\"Distributed Control Systems (DCS) and Fieldbus Control Systems (FCS) and Their Engineering Design\"
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This post was last edited by zhoudingshengs on 2023-11-30 16:33: Distributed Control Systems (DCS) and Fieldbus Control Systems (FCS) and their engineering design.
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Table of Contents
Part I: Basic Knowledge
Chapter 1 Introduction 2
1.1 Overview of Distributed Control Systems 2
1.1.1 Concept of Distributed Control Systems (DCS) 2
1.1.2 Characteristics of Distributed Control Systems 3
1.1.3 Development history of Distributed Control Systems 5
1.2 Typical DCS products and their features 9
1.3 Development trends of Distributed Control Systems 12
1.4 Overview of fieldbuses 15
1.4.1 Origin of fieldbuses 15
1.4.2 Characteristics of fieldbuses 16
1.4.3 Development trends of fieldbuses 17
1.5 Thought-provoking questions 17
Chapter 2 Communication network systems in DCS 18
2.1 Principles of networks and data communication 18
2.1.1 Basic components of communication network systems 18
2.1.2 Basic concepts and terminology 19
2.1.3 Industrial data communication 21
2.1.4 Data exchange methods 22
2.1.5 Communication channels 23
2.1.6 Error control 26
2.2 Structure of data communication systems 30
2.2.1 Structure of communication systems 31
2.2.2 Topological structures of communication networks 32
2.3 Control network standards and protocols in DCS 33
2.3.1 Reference models for protocols 33
2.3.2 Physical layer protocols 34
2.3.3 Link layer protocols 35
2.3.4 Network layer protocols 36
2.3.5 Transport layer and session layer protocols 37
2.3.6 Higher-level protocols 38
2.3.7 Network devices 39
2.4 Summary of this chapter 42
2.5 Thought-provoking questions 43
Chapter 3 Process control stations in DCS 44
3.1 Architecture of DCS 44
3.2 Structure of process control stations 50
3.3 Basic control units 53
3.3.1 Hardware of basic control units 54
3.3.2 Software of basic control units 81
3.3.3 Reliability measures for basic control units 92
3.4 Summary of this chapter 96
3.5 Thought-provoking questions 97
Chapter 4 Operator workstations 98
4.1 Structure of operator workstations 98
4.2 Basic functions of MMI 101
4.3 Recording and reporting 110
4.4 Retrieval and processing of historical data 111
4.5 Other types of human-machine interfaces 111
4.6 Development overview of human-machine interfaces 112
4.7 Summary of this chapter 113
4.8 Thought-provoking questions 113
Chapter 5 Engineer workstations and configuration software 114
5.1 Role of engineer workstations in DCS 114
5.2 Components of engineer workstations 117
5.3 Position of engineer workstations within DCS 117
5.4 System configuration 118
5.4.1 Configuration software 118
5.4.2 Differences between system configuration and other design methods 120
5.4.3 Configuration of process control stations 120
5.4.4 Configuration of operator workstations 124
5.4.5 Online debugging during configuration 126
5.5 Application configuration process of MACS 127
5.6 Summary of this chapter 129
5.7 Thought-provoking questions 130
Chapter 6 Performance indicators and evaluation of DCS 131
6.1 Brief introduction to performance indicators of Distributed Control Systems 131
6.2 Evaluation criteria for Distributed Control Systems 133
6.2.1 Evaluation of reliability and economy 134
6.2.2 Evaluation of technical performance 139
6.2.3 Evaluation of usability 141
6.2.4 Reliability assessment of control system software 142
6.3 Selection principles for DCS 145
6.4 Summary of this chapter 146
6.5 Thought-provoking questions 146
Chapter 7 Fieldbus Control Systems 147
7.1 Definitions of fieldbuses and Fieldbus Control Systems 147
7.2 DCS, PLC, and FCS 148
7.3 Several typical fieldbuses 149
7.3.1 Profibus fieldbus 149
7.3.2 CAN bus 151
7.3.3 Foundation Fieldbus 152
7.3.4 LonWorks bus 155
7.4 Composition of Fieldbus Control Systems 157
