Console subsystem software

Console subsystem is the brain of the Distributed control system. The

software is called HMI (Human machine interface) MMI ( Man machine
interface) and also as SCADA. SCADA is a stand alone software which
can be interfaced to various models of PLCs generally through dedicated
device drivers where as it is proprietory and an integral part of DCS
system.

This sub system is the tool through which an operator has access to the
parameters of the plant that need to be monitored and controlled to
operate the plant safely and efficiently. The hardware used for this
applications can be any one of the following.

Line/textual display
Operator Panel
Operator panel with touch screen
Pc based work station.
This system is practically a one is to one replacement of panel
instrumentation in control room. For all practical purposes it replaces the
controllers recorders indicators annunciators etc by the work station.
The work station basically consists of a CRT display with a dedicated
operator key board for quick access to parameters.
All the displays as per requirement are configured in Engineering sub
station and downloaded to work station via communication sub system. A
typical CRT display is configured as follows.
Graphic display

A typical process plant consists of hundreds of variables where as the crt

used may be of 21 inch diagonal size. Hence it is not possible to display
all variables in one screen.

For this purpose a plant is divided in to various areas as per operation

requirement. Each area can be further divided into many screens. Quick
access to the various screens are provided in the key display area through
soft keys.
The objects to be shown in a particular screen is prepared in the form of
process flow diagrams. The information available on the screen are
basically divided into two cateogory.

Static objects
Dynamic objects

Static Objects

These are basically pipe lines vessels and columns that are to appear on
the particular screen which does not under go any change with respect to
real time. To draw these items normally the software provides icons for
line, circle, rectangle etc. It is possible to generate standard graphic
objects for motor valve pump etc and stored in a library for repeated use.

Dynamic objects (Instantaneous display)

In some software system it is called smart objects and basically these are
generated to update information from the controller software via
communication sub system.

For example a CINP block analogue output can be accessed via

communication sub system cyclically ( at periodic intervals) and
displayed on the screen at a place selected by the user. Normally the
following display formats are in use.

Digital display
In this display format the values appear in the form of decimal numbers
along with engineering units. It is possible to configure different colours
for the numbers to display normal or alarm status. This is the most
simplest form of displaying the variable. In this format provision is there
for inputting a value into the screen and as well as display.
Bar display
Bar display represents the analogue value in the form of bar to give a
proportional representation. It is possible to configure the length and
width of the bar along with default colours and automatic changing of the
colours based on abnormalities. Bar representation helps to compare the
values of two related variables such as process variable and set point.

Status display
This format is used for displaying the status of a digital input /digital
output. This is normally used in the following applications.
Motor on /off /trip
Valve open /close
It is possible to change the colour of the motor or valve which are
normally static objects.
By using analogue values it is possible to simulate the actual running of a
motor.
Textual display
This is a variation of status display where in textual information can be
displayed. For example in a batch process consists of various stages and
using this feature it is possible to display the current status of the process.
This is the prominent display in text display panels where graphics are
not possible.

It is important to note that in Graphic display only the variables related

to that screen and configured alone are updated which will be few in
number. Hence to alert the operator on the abnormalities any where in the
plant Alarms are diplayed in over view display.

A typical over view display is as shown.

19.56 Lic 01 drum level very low 20% ack

It is to be noted that the grapic display screen changes where as the over
view display will remain the same. Any abnormality in any area will be
reported in the alarm area of the over view display. Upon receipt of alarm
the operator acknowledges it and select the screen through key area and
locates the fault and take corrective action.

Alarm logging

The function of the annunciators of the earlier control system is carried

out using this feature. The controller software system generates alarms on
the process variables and also process the status of various equipments .
Alarm logging function generates the list of alarms to be logged based on
tag numbers. The operator console as a part of back ground program
collects these values cyclically and generates the following logics.

Fault appeared and not acknowledged

Fault appeared and acknowledged
Fault disappeared and not acknowledged
Fault disappeared and reset.
In addition Firstout sequence also is possible

The alarms can be formed in different class such as error warning etc and
message texts are generated as per requirement. System diagnostics
alarms are also possible. Alarm are stored as alarm history for analysis at
a later date. The latest unacknowledged alarm appear on the over view
display. Occurrence of an alarm always switch on the hooter to catch the
attention of operator.

The software provides the facility for the follwing in the form of soft
switches in over view display.

Loop in alarm: by actuating this switch by the operator the screen

corresponding to the troubled area appears on the screen.
Operator guide messages: By actuating this switch the operator is
directed to a screen that gives the possible root cause of the problems and
suggested remedies.

Tag logging:
This feature does the data acquisition of process variables which were
earlier carried out by recorders. The tag listing of the analogue parameters
to be stored (archived) is done in tag logging upon which the datas are
collected at specified cycles from the controller sub system by the
background program.. In all the trend format the x axis is time based and
y axis is for the process variables. Facility for multi point trending on one
screen with facilities to switch off/on pens and zooming in and out for x
and y axis are established standard of the day for any dcs system. The
acquired data is displayed graphically in any one of the following format.

Real time trend: In this format the process variables appear in real time
mode.
Historical trend:
In this mode the process variables appear based on the time range
selected there by history can be read.
Tuning trend:
This is specifically meant only for controllers. It displays the process
variable setpoint and output of a controller in the same screen along with
the facility for adjust of proportional gain reset gain a differential gain.
This is an on line tool for tuning a controller.

There is no limitation what so ever on the numbers of screens that can be

configured.

Communication sub system:

This is like the nerve system of our body connecting all the subsystems
and facilitate data transfer by standard protocols
A communicaiion processor is used for the transfer of data between the
nodes. The communication task is split into two parts.
Sub system cpu to communication processor internal)
Communication processor of one node to another node
The communication processor is under the control of sub system Cpu and
performs the actual communication on the data high way. Based on the
communication request received from various nodes the sub system Cpu
gives the following command to communication processor.
Starting address of the data to be sent
Amount of data to be sent
Destination address
The Cpu and communication processor share a common data base and
upon receipt of the command the communication processor acts.
Proprietary protocols and internal software routines are written for Cpu
to communication processor.
Communication processor perform node to node communication based on
any one of the following protocol.
Point to point protocol using Rs 232/RS 422
Ethernet ptotocol on industrial ehernet
Tcp/ Ip protocol on Ethernet
Modbus protocol on profinet

Engineering Sub station: This contains the complete system software

required to run the system. Further System development software is
stored in this node only. All back ups and archived data are available with
this node only.

Gateway:

Dedicated Driver software and utility software for the third party devices
need to be installed for establishing communication with other nodes.