EPKS Overview Evolution Training

ExperionPKS Training Module - Overview

Prepared By: Viswanathan Raju

Product & Process Excellence, HTSL-Bangalore

Version: Initial Draft

Date: 25Jan06

(For Internal use within HTSL)

2 Honeywell Confidential File Number- 2

ExperionPKS Overview

Training Agenda:

-Evolution (TDC2000 / TDC3000 / TPS / PlantScape / ExperionPKS)


Evolution – TDC2000

CB

AMC

LEPIU

DHP

RCD

Data Hiway

LLPIU

HLPIU

EC

BOS

EOS

• Honeywell introduced the world’s first DCS system in 1970s called TDC2000 system

• TDC2000 comprised of a variety of Process Controllers/Devices called as below:•CB – Basic Controller•EC – Extended Controller•AMC – Advanced Multifunction Controller•DHP – Data Hiway Port (to connect 3rd Party PLCs)•RCD – Reserve Controller Director (for CB and AMC)•HLPIU – High Level Process Interface Unit•LLPIU – Low Level Process Interface Unit•LEPIU – Low Energy Process Interface Unit•EOS – Enhanced Operator Station•BOS – Basic Operator Station

• All these Controllers (also called as Boxes) / Devices were connected to a common Process control Network called as “Data Hiway” on the one side and the Field Terminations on the other side (Analog Inputs / Outputs and Digital Inputs / Outputs).

• “Data Hiway” is a proprietary Process Control Network of Honeywell

• Each of the Controller / Device has its own Configuration specification that allows theuser to Configure / Download / Monitor the Control Strategies.

• For e.g., a CB would allow to configure a maximum of 8 Analog Inputs (Open Loops) and 8 Regulatory Loops (Closed loops)• There exist a variety of Control Algorithms and specific features that meets theProcess Automation needs and demands.


Evolution – TDC3000

Hiway Gateway (HG)

CB

AMC

PIU

DHP

RCD

Universal Station

(US)

Network Interface Module (NIM)

Data Hiway Universal Control Network (UCN)

Local Control Network (LCN)

History Module

(HM)

ApplicationModule

(AM)

PM

APM

HPM

• In 1980s, TDC3000 system was introduced as shown in the figure.• EOS and BOS capabilities were carried out by US with ENGR / SUP / OPER Access level personalities.• HM was introduced to function as the Memory module both for System and User data.• AM was introduced to carry out Supervisory functions / Complex algorithms and Peer to Peer connections between multiple Process Control Networks (Data Hiways / UCNs)• A proprietary Supervisory Network was introduced as LCN.• HG and NIM served as the Gateways for Data Hiway and UCN connectivity to LCN.• In UCN, three Controllers were introduced as follows with specific improvements to their processing capabilities:

• PM – Process Manager• APM – Advanced Process Manager• HPM – High Performance Process Manager

• PM Family has its own Control Processor and IOs.• PM Control Processing capability was defined by PU s called Processing Units. For. e.g., 1 Regulatory loop running at 1 sec would consume 1 PU.• PM – 80 PU s; APM – 160 PU s; HPM – 800 PU s.• PM Control Processor gets connected to its IOs (PM IOPs) through IOLINK communication.

•Difference between Data Hiway and UCN control networksis that DH allowed Fixed configuration and UCN allowed Variable Configuration limited by PU s.The end users / Project engineers could customize the Control Data per their needs in PM family limited by PU s.


Evolution - TPS

Hiway Gateway (HG)

CB

AMC

PIU

DHP

RCD

Universal Station

(US)

Network Interface Module (NIM)

Data Hiway Universal Control Network (UCN)

Local Control Network (LCN)

History Module

(HM)

ApplicationModule

(AM)

PM

APM

HPM

Global User Station (GUS)

Plant History Database (PHD)

Application Platform Processor (APP

Ethernet

•In 1990s, Honeywell introduced TPS (Total Plant Solution) System that made them enter into the Open Systems environment.• GUS node provided the US features with Ethernet connectivityand in turn operated on Windows OS.• PHD with HM capability and APP with AM capability resulted in a Windows environment provided the other Applications thatsit on Ethernet to access the Process Control Network System’sdata seamlessly.• With TDC2000 / TDC3000 / TPS Systems, Honeywell had anenormous number of Customer bases particularly in the Oil & Gas / Petrochemicals / Refining / Chemicals sector.