7.5 Methods for designing Fieldbus Control Systems 159
7.6 Configuration of Fieldbus Control Systems 161
7.7 Debugging and maintenance of Fieldbus Control Systems 163
7.8 Summary of this chapter 164
7.9 Thought-provoking questions 164
Chapter 8 Fieldbus communication systems 165
8.1 Overview of fieldbus communication systems 165
8.1.1 Relationship between fieldbus communication systems and the ISO/OSI reference model 165
8.1.2 Main components of Profibus fieldbus communication systems 167
8.2 Profibus physical layer 167
8.2.1 RS-485 transmission in Profibus-DP 168
8.2.2 Optical fiber transmission in Profibus-DP 170
8.3 Profibus data link layer 171
8.3.1 Media access control in Profibus 171
8.3.2 Message format in Profibus 172
8.3.3 Address encoding method in Profibus 174
8.3.4 Services provided by Profibus data link layer 175
8.4 Profibus application layer 176
8.5 Profibus user layer 178
8.5.1 Overview of Profibus-DP user layer 178
8.5.2 Functions of DDLM 179
8.5.3 User interface 180
8.5.4 Operating specifications for Profibus-DP 181
8.6 Summary of this chapter 181
8.7 Thought-provoking questions 182
Chapter 9 Fieldbus devices 183
9.1 Classification and characteristics of fieldbus devices 183
9.1.1 Classification of fieldbus devices 183
9.1.2 Characteristics of fieldbus devices 184
9.2 Fieldbus differential pressure transmitters 185
9.2.1 Overview 185
9.2.2 Working principle 186
9.3 Fieldbus temperature transmitters 188
9.3.1 Overview 188
9.3.2 Working principle 188
9.3.3 Temperature sensing elements 189
9.4 Fieldbus valve positioners 191
9.4.1 Overview 191
9.4.2 Working principle 191
9.5 Fieldbus electric actuators 193
9.5.1 Overview 193
9.5.2 Working principle 193
9.6 Fieldbus-to-pneumatic converters 194
9.6.1 Overview 194
9.6.2 Working principle 194
9.7 Current-to-fieldbus converters 196
9.7.1 Overview 196
9.7.2 Working principle 196
9.7.3 Installation and calibration 197
9.8 Fieldbus-to-current converters 198
9.8.1 Overview 198
9.8.2 Working principle 198
9.9 Fieldbus interface devices 199
9.9.1 Overview 199
9.9.2 Working principle 200
9.9.3 Installation and maintenance 201
9.9.4 Other bus interface devices 202
9.10 Fieldbus power supply devices 203
9.10.1 Overview 203
9.10.2 Working principle 204
9.11 Fieldbus accessory devices 205
9.12 Summary of this chapter 206
9.13 Thought-provoking questions 207
Part II: Engineering Applications
Chapter 10 Engineering design of DCS 210
10.1 General process of application design and implementation of DCS 210
10.2 Overall design of DCS 211
10.2.1 Feasibility study and overall design 211
10.2.2 Preliminary design of DCS 211
10.2.3 Detailed design of construction drawings 214
10.3 Engineering design of DCS systems 217
10.4 Configuration and debugging of DCS 219
10.5 Installation and acceptance of Distributed Control Systems 219
10.6 Case study: Temperature control for electric heating boilers 220
10.6.1 System overview 220
10.6.2 Preliminary design of the system 220
10.6.3 Determination of control scheme for electric heating boilers 222
10.7 Constant-pressure oxygen control using MACS in the air separation industry 229
10.8 Summary of this chapter 234
10.9 Thought-provoking questions 234
Chapter 11 Engineering design of FCS 235
11.1 Principles of engineering design for FCS 235
11.2 Methods of engineering design for FCS 236
11.3 Design process of FCS control systems 237
11.3.1 Overall scheme design 238
11.3.2 Preliminary design of control systems 240
11.4 Examples of applications of FCS engineering control systems 240
11.4.1 Design overview 240
11.4.2 Network topology and parameter configuration 241
11.4.3 Hardware design of the system 244
11.4.4 Software design of the system 249
11.4.5 Anti-interference measures for the system 254
11.5 Summary of this chapter 256
11.6 Thought-provoking questions 256
Appendix A: Architecture and technical features of next-generation DCS 258
