Data Communications and Networking Prepared by: CMMFesarit

DCS Architecture – Software

Software

 The totality of programs, procedures, rules, and (possibly) documentation used in conjunction with
computers, such as compilers, assemblers, narrators, routines, and subroutines.
 References are made to the software and hardware parts of a system, where the hardware comprises the
physical (mechanical and electronic) components of the system.
 Software refers to one or more computer programs and data held in the storage of the computer for some
purposes. In other words, software is a set of programs, procedures, algorithms and its documentation
concerned with the operation of a data processing system. (wikipedia.com)

Firmware

 In electronic systems and computing, firmware is a term often used to denote the fixed, usually rather
small, programs and/or data structures that internally control various electronic devices.
 There are no strict boundaries between firmware and software, as both are quite loose descriptive terms.
However, the term firmware was originally coined in order to contrast to higher level software which
could be changed without replacing a computer hardware component, and firmware is typically involved
with very basic low-level operations without which a device would be completely non-functional.

Controller Station Configuration

Controller - Executes control algorithms to control the process equipment and communicates the process data to
the operator.

Engineering Tools
 Used for engineering control strategies, operating the process and diagnostics of the system on-line.
 Configuration, Operation and Configuration Database
 View the system’s software and hardware components
 Create and edit graphic displays for operator interface and HMIs
 Configure alarms and diagnostics reporting

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Data Communications and Networking Prepared by: CMMFesarit

Operator Station Configuration

Operator Tools

 Operation and Diagnostics

 View/monitor and control the process
 Detect and identify software and hardware problems
 Alarms reporting
 Diagnostics events

PC Operating Systems

Microsoft as the software infrastructure provider:

 Has a dominant (some say monopolistic) market position in the personal computer market
 Has created a familiar desktop paradigm, Windows, for viewing and navigating through complex
information, which is highly refined and accepted
 Has created and integrated a complete operating, infrastructure support and application-development
environment, including a large number of key applications, around a central framework, Microsoft’s
Distributed Component Object Model (DCOM) software architecture

 This provides a rich framework, which includes:

 Windows NT multitasking, multithreaded operating systems, and infrastructure

 interprocess messaging and communications technologies
 software object libraries (ATL, MFC)
 application-development environments and languages (Visual Studio)
 database management systems (Access, FoxPro, MS SQL)
 a wide variety of applications
 a highly structured and supported application programming interface (ActiveX), which enables
independent applications (and application developers) to communicate information and share
application components

 PC Operating Systems

 Windows NT
 Windows ME
 Windows 98
 Windows 2000
 Windows XP Professional
 Windows Vista
 Windows Server 2003, 2008, 2012, 2016
 Windows 7, 8, 10

Communication Software

 Data Communication

 HART
 Modbus
 FOUNDATION Fieldbus
 Profibus PA
 Profibus DP
 Profibus FMS
 AS-i
 CANbus
 ControlNET
 DeviceNet
 BACnet
 OPC Data Access, OPC Alarms & Events, OPC Historical Data Access, SQL, Web services

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 They do not require user intervention for routine operation, but may permit operator interaction via a
supervisory control and data acquisition (SCADA) interface.
 DCS consist of a remote control panel, communications medium, and central control panel. They use
process-control software and an input/output (I/O) database.
 Some suppliers refer to their remote control panels as remote transmission units (RTU) or digital
communication units (DCU). Regardless of their name, remote control panels contain terminal blocks, I/O
modules, a processor, and a communications interface.
 The communications medium in a DCS is a wired or wireless link which connects the remote control panel
to central control panel, SCADA, or human machine interface (HMI).
 Specialized process-control software is used to read an I/O database with defined inputs and outputs.
Selecting DCS requires an analysis of network protocols.
 Ethernet is a local area network (LAN) protocol that uses a bus or star topology and supports data
transfer rates of 10 Mbps. To handle simultaneous demands, Ethernet uses carrier sense multiple access
/ collision detection (CSMA/CD) to monitor network traffic.
 Fieldbus is a bi-directional communications protocol used for communications among field
instrumentation and control systems. Network protocols for DCS also include controller area network bus
(CANbus), control network (ControlNet), DeviceNet, INTERBUS (Phoenix Contact GmbH & Co),
FOUNDATION Fieldbus and PROFIBUS (PROFIBUS International).
 In terms of applications, some DCS are used in electrical power grids or electrical generation facilities.
Others are used in environmental control systems, wastewater treatment plants, and sensor networks.
 DCS for petroleum refineries and petrochemical plants are also common. Fully-distributed systems enable
remote nodes to operate independently of the central control. These nodes can store all of the process
data necessary to maintain operations in the event of a communications failure with a central facility.

