INFERCON AUTOMATION PVT LTD

TRAINING MODULE FOR DELTAV DCS

VILT-DAY-

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 INTRODUCTION - PROCESS CONTROL
Process Control applications typically involve the transformation of raw materials through the
reaction of component

chemicals or the introduction of physical changes to produce a new, different product.

MAJOR PROCESS PARAMETERS:

• Flow

• Level

• Pressure

• Temperature

CONTROL SYSTEM

The Process Control applications may be composed of one or more process unit operations piped
together. One key characteristic is that the operator can't see the product. It is usually held within a
vessel and may be hazardous in nature. There is usually a large amount of simple to complex analog
control (i.e., PID or loop control). This type of process is often controlled by a DCS.

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 INTRODUCTION TO DCS
A Distributed Control System (DCS) refers to a control system of a process plant and industrial
process, wherein control elements are not only located in central location (like the brain) but are also
distributed throughout the system with each component sub-system controlled by one or more
controllers so the intelligence is distributed across the sections of the plant.

In a DCS, a hierarchy of controllers are connected by communication network for command and
monitoring.

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 PLC DCS
Application Machine, Small line, Single Big Process, Plant
Batch
Complexity Simple Continuous, Complex
Cost Low High
Core of the PLC SCADA
system
Processing Faster Slower
Speed
Supervisory No Yes
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 SCAN TIME of the DCS

The DCS doesn't have to be that quick - most of the time. The regulatory control loops normally
scan in the 100 to 500 millisecond range. In some cases, it could be detrimental to have control
logic execute any faster -possibly causing excessive wear on final control elements such as valves,
resulting in premature maintenance and process issues.

HEART OF THE DCS SYSTEM (HMI/SCADA)

In Process Control, where the environment can be volatile and dangerous, and where operators
can't see the actual product, the HMI/SCADA is considered by most to be the heart of the
system. In this scenario, the SCADA is a central control room console that provides the only
complete "window" into the process, enabling the operator to monitor and control the processes
which are occurring inside pipes and vessels located throughout the plant.

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 PROCESS REDUNDANCY
In Process Control applications running 24/7/365 days, downtime is one of the gremlins you try to avoid
at all cost, and money is not the only deciding factor. Dangerous downtime is clearly another deciding
factor in the system selection process. For example, a refinery has flares that are continuously burning
off gas. The system controlling those flares simply can't fail, because if the gas isn't burning, it's
collecting and pooling, causing an extremely dangerous situation. The more volatile the application, the
more it may require a solution with lots of redundancy to ensure that the system is available when
needed
Also,

• Downtime not only results in lost production, but can result in dangerous conditions.

• Downtime can result in process equipment damage (product hardens, etc.)

• Return to steady state production after an unplanned outage can be long, expensive, and difficult.

Different Types of Redundancy:

• Controller Redundancy

• Communication Redundancy

• Server Redundancy

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 DeltaV Overview

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 Objectives
Upon completion of this module, you will be able to define:
• PlantWeb/DeltaV System architecture
• DeltaV Software components
• DeltaV System capacities
• Identify and launch DeltaV applications
• Identify, decommission, and commission a controller

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 DeltaV System Architecture
10/100BaseT Cable
Maximum Length 100 m (330 ft)
Workstation
Controller
Primary Switch

Secondary Switch

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 DeltaV System Architecture
Multiple Nodes
Workstation

Primary Switch Secondary Switch

System Power Supply,

Controller, and I/O Subsystem

Legend:
Primary Control Network
Secondary Control Network

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 DeltaV System Architecture – System Capacities
Multiple Nodes
A DeltaV Control Network with eight nodes is illustrated above.
Maximums:
• 120 – Nodes
• 100 – Controllers / Simplex or Redundant Pairs
• 65 – Workstations
• 30,000 Device Signal Tags (DSTs)
• 25,000 max (recommended) SCADA tags
• 1500 max DSTs per MX/SX Controller, 750 max. DSTs per MD/SD Controller
• 15,000 Advanced Unit Management DSTs
Note: A server may be required depending on system size.
Refer to DeltaV Books Online for additional information about the DeltaV system’s
capacities.
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 PlantWeb Architecture