A.1 Reasons behind the emergence of next-generation DCS 258
A.2 Architecture of next-generation DCS 259
A.3 Main functions and technical features of next-generation DCS 262
References 270
Part I: Basic Knowledge
Chapter 1 Introduction 2
1.1 Overview of Distributed Control Systems 2
1.1.1 Concept of Distributed Control Systems (DCS) 2
1.1.2 Characteristics of Distributed Control Systems 3
1.1.3 Development history of Distributed Control Systems 5
1.2 Typical DCS products and their features 9
1.3 Development trends of Distributed Control Systems 12
1.4 Overview of fieldbuses 15
1.4.1 Origin of fieldbuses 15
1.4.2 Characteristics of fieldbuses 16
1.4.3 Development trends of fieldbuses 17
1.5 Thought-provoking questions 17
Chapter 2 Communication network systems in DCS 18
2.1 Principles of networks and data communication 18
2.1.1 Basic components of communication network systems 18
2.1.2 Basic concepts and terminology 19
2.1.3 Industrial data communication 21
2.1.4 Data exchange methods 22
2.1.5 Communication channels 23
2.1.6 Error control 26
2.2 Structure of data communication systems 30
2.2.1 Structure of communication systems 31
2.2.2 Topological structures of communication networks 32
2.3 Control network standards and protocols in DCS 33
2.3.1 Reference models for protocols 33
2.3.2 Physical layer protocols 34
2.3.3 Link layer protocols 35
2.3.4 Network layer protocols 36
2.3.5 Transport layer and session layer protocols 37
2.3.6 Higher-level protocols 38
2.3.7 Network devices 39
2.4 Summary of this chapter 42
2.5 Thought-provoking questions 43
Chapter 3 Process control stations in DCS 44
3.1 Architecture of DCS 44
3.2 Structure of process control stations 50
3.3 Basic control units 53
3.3.1 Hardware of basic control units 54
3.3.2 Software of basic control units 81
3.3.3 Reliability measures for basic control units 92
3.4 Summary of this chapter 96
3.5 Thought-provoking questions 97
Chapter 4 Operator workstations 98
4.1 Structure of operator workstations 98
4.2 Basic functions of MMI 101
4.3 Recording and reporting 110
4.4 Retrieval and processing of historical data 111
4.5 Other types of human-machine interfaces 111
4.6 Development overview of human-machine interfaces 112
4.7 Summary of this chapter 113
4.8 Thought-provoking questions 113
Chapter 5 Engineer workstations and configuration software 114
5.1 Role of engineer workstations in DCS 114
5.2 Components of engineer workstations 117
5.3 Position of engineer workstations within DCS 117
5.4 System configuration 118
5.4.1 Configuration software 118
5.4.2 Differences between system configuration and other design methods 120
5.4.3 Configuration of process control stations 120
5.4.4 Configuration of operator workstations 124
5.4.5 Online debugging during configuration 126
5.5 Application configuration process of MACS 127
5.6 Summary of this chapter 129
5.7 Thought-provoking questions 130
Chapter 6 Performance indicators and evaluation of DCS 131
6.1 Brief introduction to performance indicators of Distributed Control Systems 131
6.2 Evaluation criteria for Distributed Control Systems 133
6.2.1 Evaluation of reliability and economy 134
6.2.2 Evaluation of technical performance 139
6.2.3 Evaluation of usability 141
6.2.4 Reliability assessment of control system software 142
6.3 Selection principles for DCS 145
6.4 Summary of this chapter 146
6.5 Thought-provoking questions 146
Chapter 7 Fieldbus Control Systems 147
7.1 Definitions of fieldbuses and Fieldbus Control Systems 147
7.2 DCS, PLC, and FCS 148
7.3 Several typical fieldbuses 149
7.3.1 Profibus fieldbus 149
7.3.2 CAN bus 151
7.3.3 Foundation Fieldbus 152
7.3.4 LonWorks bus 155
7.4 Composition of Fieldbus Control Systems 157
7.5 Methods for designing Fieldbus Control Systems 159
7.6 Configuration of Fieldbus Control Systems 161
7.7 Debugging and maintenance of Fieldbus Control Systems 163
7.8 Summary of this chapter 164
7.9 Thought-provoking questions 164
