DeltaV Process Control
System
CM4120
Unit Operations Lab
January 2011
1
Outline
Evolution of Process Control
Layout and Architecture of the DeltaV system in
the PSCC
Physical connections between process
instrumentation and the DCS
What the engineers and operators see
2
Evolution of Controllers
1930’s – Pneumatic Controllers
• air pressure w/ flappers, bellows, and valves
adjust valve position based on measured
process variable for P, PI, later PID control
1950’s – Electronic Controllers
• transistors, resistors, and capacitors for P, PI,
PID control
• capable of remote installation
1960’s – Mainframe Computer Control
• Refineries were typical users
• Alarming capability and supervisory control
• Single point of failure, no user-friendly
graphical interface
3
Evolution of Controllers
Late 1970’s – Distributed Control Systems
(DCS)
• Networked computers distributed thru plant
• Pre-configured controllers
• Data archival capabilities
• Included an operator console
• Hardware was proprietary
Late 1990’s – DSC’s built on commodity
hardware platforms (COTS)
• Better scalability
• Affordable
4
Distributed Control System (DCS)
Functionality
y Continuous control of processing equipment
y Pre-programmed control software – needs
only to be configured
y Control functions are distributed throughout
redundant, deterministic networked computer
architecture
◦ I/O interface and level 1 (basic) control
functions
◦ advanced control functions
◦ interactive graphical interface (HMI)
5
DeltaV Architecture: ProPlus server
Plant Area – valves, xmitters
MD Controller
and I/O Cards
ProPlus
Server
PSCC_DeltaV
Redundant Hub
•Stores/serves configuration
•Archives data
•Displays information
•Allows control of process
6
DeltaV Architecture: Operator Stations
Plant Area – valves, xmitters
MD Controller
and I/O Cards
ProPlus
Server
PSCC_DeltaV
Redundant Hub
•Archive data
•Display information (HMI)
•Allows process changes Operator Stations
7
Communication paths…
Redundant Control network
MD Controller
Windows XP Workgroup –
PSCC_DeltaV
PSCC_DeltaV
Windows Networking and Redundant Hub
ProPlus
TCP/IP protocol Server
Operator Stations
8
DeltaV’s MD Controller and I/O –
How it connects to the process…
Plant Area – valves, xmitters
MD Controller
and I/O Cards
I/O cards are specific to device requirements
•4-20 mA input, 4-20 mA output
•24 VDC input, 24 VDC output, etc.
•Foundation Fieldbus Interface
9
Emerson’s DeltaV System –
Current State of the Technology
PID control
Discrete logic control
Signal conversions
Alarming
Fuzzy control, etc.
are continuously executed
by the “MD” controller
10
Wiring Systems Connect Transmitters
to DCS – at the Instrument End:
Wiring to field
Level transmitter junction cabinet
RTD or T/C head
Wiring from
transmitter to temp
measuring element
Temperature
transmitters
11
Wiring Systems Connect Transmitters
to DCS – at a Marshalling Cabinet:
Single pairs
from field
devices
8 pr. Cables to
controller
cabinet
8-pr. cables run from Field Junction Box (Marshalling
Cabinet) to Distributed Control System
12
Wiring Systems Connect Transmitters
to DCS – in the Controller Cabinet:
DeltaV “MD” controller
I/O cards
Power-limiting
Zener barriers
8 pr. cables from
field junction cabinet
2nd I/O chassis w/4-20
mA Output cards
13
Wiring Systems Connect DCS to
Transducers – at Marshalling Cabinet:
8-pr. cable from
controller cabinet
Current to pneumatic
transducers
Air lines to Wire prs. to transducers
control valves
14
Regulatory Control Valve
Air line from I/P transducer
Actuator w/ positioner
Control valve
Block valves
Bypass valve
15
Output Signals from Control System
to Control Solenoids
Solenoids for 2-position 8-pr. cable from
air-actuated ball valves controller cabinet
Air lines to
ball valves
Wire prs. to solenoids
16
Installed Field Devices:
Ball Valve w/ Actuator
Air line from
solenoid
Ball valve body
Actuator
Process line
17
DeltaV & Foundation Fieldbus
(4) mass flows, (4) densities,
and (4) RTD temps
(3) 8-multiplexed RTD temps
(2) temp-only transmitters
(1) wire
18
The directory tree for our DeltaV
system…
Control modules
ProPlus server
MD controller w/ I/O
cards and controllers
Fieldbus I/O card
w/instruments
Operator Stations
19
A typical PID Control Module…
Analog Input
function block
PID function block
Analog Output
function block
20
Configuring a PID Control Module…
Alarm
configuration
PID tuning
configuration
Configuration for
I/O signals
Configuration of
operating
parameters
21
What an operator might see…
22
References
[Link]/rosemount/,
Rosemount, Inc., Oct. 2006.
[Link]/micromotion/, Micro
Motion, Inc., Oct. 2006.
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