Management Execution

Integrated, Modular Software

DeltaV/AMS
Intelligent Device Manager

Wireless I/O
Card

Integrated smart SIS

Intelligent Field Devices
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 PlantWeb Architecture
PlantWeb is the digital plant architecture that uses predictive intelligence to improve plant
performance.
• Intelligent Field Devices – Can be remotely configured and calibrated via software
using an appropriate host or configurator. Diagnostic information is passed to
Maintenance stations via PlantWeb alerts. Many field devices include PID functions.
• Scalable platforms – The DeltaV host has been designed to manage large amounts of
data. It is equally well suited for small and large applications.
• Integrated, modular software (AMS) – A package that allows users to commission,
configure, calibrate, and troubleshoot devices from a Windows Explorer type screen.
• Management execution – With OLE for Process Control (OPC), data from the
DeltaV system can be communicated via the existing business LAN to other
compliant Windows applications such as Excel and Access.
• Integrated smart SIS – TÜV certified for SIL 3 applications, integrated yet separate.
• Smart Wireless Integration – The Smart Wireless Gateway provides plug-and-play
seamless integration with Self-organizing Networks.
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 DeltaV Zones Architecture
Zone 1 Zone 2
Inter-Zone
Servers

Zone 3 Zone 4

Inter-Zone
Servers

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 DeltaV Zones Architecture
DeltaV Zones allow multiple DeltaV Systems to communicate operating data and alarms
between one another via Inter-Zone Servers (IZS).
Each zone is a standalone DeltaV system comprised of the ProfessionalPLUS node, an
Inter-Zone Server node, and other nodes as desired.
Zone considerations:
• The ability to upgrade systems independently while maintaining communications
• Large systems greater than 30,000 DSTs and/or 120 Nodes
• A maximum of 15 Zones
• Optional redundant IZS
• Each Zone requires a license

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 DeltaV M-series I/O Interface
2-Wide Power/ 8-Wide I/O
Controller Carrier Interface Carrier

Mounting Screw
DIN Rail I/O Card I/O Terminal Block

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 DeltaV M-series I/O Interface
The I/O Subsystem includes I/O Interfaces mounted on one or more 8-wide I/O Interface
Carriers and an optional power source that provides power to field devices.
The I/O Interface consists of the following components as illustrated above:
• I/O Terminal Block snaps onto the I/O Interface Carrier to provide screw
terminations for field wiring.
• I/O Card snaps over the I/O Terminal Block on the I/O Interface Carrier to convert
field signals to a digital format for control and communications.
Refer to DeltaV Books Online for additional information about the DeltaV system’s
architecture.

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 DeltaV M-series I/O Card Types
Analog Inputs Discrete Inputs
AI 4-20 mA HART 8 channels DI 24 VDC Isolated 8 channels
AI 4-20 mA HART 16 channels DI 24 VDC Dry Contact 8 channels
AI Isolated (TC/RTD/MV/Ohms/Voltage)
DI 120 VAC Isolated 8 channels
4 channels
I.S. AI 4-20 mA HART 8 channels DI 120 VAC Dry Contact 8 channels
Millivolt 8 channels DI HD 24 VDC Dry Contact 32 channels
RTD 8 channels I.S. DI 12 VDC I.S. Power 16 channels
Thermocouple 8 channels DI Multi-function (High Frequency) 4 channels
SOE, (DI 24 VDC) 16 channels

Analog Outputs Discrete Outputs

AO 4-20 mA HART 8 channels DO 24 VDC Isolated 8 channels
I.S. AO 4-20 mA HART 8 channels DO 24 VDC High Side 8 channels
DO 120/230 VAC Isolated 8 channels
DO 120/230 VAC High Side 8 channels
DO HD 24 VDC High Side 32 channels
I.S. DO 12 VDC I.S. Power 4 Channel

