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HOLLIAS DCS

key word:Heat exchange element

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Product description

1. The development of process control system

The early control system is often a secondary instrument control a loop, there is no correlation between the instruments in each loop, the normal operation of the instruments in other loops will not be affected after the instrument in a single loop is damaged.

The first generation process control system (PCS) is a pneumatic instrument control system based on gas signal;

The second generation of process control system (ACS) is a combined instrument control system of electric analog unit based on analog current signal;

In the 1980s, with the appearance and application of microprocessors, distributed control system (DCS) came into being;

In the 1990s, the emergence of fieldbus technology produced a new generation of process control system, namely fieldbus control system (FCS).

DCS is also called distributed control system. It means that all the secondary display instruments are centralized on the computer by using computer technology, and all the primary meters and control valves are still installed in the production site. The core of DCS system is the field control station arranged in the cabinet room. Once the control station fails, it will lead to disastrous consequences, All DCS manufacturers adopt on-line redundancy (just like the standby pump of the pump, one is broken, the other is running automatically, and it is undisturbed switching. In this way, we can't feel any change at all.

The main foundation of DCS system is 4C technology, namely computer, control, communication and CRT display technology.

DCS connects the field control station distributed in the industrial field with the operator station and engineer station in the operation room (control center) through some kind of communication network (such as Ethernet, bus, etc.), so as to complete the decentralized control and centralized operation and management of the field production equipment (engineer station and operation station are common computers, It is only because of its internal configuration software, in most cases, the engineer station can also be used as the operation station).

The following figure shows the application process of DCS system in actual production with an example of water level signal regulation.

Controlled object (process): process production equipment (such as reactor, heat exchanger, drum, water tank, etc.), from sensor (measurement and transmission unit) to actuator.

Controlled parameters: various process parameters, such as liquid level, temperature, pressure, etc.

Measurement and transmission: a device for measurement and conversion of controlled parameters (converted into standard signal).

Regulator: a device that compares and calculates the measured value with the set value and outputs the control signal.

Actuator (control valve): the device that receives the signal from the regulator and executes it.

We can extend the above process as follows:

 

2. Present situation and development trend of DCS system

After more than 20 years of development, DCS has changed a lot. This change comes from two aspects: the continuous improvement of user demand and the rapid development of electronic and information technology. At the same time, with the progress of electronic and information technology, the performance of components (electronic components, processor, software, network, etc.) of DCS application is greatly improved and the price is greatly reduced, In particular, the development of various board level OEM components and HMI Software further simplifies the development difficulty of DCS and reduces the development cost.

At present, a satisfactory DCS system should have the following characteristics:

2.1. The system has an open architecture and can provide multi-layer open data interface;

2.2. The system should have powerful processing function, and provide the ability to easily configure complex control system and the support ability of users to independently develop special advanced control algorithm;

2.3. The system should support a variety of fieldbus standards to meet the needs of future expansion;

2.4. The system should be highly reliable, easy to maintain, advanced technology and reasonable price.

 

 

3. Hollias DCS system

Hollias DCS system has undergone a huge transformation from HS-DCS-1000 and HS2000 to MACS. Now the commonly used systems are SmartPro system and MACSV system, and HS-DCS-1000 and HS2000 have been withdrawn from the historical stage. Next, SmartPro system and MACSV system are introduced respectively.

3.1. Smartpro system

3.1.1. System architecture

The system is an integrated automation system composed of engineer station, operator station, field control station, communication control station, printing service station and data server connected by Ethernet and control network using fieldbus technology. The above-mentioned middle stations are named according to their different tasks in the control system, but they are all ordinary computers Medium sized distributed control system (DCS), large data acquisition and monitoring system (SCADA) function.

The system software includes: ConMaker controller software, ConRTS field controller running software, FacView human-machine interface software, Internet browsing software, OPC toolkit, etc.

3.1.1.1. Engineer station

The engineer station generally adopts the windows operating system and runs the corresponding configuration management program to control and manage the whole system. The engineer station mainly has the following functions:

3.1.1.1.1. Control strategy configuration (including system hardware, database, control algorithm), human-machine interface configuration (including graphics, reports) and related system parameters setting.

3.1.1.1.2. On line modification of man-machine interface of operator station.

3.1.1.1.3. After running the real-time monitoring program of the operator station on the engineer station, the engineer station can be used as the operator station.

3.1.1.2. Operator station

The operator station adopts windows operating system and runs corresponding real-time monitoring program to monitor and control the whole system. The main functions of the operator station are as follows:

3.1.1.2.1. Display, query and print of various monitoring information, mainly including process flow chart display, trend display, parameter list display, alarm monitoring, log query, system equipment monitoring, etc.

3.1.1.2.2. Through the keyboard, mouse or touch screen and other human-machine equipment, through the modification of commands and parameters, the system can be manually intervened, such as online parameter modification, control adjustment, etc.

3.1.1.3. Communication station

As the communication interface between SmartPro system and other systems, communication station can connect enterprise's ERP system (such as HS2000ERP of Hollysys) and Real MSI, or access Internet / Intranet / Extranet. Each department of the factory can grasp more production information, so as to provide more products and better services for the end users. It not only provides the management of production process, personnel, equipment and resources, but also helps users to find the causes of problems and bottlenecks in the production process.