Application Software

 Used for information collection and distribution to outside networks

 Not used for configuration or operations
 Run-time database plus user selected applications
 Batch
 Continuous Historian
 Third-party system integration
 OPC Applications
 Web Services
 Excel Add-in

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DCS Architecture - Communications

Data Highway/Control Networks

 The Control Network is an open, high-speed deterministic network used for transmitting time-critical
information.
 It provides real-time control and messaging services for peer-to-peer communication.
 A high-speed link between controllers and I/O devices.
 You can connect a variety of devices to a Control Network, including personal computers, controllers,
operator interface devices, drives, I/O modules, and other devices with Control Network connections.
 At the control layer, a Control Network combines the functionality of an I/O network and a peer-to-peer
messaging network.
 This open network provides the performance required for critical control data, such as I/O updates and
controller-to-controller interlocking. Control Network also supports transfers of noncritical data, such as
program uploads, downloads, and messaging.

Device Networks

 A Device Network is an open, low-level communication link that provides connections between simple,
industrial devices (such as sensors and actuators) and high-level devices (such as controllers).
 Based on standard controller area network technology, this open network offers a level of interoperability
between like devices from multiple vendors.
 A Device Network reduces installation costs, start-up and commissioning time, and system and machine
down time.
 At the device layer, a Device Network can connect low-level devices directly to plant-floor controllers
without the need to interface them through I/O modules.

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PLC and Foreign Device Connectivity

 A PLC can be a component of a DCS.

 A DCS can include Networked PLCs, PCs, or other control equipment sharing or distributing control of a
process or processes.
 Modems, multiplexers, printers, SCADA

Plant Enterprise Networks

 Information Network
 The TCP/IP Ethernet network is a local area network designed for the high-speed exchange of information
between computers and related devices.
 With its high bandwidth (10–100 Mbps), an Ethernet network allows many computers, controllers, and
other devices to communicate over vast distances.
 At the information layer, an Ethernet network provides enterprise-wide systems access to plant-floor
data.
 With an Ethernet network you have many possibilities because you can maximize communication between
the great variety of equipment available from vendors.
 TCP/IP is the protocol used by the Internet.

Summary

Network Type Application

Control Network  High-speed transfer of time-critical data between controllers and

I/O devices
 Deterministic and repeatable data delivery
 Program maintenance
 Media redundancy or intrinsic safety options
 Connections between controllers and I/O adapters
 Distributed controllers so that each controller has its own I/O and
communicates with a supervisory controller
Device Network  Connections of low-level devices directly to plant floor
controllers, without the need to interface them through I/O
modules
 More diagnostics for improved data collection and fault detection
 Less wiring and reduced start-up time than a traditional, hard-
wired system
Plant Enterprise Network/  High-speed data transfer between information systems and/or a
Information Network large
quantity of controllers
 Internet/Intranet connection
 Program maintenance
 Plantwide and cell-level data sharing with program maintenance
PLC and Foreign Device  PLC
Connectivity  Modems
 Messages that send and receive ASCII characters to or from
devices such as ASCII terminals, bar-code readers, message
displays, weigh scales, or printers
 Supervisory control and data acquisition (SCADA)