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 DeltaV M-series Communication Interfaces
FOUNDATION fieldbus Interface
• 2 Ports, maximum of 16 Devices/Port, 1900 meters
DeviceNet
• 1 Port, maximum of 61 Devices, 500 meters @ 125K baud
Profibus DP
• 1 Port, maximum of 64 Devices, 2000 meters @ 1.5M baud
Actuator Sensor Interface (AS-i)
• 2 Ports, maximum of 31 Devices/Port, 300 meters
Serial Interface
• 2 Port Modbus Protocol, RS232/RS485 or 2 Port Programmable

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 M-series Controller
2-Wide Power/ 8-Wide I/O
Controller Carrier Interface Carrier
I/O Card

DIN Rail
Mounting Screw I/O Terminal Block
Controller
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 M-series Controller
The DeltaV Controller mounts in the right slot of the 2-wide Power/Controller Carrier as
illustrated above. Vertical mount carriers are also available for Controllers and I/O cards.

Refer to DeltaV Books Online for additional information about DeltaV carriers,
controllers, and I/O cards. Search for Installing Your DeltaV System.

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 DeltaV S-series
The S-series is recognizable by its silver color. Installation is simplified with snap-in
cards that are released by a push button on top. Protected venting allows for cooling and
prevents debris from falling in the top of the cards.

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 DeltaV S-series
The S-series provides the same I/O card types as the traditional M-series. The SD and SX
controllers offer the same performance as the MD and MX controllers, respectively.

Note: S-series controllers are required for Wireless I/O cards and Electronic
Marshalling.

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 S-series Electronic Marshalling
S-series Electronic Marshalling provides circuit protection, isolation, and single-channel
granularity with full redundancy. The CIOCs and CHARMs can be installed in field
junction boxes and can eliminate traditional marshalling cabinets.
CTLR 1 . . . . . CTLR4

CHARM I/O Cards

(CIOC)

Characterization Modules
(CHARMS)

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 CHARM Classes and Types
CHARM Class CHARM Type
Analog Input (AI) AI 4-20 mA HART
Analog Output (AO) AO 4-20 mA HART
DI NAMUR
DI 24 VDC Low side
Discrete Input (DI) DI 24 VDC Isolated
DI 120 VAC Isolated
DI 230 VAC Isolated
DO 24 VDC High side
Discrete Output (DO) DO 24 VDC Isolated
DO 120/230 VAC Isolated
Thermocouple Input Thermocouple/mV
RTD Input RTD / Resistance input
Voltage AI 0-10 VDC Isolated

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 Wireless I/O Card
The Wireless I/O Card provides redundant communications between controllers and
Smart Wireless Field Links, which communicate to wireless field devices using the self-
organizing network.
CTLR 1 . . . . . CTLR4
Smart Wireless
Field Links
Wireless I/O Cards
(WIOC)

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 Switches
Unmanaged switches provide a means to connect multiple nodes in smaller DeltaV
systems containing less than 15 network devices. This type of switch serves as a
connection point and rejuvenates the electrical signal as messages are forwarded on the
control network.
DeltaV Smart Switches are the preferred switch to be used within the DeltaV network as
they provide network management and automatic lockdown capability. The switches are
plug-and-play and pre-configured for a DeltaV Network.
To ensure that you have proper switch configuration and the correct switch software for
your DeltaV system, you should purchase switches through normal Emerson channels.

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 DeltaV Smart Switches
DeltaV Smart Switches offer a variety of environmental, mounting, and sizing options.

RM100 MD20/30

FP20

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 DeltaV Switches
Available DeltaV Smart Switches:
• FP20 is a Fixed Port with 8 ports
− Wired and fiber combinations
− Extended operating temperature range (–40° to 70°C) for remote mounting
• MD20/30 is a Modular DIN rail with up to 24 ports
− Eleven different modules, wired and fiber ports
− Extended operating temperature range (–40° to 70°C) for remote mounting
− MD30, 2 Gigabit uplinks, up to 26 ports
• RM100 is Rack Mountable up to 24 ports
− 2 Gigabit uplinks, fiber or wired
Gigabit connections are supported only between switches. Connections between
controllers and workstations are 10/100MB.

