1: Internal Architecture of Functional block

5.1. PROCESS FUNCTIONS

There are four processing functions; input processing, calculation processing, alarm
processing and output processing. The data is obtained from the field instruments and is read by the
controller through this system software. The set point is given to each function block that is present
in the system. Calculation is done in the functional block according to the set point and the process
variable (PV). Certain ranges are specified in the block, so that if the process variable exceeds the
specified range, alarm processing is triggered and the alarm status is high, alerting the operator to
take necessary actions.
 45

Figure 5.2: Sample input output process function block

5.2. CONTROL LOGICS

This is the open loop logic block. The value in range of 0 – 100% is fed to the DCS controller from
the field device, that is, transmitter. Operators get the information of the flow / pressure / temperature
from the transmitter which is situated in field area.

Figure 5.3: Open loop logic block

This is the closed loop logic block where the transmitter sends the current position value of the
control valve to the DCS controller from the specified range of 0 – 80% value, and in response, the
operator can set the new position value from HIS to the controller and to the field device.

Figure 5.4: Closed loop logic block

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ON/OFF Valve
The ON/OFF valve has 2 nos. Digital Inputs and 1 no. Digital Output.

The digital inputs are

i. Open Limit switch – ZSO2009
ii. Close Limit switch – ZSC2009
The digital output is
i. SOV Digital Output – SOV2009
Internal Switch used are
i. Interlock signal – XV2009

Figure 5.5: Sample reference image of logic blocks

The digital inputs and outputs are connected to SIO-21E block. The SIO-21E block takes two digital
inputs and one digital output.

6. PROJECT DEMONSTRATION & RESULTS

6.1. DEMONSTRATION OF OPENING AND CLOSING OF SOLENOID VALVE

The operation of the valve XV2009 is as below.

6.1.1 Opening of XV2009 valve:

Click on the valve XV2009 in the graphic. The XV2009 faceplate appears. The “ON”
command is given from the XV2009 faceplate (Red indication) to energize the SOV in
the field. The “ON” command triggers the “DO signal” SOV2009 to become “ON”.
When the valve is in transition state, both the Open & Close limit switches are in
“OFF” state. So, the feedback indication (Green indication) in XV2009 faceplate is in
middle position (Neither “ON” nor “OFF”). The valve symbol is in white colour in the
graphic during the transition.
 47

Figure 6.1: Process flow simulation when no action is taken

When the Open limit switch of the valve becomes “ON”, the feedback indication
(Green indication) in XV2009 faceplate moves to “ON” position. The valve symbol
changes to Green color in the graphics, indicating that the valve XV2009 has opened
fully.

Figure 6.2: Process flow simulation when opening the solenoid valve
 48

6.1.2. Closing of XV2009 valve

Click on the valve XV2009 in the graphic. The XV2009 faceplate appears. The “OFF”
command is given from the XV2009 faceplate (Red indication) to de-energize the SOV in the
field. The “OFF” command triggers the “DO signal” SOV2009 to become “OFF”. When the
valve is in transition state, both the Open & Close limit switches are in “OFF” state. The
feedback indication (Green indication) in XV2009 faceplate is in middle position (Neither
“ON” nor “OFF”). The valve symbol is in white color in the graphic during the transition.

Figure 6.3: Process flow simulation when closing the solenoid valve

When the close limit switch of the valve becomes “ON”, the feedback indication (Green indication)
in XV2009 faceplate moves to “OFF” position. The valve symbol changes to Red colour in the
graphic indicating that the valve XV2009 has closed fully.

The project demonstration is done in two parts:

 Project Engineering
 System Engineering

The first step in the Project Engineering is to check the General and Internal arrangement of the
System cabinet, marshaling cabinets and PDB cabinet according to the design provided to the
customers. This is mainly done during Factory Acceptance Test (FAT) in front of the client to check
 49

whether all the components are mounted in the cabinets neatly and accordingly. Complete hardware
checks are being carried out.

As there are no field instruments available during the testing in Factory, some calibration devices are
used such as Calibrator is being used to replicate the field instruments. Analog signals are in the
range of 4 – 20 mA and digitals signals are binary numbers, 0 or 1.

Figure 6.4: Calibrator kit used for testing

Sensors and instruments require a wide variety of operation checks in the field. The Yokogawa
CA71, Handy Calibrator is a small, lightweight, multifunction calibrator that can simultaneously
source and measure voltage, current, resistance, TC, RTD, frequency, and pulse signals.

The calibrator CA71 shown in Figure 6.4 is a comprehensive generating / measuring instrument for
all your calibration and equipment checking needs at maintenance and production sites, making a
task much easy. In addition, The CA71 incorporates a rotary switch for simple handling. Just open
the carrying case cover and connect the cables, and you’re ready to take measurements
The following checks are done during FAT:
1. Visual inspection of all components and cabinets according to the design provided.
2. Power supply check, by turning on the MCB from the PDB cabinet
3. For system redundancy check, each redundant module is failed to test the working of the
system
4. Hardware check is carried out by Loop checking to see whether all the connections and
 50

wiring are done according to provided design to the manufacturer.

5. Software check is carried out in test function mode. Also, the system graphics and logic
checks are done for proper working on site.