Evolution - PlantScape

SCAN3000

Honeywell UDC5000

SPP Controller

SCAN3000 AB SLC500 PLC

SCAN3000

Hybrid Controller

(Regulatory / Logic

/ Sequential Control)

In 1990s, Honeywell acquired a company called SCAN3000, who were specialists in MMI (Man Machine Interface) or HMI (Human Machine Interface).PlantScape Vista was introduced with SCAN3000 as MMI that connected Honeywell’s UDC5000 Set Point Programming (SPP) Controller.This product was targeted for Batch Industries.

PlantScape Vista

PlantScape SCADA

PlantScape Process

PlantScape SCADA was introduced with SCAN3000 as MMI that connected Allen Bradley’s SLC500 PLC.This product was targeted for Batch Industries and other medium scaleIndustries who wanted a capable SCADA system for their Automation needs.

PlantScape Process was introduced with SCAN3000 as MMI that connected to a Hybrid Controller (CPM or C200). This product wasintroduced with Honeywell and Allen Bradley entering into an agreementthat Controller would be from Honeywell and IOs would be from AB.

C200 controller could do Regulatory / Logic and Sequential control and it was named as “Hybrid” Controller. Controller Redundancy was provided but, IOs were Non Redundant.

This product was targeted for medium scale industries who wanted to gofor an intermediate version between DCS and PLC capabilities.


Architecture Overview – Experion R300

TPS, TDC2000, TDC3000

WirelessDevices

(Operations and Maintenance)

Safety Manager

SCADA Devices (OPC, Modbus

,

DH+, and many more!)

PM I/O

Remote Engineering

Tools

Investment Protection –Complete Integration

Comprehensive Support for Smart Field Devices

GE FanucVersamax

MTL 8000

FrequencyConverter

FTE Network

WirelessDevices

(Operations and Maintenance)

,

–

State-of –the Art Operation and Engineering ToolsAdvanced Applications and Integration

www

eServer

Casual Users

Allen-BradleyControlLogixPLC

C200

Digital Video Manager

RedundantServers

Ethernet

ExperionStationsApplication

ControlEnvironment

Video as a Process Input!

www

Allen-BradleyControlLogixPLC

Digital Video Manager

Ethernet

Unlimited Secure Access

ESVT

PHDHistorian

C300

NIM

PMD

IO Link


Evolution - ExperionPKS

•As there was a need to provide “Open” System (since all DCS competitors were venturing), Honeywell came out with an Open system called ExperionPKS DCS.This system aimed at providing a Common Platform for all the Legacy Systems introduced by Honeywell earlier and also with some key features like Fault Tolerant Ethernet (FTE) / HMI Web Displays / New Controllers / IOs etc.,

•Experion PKS unified architecture combines DCS functionality and a plant-wide infrastructure that unifies business, process, and asset management to:

• Facilitate knowledge capture• Promote knowledge sharing• Optimize work processes• Accelerate improvement and innovation.

•Refer the ExperionPKS Architecture for R300 in the previous slide further.•Various Levels of Experion PKS system:L1 – Embedded Nodes like Controllers / Interface Modules (C200 / C300 / FIM4 / FTEBs etc.,)L2 – Non Embedded Nodes like Servers / Stations / Supervisory Control nodes (EPKS Server / Console Station / ACE / SCE / Flex Stations / EST / ESVT etc.,)L3 – Application Nodes like Uniformance / PHD / DSA ServersL4 – Management Information Systems / Remote Servers access through Firewall


Evolution - ExperionPKS

While approaching the ExperionPKS design, the following approaches were taken:

EHG Integration – A node called EHG (EHG Node plus Data Hiway Ethernet Bridge) was introduced. DHEB interfaced Data Hiway and FTE. This Integration targeted all the Data Hiway Boxes to be configured from ExperionPKS Server. This approach eliminated the configuration through legacy Hiway Gateway.

PMIO Integration – In the Hybrid Controller (C200) configuration, a new Interface Module was introduced as IOLIM (I/O Link Interface Module) that allowed integration of PM Family IOPs to C200. The existing role of Controllers like PM/APM/HPM was replaced by C200 by retaining the PM IOPs.