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 M-series Power Distribution
G Bulk Power Supply

N Power
Distribution
N

Ground DC Return

- +

Pwr
Fault
1

DC Return 2
3
4
5
6
7
8

Bulk Power Supply

System Power Supply

2 3 4 5 6 7 8

2-Wide I/O Carrier

Power/Controller
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 S-series Bussed Field Power

Secondary

Secondary
Secondary
Primary

Injected

Injected

Injected
Primary

Internally Bussed Field Power: 12 A (3 A per card maximum)

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 DeltaV Power Supplies
The DeltaV System Power Supply consists of the following options:
• System Power Supply (AC/DC) – Input 100 to 264 VAC (M-series)
• System Power Supply (Dual DC/DC) – Input 24 VDC or 12 VDC (M-series)
• System Power Supply (DC/DC) – Input 24 VDC (S-series)
The DeltaV Bulk Power Supply consists of the following options:
• Bulk AC to 24 VDC Power Supply
• Bulk AC to 12 VDC Power Supply
An Intrinsically Safe Power Supply is available for the Intrinsically Safe I/O:
• Intrinsically safe (DC/DC) – Input 24 VDC

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 Workstation Types
Workstations are licensed, based on the functionality required, as follows:
• ProfessionalPLUS Station – Configuration, Operation, and Configuration Database
node
• Professional Station – Configuration and Operation
• Operator Station – Operation
• Maintenance Station – Diagnostics
• Base Station – Select necessary functionality
• Application Station – Run-time database plus user-selected applications. User
applications include DeltaV Batch software or other third-party OPC applications
for interfacing to the plant business systems.

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 Capacity Limits for Workstations
• Up to 65 max Workstations
− 1 ProfessionalPLUS Station
− 10 maximum Professional Stations
− Up to a total combination of 59 Operator, Maintenance, and Base Stations
− 20 maximum Application Stations
• 72 max Remote (licensed) Workstations
− 8 max Remote Data Servers (ProfessionalPLUS and 7 Application Stations)
• 15 max (recommended) Remote clients per Professional PLUS or Operator Station

For additional information on “Capacity Limits for Workstations” refer to

DeltaV Books Online.

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 Common Workstation Software Components
The DeltaV Workstations usually contains the following:
• DeltaV FlexLock
• DeltaV Operate
• Configuration Software Suite
• Diagnostics

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 DeltaV FlexLock
The DeltaV FlexLock application creates dual desktops on a single workstation to provide
both a secure operating environment and a wide open engineering environment.
Access to a desktop is determined by the current user's privileges.

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 DeltaV Operate (Run)
DeltaV Operate (Run) is used by the operator to view and control the process. It consists
of three items:
• Button Toolbar
• Working Area
• Alarm Banner
DeltaV Operate (Configure) is used to create and edit DeltaV graphics.
Access DeltaV Operate by selecting . . .
Start  All Programs  DeltaV  Operator  DeltaV Operate Run

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 Decommissioned Controllers
Launch DeltaV Explorer to view a list of decommissioned controllers by selecting . . .
Start  All Programs  DeltaV  Engineering  DeltaV Explorer
Decommissioned controllers are listed in the Contents window of DeltaV Explorer by
selecting . . .
Physical Network  Decommissioned Nodes

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 Decommissioned Controllers
CTLR-02599C, shown above, is a decommissioned controller.
Decommissioned State – Controller(s) are non-active members of a Control Network. For
example, when:
• A new controller is added to the Control Network
• A replacement is installed for an existing controller (any new controller starts in
the decommissioned state)
• A controller is deliberately decommissioned for an extended scheduled shutdown
Decommissioned State Visual Indicators –
Power LED (Green) ON
Error LED (Red) FLASH at one-second interval
Active/Standby LED (Green) OFF
Yellow LEDs FLASH at random

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 Decommission a Controller
In DeltaV Explorer, right-click on a commissioned controller and select Decommission.
After being decommissioned, a controller placeholder remains in the Control Network.