The HIS and the DCS controller, which is mounted in the system cabinet is connected through the
Vnet/IP cables. So, the communication between the I-O module card and the terminal block takes
place. This ensures that the connection is done properly when the tag is been called out. Now, in case
of 4-wire connection, the field instrument has voltage and control signal provided through the cables.
In case of 2-wire connection, only control signal is provided through the cables.

Tasks Performed:
Projects Handled:

Project 01 : Catasynth Special Chemicals Private Ltd.,(Anthea Group),

Mangalore, India. (Job Code-18MC41)
 Graphics Editing and linking on Fox Control Services (FCS) HMI.
 DCS Graphics generation, dynamic linking and editing.
 Review of cabinets loading, wiring, and internal arrangements as per the
approved drawings in the staging area.
 Generation of Cause and Effect Interlocks.
 Debugging and Modification of process, interlock & cause and effect
graphics.
 Tuning of various field tags.
 Interpretation of Piping & Instrumentation Diagrams (P&ID’s).

Project 02 : Camlin Fine Sciences Ltd., Mumbai, India (Job Code-18MC35)

 Graphics Editing and linking on Fox Control Services (FCS) HMI.
 DCS Graphics generation, dynamic linking and editing.
 Tuning of various field tags.
 51

6.2 RESULTS

1. Analog input: This signal is from field device or instrument to the DCS controller. 4 – 20 mA
signal is forced from the calibrator to check the status on the faceplate of the respective tag.
The input 4, 8, 12, 16, 20 (in mA) corresponds to 0, 25, 50, 75, 100% of signal level
respectively.
2. Analog output: This signal is from DCS controller (or HIS) to the field instruments. The
signal is given in the form of 0, 25, 50, 75, 100% on the faceplate of the tag and 4, 8, 12, 16,
20 (in mA) is displayed on calibrator. This means, in case of field instruments, the control
valve is partially opened or closed with respect to the given signal.
3. Digital input: This type of signal is tested using a short link just enough to closed to control
loop. The contacts are closed depicting the closing of the switch and status is changed to 1
from 0 on the faceplate.
4. Digital output: This type of signal is checked by the signal condition whether it is wet
contact or dry (potential free) contact. In case of wet contact, 24V DC or 110V AC is present
in the loop and when connected to multi-meter, it displays 24V DC or 110V AC on it, when
the start or open command is activated. In case of dry (potential free) contact, buzzer sound
can be heard when the loop is connected.
System Redundancy Check: This test is carried out by failing one of the redundant modules and
checking whether is signal is active or failed. Redundancy meaning if one module or controller fails,
the standby module or controller will take over the control of the entire system.
The first step in the System engineering is to check the system graphics according to plant layout and
Piping & Instrumentation diagram (P&ID) provided. The next step is to check the working of the
control loops, functional block diagrams and control logics according to the cause and effect matrix
provided by the vendor. Each and every tag in the field has to be configured and checked, when the
DCS controller is able to monitor and control the field devices via the HIS or engineering station.

5. CONCLUSION
Generally, Distributed control systems (DCS) are very expensive as it costs in crores (INR) including
both hardware and software. The costs also depend on the following –
 Scope of the project and its implementation depending on the environment
 Number of controllers required for the project
 Number of input-output card module and boards
 52

 Control logics and Control scheme to be implemented

 Costs of cables, panels, operator consoles (if required)
 Emergency Shutdown (ESD) and Fire & Gas (F&G) systems if the project has hazardous
surroundings.

Keeping all the above mention criteria and design requirements, and the scope of the overall project
with layout drawings, Piping & Instrumentation diagrams (P&ID), a detailed project plan is
followed.

The project begins with Input-Output summary containing the information and count of the various
instruments that are available in the field. Each field device is assigned with special name and
number for easy identification. This are called tags. Depending upon the number of the Input-Output
tags, the I-O card module are designed and mounted in the system cabinet.
According to the number of input-output tags, additional 20% spares tags are considered for the
future scope of the project. System configuration gives the overall plan of the control room layout
where the panels, cabinets and operator consoles and HIS engineering station will be placed.

Software system engineers generate graphics, Functional block diagram and control logics for the
working of the control loops. Each and every tags and field instrument are configured for proper
working of the field instruments. Cause and Effect matrix is provided to design the control logics.
Graphics are generated for every section so that overall view of the process control for particular
section can be monitored and controlled.

Finally, the FAT is done after completing the project to check the proper working of the control
loops. Visual checks and Redundancy check are done to check if any one of the modules fails, the
standby module can take over the control of the entire system.
 53

References

[1] Yokogawa DCS Centum VP training manual, 2017.

[2] Yokogawa Pro-Safe training manual, 2017.
[3] Liptak, “Control Centre, Workstation and Logic Design”, Instrument EngineerHandbook,
Fifth Edition 2016.
[4] Distributed Control Systems www.yokogawa.com/in/Distributed_control_systems
[5] Thermocouple https://instrumentationtools.com/thermocouple-and-its-principle/
[6] Distributed Control System https://en.wikipedia.org/wiki/Distributed_control_system
[7] Yokogawa Calibrator for Testing of control loops
http://www.electrometers.com/yokogawa/portable-calibrators/ca71-multi-functional/