Evolution – ExperionPKS – Level 1

Fieldbus Integration – A new Interface Module called FIM (Fieldbus Interface Modulewas introduced within C200 family that allowed Fieldbus Devices to be integratedinto ExperionPKS family. FIM is a double wide module that occupied 2 slots in the chassis. Each FIM could support 2 FF Links and in turn 16 Devices per Link.

Profibus Integration – Another Interface module called Profibus Interface Module(PBIM) was introduced with a tie up between Honeywell and Woodhead Connectivity(SST). PBIM is a single slot module that could sit along with a C200 configuration.

DeviceNet Integration – An interface module called DeviceNet Interface Module(DNET_IM) was introduced that allowed DeviceNet protocol devices to be integratedwith C200 family.

HART Integration – First attempt was made with 1756 HART modules between Honeywell and Spectrum Controls company in coming out with 1756 wide HARTAnalog Input and Analog Output modules. These modules were Non Redundant and could accommodate 8 Input or Output channels. HART Software Multiplexer wasintroduced and HART digital data was made available.



PMIO HART Integration – PMIO HART was introduced to address RedundantHART IOPs and increased channel capacity of 16 per IOP. These IOPs were addedto PMIO Family within ExperionPKS and support was not provided for TPS PMIO Family.

C300 Controller – A new Embedded Ethernet based controller calledC300 was introduced with increased Form factor and Green Hills Integrity OS. ThisController could accommodate one CEE environment and two IO Links. User couldconfigure PMIO / Series C IOs or both of the same IO family in each of these links.C300 controller offers Module wide Redundancy unlike C200’s concept of Chassiswide Redundancy. C300 controller also falls under Series C HW. Series C HW consists of IOM (IO Module) and IOTA (IO Termination Assembly)

Series C IO - A new range of IO family with an 18 degree slant design enables moreheat dissipation. IO Modules include AI (HART enabled) / AO (HART enabled) / DI /DO / LLMUX during R300 release.

FIM4 Module – Another HW in Series C family is FIM4 module for Fieldbus Integration with 4 FF links. Could accommodate 16 Devices per link and totaling 64 Devices per FIM4.



CF9 Module – Control Firewall switches were introduced exclusively for Series CHW in R300 release to provide more security for the C300 Controllers and IOs.These switches could be compared with a Cisco L1 Switch for FTEB based C200 Controller topology.



ExperionPKS Servers – EPKS Servers could be configured as either Redundantor Non Redundant ones. These nodes act as the centralized data storage andpass the control / monitoring data to and from Operator Stations and ControlNetworks.

Flex Stations – Flex Stations are Operator Interfaces (HMI / MMI) for operating upon Point Detail / Group Detail displays / Alarms / Trends / History / Events etc., There are two Security levels one Operator based security and another Station basedsecurity. Normally, Flex Stations access data from EPKS Servers and display itfor Operators.

Console Stations – Console Stations are also Operator Interfaces. Differencebetween Flex and Console stations is that in case of failure of both EPKS Servers,Flex stations will have loss of view, but Console stations access data directly fromControl Networks.

ACE – Application Control Environment (ACE) Node will allow users to perform Supervisory Control Functions, Peer to Peer between different Control Networks,host complex Custom Control Algorithms etc., It could be considered as a Controllerrunning on Windows OS.



SIM-C200 – Simulation Control Environment (SCE) Node will allow users to perform Simulation of C200 controller.

SIM-IOLIM – Simulation of IOLIM environment is achieved using this. It simulatesPM IOPs and hosts IOLINKs in IOLIM.

SIM-C300 / SIM-FIM development is in progress.

eServer – A node that allows Plant data to be sent to the Internet as a Read only data.There are two licenses available called Regular – Snapshot data is provided andPremium – Real Time data is provided.

EST – ExperionPKS Station TPS Node acts as an Operator interface for TPS networkin EPKS HMI environment.

ESVT – ExperionPKS Server TPS Node acts as a Server interface for TPS networksin EPKS environment.

EPKS Overview Evolution Training

Documents

medium scale industries

honeywell confidentialfile number

application module

history module

pm iops

fieldbus integration

batch industries

data hiway