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 Identify Controller
Identify the controller from DeltaV Explorer by selecting . . .
(right-click) Decommissioned Controller 
(left -click) Properties  Flash lights

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 Identify Controller
Identify State – A specific controller is located on the Control Network. Identify is a
property of the controller that can be used to locate a specific controller when multiple
controllers are part of a Control Network. Identify can be performed on decommissioned
and commissioned controllers.
Identify State Visual Indicators –
Power LED (Green) ON
All other LEDs FLASH at one-second interval
Note: Automatically terminate the identify state by closing the Identify dialog box or
selecting Stop Flashing on the controller’s Properties window.

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 Commissioning a Controller & Auto-Sensing
I/O Cards
Commission – The act of making a controller an active member of a DeltaV Control
Network. A TCP/IP address is automatically assigned by the ProfessionalPLUS
workstation at commissioning. Commissioning can be performed from the DeltaV
Explorer or Configuration Assistant application. The last step of commissioning will
prompt you to Auto-Sense I/O cards.

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 Commissioning a Controller & Auto-Sensing
I/O Cards
Commission a controller and auto-sense the I/O cards from the DeltaV Explorer
by selecting the Decommissioned Controller CTLR-02599C and dragging and dropping it
onto the Control Network or existing placeholder. A Properties window appears
requesting various information.

Drag and Drop

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 Commissioning a Controller

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 Commissioning a Controller
The fields in the controller Properties dialog box are:
• Name – A user-defined name with a maximum of 16 characters containing at least
one alpha character. It may also contain $, -, or _.
• Description – An optional user description of no more than 255 characters
appearing in the DeltaV Explorer. It is for information only and not used by the
controller.
• Associate Alarms & Events with Area – Define the plant area that will be associated
with the controller node and subordinate field device alarms.
• Enable System Hardware Alarms – Checking the box  enables controller
hardware errors to appear as alarms.
• Enable network redundancy for this node – Checking the box  enables the
secondary control network for the node.

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 Commissioning a Controller
• Show integrity error when not in time sync – Checking the box  enables an
integrity error on this controller when the time is not synchronized with the master
time server.
• Node is redundant – A Simplex Controller will be grayed out. A checked box 
indicates the controller is redundant.

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 Auto-Sensing I/O Cards
When the above fields have been completed, click OK to continue. The last step in
commissioning the controller permits you to Auto-sense the I/O cards for the controller.

Auto-Sense I/O cards – Clicking YES causes the controller to scan its I/O sub-system and
identify the card types and carrier slots where the I/O cards are installed. By clicking NO,
the controller WILL NOT SCAN the I/O sub-system for installed I/O cards but will
continue to commission itself. Auto-sense can be performed at any time from the DeltaV
Explorer.
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 Status Indicators
DeltaV Explorer provides visual indicators on the status of nodes and modules.
Select and right-click the object with the visual indicator, then select Help from the menu.
Click the Status Indicators link to open a detailed help window for the visual indicators.

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 Status Indicators

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 Workshop – Commission the Controller
This workshop requires you to
• Use the Identify Controller Property
• Commission and decommission the Controller
• Access the Status indicator information

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 Workshop – Commissioning the Controller
Commission the decommissioned controller CTLR-XXXXXX from DeltaV Explorer by
performing the following tasks:
Step 1. Identify the M- or S-series controller using the Identify State.
Step 2. Commission the M- or S-series controller, name it, give it a description,
enable network redundancy, and Auto-sense I/O.
Step 3. Access the Status indicators by right-clicking Help on the controller.
Step 4. Identify the controller using the Identify State after being commissioned.
How many nodes are shown in DeltaV Explorer and in DeltaV Diagnostics?
Step 5. Decommission the controller.
Can you find where the decommissioned controller goes to?
Step 6. Commission the controller again.

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 Summary
You should now be able to define:
• PlantWeb/DeltaV System architecture
• DeltaV Software components
• DeltaV System capacities
• Identify, decommission, and commission a controller

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