Chapter 8 Fieldbus communication systems 165
8.1 Overview of fieldbus communication systems 165
8.1.1 Relationship between fieldbus communication systems and the ISO/OSI reference model 165
8.1.2 Main components of Profibus fieldbus communication systems 167
8.2 Profibus physical layer 167
8.2.1 RS-485 transmission in Profibus-DP 168
8.2.2 Optical fiber transmission in Profibus-DP 170
8.3 Profibus data link layer 171
8.3.1 Media access control in Profibus 171
8.3.2 Message format in Profibus 172
8.3.3 Address encoding method in Profibus 174
8.3.4 Services provided by Profibus data link layer 175
8.4 Profibus application layer 176
8.5 Profibus user layer 178
8.5.1 Overview of Profibus-DP user layer 178
8.5.2 Functions of DDLM 179
8.5.3 User interface 180
8.5.4 Operating specifications for Profibus-DP 181
8.6 Summary of this chapter 181
8.7 Thought-provoking questions 182
Chapter 9 Fieldbus devices 183
9.1 Classification and characteristics of fieldbus devices 183
9.1.1 Classification of fieldbus devices 183
9.1.2 Characteristics of fieldbus devices 184
9.2 Fieldbus differential pressure transmitters 185
9.2.1 Overview 185
9.2.2 Working principle 186
9.3 Fieldbus temperature transmitters 188
9.3.1 Overview 188
9.3.2 Working principle 188
9.3.3 Temperature sensing elements 189
9.4 Fieldbus valve positioners 191
9.4.1 Overview 191
9.4.2 Working principle 191
9.5 Fieldbus electric actuators 193
9.5.1 Overview 193
9.5.2 Working principle 193
9.6 Fieldbus-to-pneumatic converters 194
9.6.1 Overview 194
9.6.2 Working principle 194
9.7 Current-to-fieldbus converters 196
9.7.1 Overview 196
9.7.2 Working principle 196
9.7.3 Installation and calibration 197
9.8 Fieldbus-to-current converters 198
9.8.1 Overview 198
9.8.2 Working principle 198
9.9 Fieldbus interface devices 199
9.9.1 Overview 199
9.9.2 Working principle 200
9.9.3 Installation and maintenance 201
9.9.4 Other bus interface devices 202
9.10 Fieldbus power supply devices 203
9.10.1 Overview 203
9.10.2 Working principle 204
9.11 Fieldbus accessory devices 205
9.12 Summary of this chapter 206
9.13 Thought-provoking questions 207
Part II: Engineering Applications
Chapter 10 Engineering design of DCS 210
10.1 General process of application design and implementation of DCS 210
10.2 Overall design of DCS 211
10.2.1 Feasibility study and overall design 211
10.2.2 Preliminary design of DCS 211
10.2.3 Detailed design of construction drawings 214
10.3 Engineering design of DCS systems 217
10.4 Configuration and debugging of DCS 219
10.5 Installation and acceptance of Distributed Control Systems 219
10.6 Case study: Temperature control for electric heating boilers 220
10.6.1 System overview 220
10.6.2 Preliminary design of the system 220
10.6.3 Determination of control scheme for electric heating boilers 222
10.7 Constant-pressure oxygen control using MACS in the air separation industry 229
10.8 Summary of this chapter 234
10.9 Thought-provoking questions 234
Chapter 11 Engineering design of FCS 235
11.1 Principles of engineering design for FCS 235
11.2 Methods of engineering design for FCS 236
11.3 Design process of FCS control systems 237
11.3.1 Overall scheme design 238
11.3.2 Preliminary design of control systems 240
11.4 Examples of applications of FCS engineering control systems 240
11.4.1 Design overview 240
11.4.2 Network topology and parameter configuration 241
11.4.3 Hardware design of the system 244
11.4.4 Software design of the system 249
11.4.5 Anti-interference measures for the system 254
11.5 Summary of this chapter 256
11.6 Thought-provoking questions 256
Appendix A: Architecture and technical features of next-generation DCS 258
A.1 Reasons behind the emergence of next-generation DCS 258
A.2 Architecture of next-generation DCS 259
A.3 Main functions and technical features of next-generation DCS 262
References 270
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