3.1.1.4. Site control station

The field control station is composed of intelligent IO unit, power supply unit, fieldbus and special cabinet of the main control unit. It adopts distributed structure design and has strong expansibility. The main control unit is a special designed controller, which runs the control program installed under the engineer station, carries out the transformation and control operation of the engineering unit, and communicates with the engineer station and the operator station through the monitoring network to complete the data exchange; Intelligent IO unit completes data acquisition and control output in the field; Power supply unit provides stable power supply for main control unit and intelligent IO unit; The communication link is provided by data exchange between the main control unit and intelligent IO unit of fieldbus.

3.1.1.4.1. The master control unit adopts redundant configuration, and connects with each intelligent I/O unit through Profibus DP. The corresponding board level program is solidified on the main control unit and intelligent IO unit. The board level program of the main control unit is solidified in semiconductor memory, and the real-time data is stored in SRAM with power loss protection, which can meet the requirements of reliability, security and real-time of control system. The board level program of intelligent IO unit is also solidified in semiconductor memory.

3.1.1.4.2. The field control station is the front end of MACS system to realize data acquisition and process control, which mainly completes data acquisition, engineering unit transformation, open-loop strategy control algorithm, process quantity acquisition and control output, system network transmits data and diagnosis results to system monitoring network, and has complete indicator lights for I/O module and MCU operation status.

3.1.1.4.3. The field control station is composed of the main control unit, intelligent IO unit, power supply unit, fieldbus and special cabinet. On the main control unit and intelligent IO unit, the MCU software and I/O unit operation software are solidified respectively.

3.1.1.4.4. The distributed structure is adopted in the field control station. The main control unit of the field control station is connected with the control network, which can be configured in redundancy. The main control unit is connected with each intelligent IO unit through Profibus-DP.

3.1.2. System network

HOLLIAS-MACS system consists of two network layers: SNET and CNET. The upper monitoring network is mainly used for communication connection among engineer station, operator station and field control station; The lower control network exists in each field control station, which is mainly used for the communication between the main control unit and the intelligent I/O unit.

3.1.2.1. Monitoring network

The upper monitoring network is a redundant high-speed Ethernet link, and each communication node is connected to the central switch by using five kinds of shielded twisted pair and optical fiber. The main communication nodes in the network include engineer station, operator station and field control station. TCP / IP communication protocol is adopted, which can not only provide 100Mbps data connection, but also connect to intranet and Internet for data sharing.

The monitoring network realizes the data communication among engineer station, operator station and field control station. Through the monitoring network, the engineer station can download the control algorithm program to the main control unit of the field control station. At the same time, the engineer station and the operator station can also collect real-time data from the main control unit for data display on the human-computer interface.

3.1.2.2. Control network

The control network is located in the field control station. The main control unit and intelligent I/O unit are connected to Profibus DP field bus, and connected by shielded twisted pair copper wire (serial bus), which has strong anti-interference ability. The communication nodes in the network mainly include DP master station (FB121 module in the master control unit) and DP slave station (Intelligent I/O unit - input / output module of FM Series). The bus technology is used to realize the communication between the main control unit and the process I/O unit, so as to complete the transmission of real-time input / output data and the diagnosis information of the slave station equipment. By adding the DP repeater module, the long-distance communication can be realized, or more intelligent I/O units can be connected.

Each node is identified by a fixed assigned IP address. In order to realize the redundancy of the monitoring network, the host of each node in the network is equipped with two Ethernet cards, which are connected to the switches of 128 and 129 network segments respectively. The first two IP addresses of the monitoring network are 128.0 and 129.0 respectively. The last two IP addresses of the main control unit of the field control station have been automatically assigned by the program. The last two IP addresses of the engineer station and the operator station can be defined by themselves.

  Computer 0 Computer 1 Computer 2 Computer n  (0n<88)
128  net segment 128.0.0.50 128.0.0.51 128.0.0.52 128.0.0.(50+n)
129  net segment 129.0.0.50 129.0.0.51 129.0.0.52 129.0.0.(50+n)

 

Generally, the two redundant main control units in a field control station are called machine a and machine B respectively. Their IP address is set through a dial switch, and the specific settings are shown in Table 1.1. For the computer of engineer station and operator station, we regard it as the same kind of computer and number it uniformly.

Table 1.1

  #10 station main control unit #11 station main control unit #12 station main control unit #n station main control unit
Computer A 128 net segment 128.0.0.10 128.0.0.11 128.0.0.12 128.0.0.n
129 net segment 129.0.0.10 129.0.0.11 129.0.0.12 129.0.0.n
Computer B 128 net segment 128.0.0.138 128.0.0.139 128.0.0.140 128.0.0.(128+n)
129 net segment 129.0.0.138 129.0.0.139 129.0.0.140 129.0.0.(128+n)

Fieldbus is a digital, two-way transmission, multi branch communication network connecting intelligent field equipment and automation system. Its key sign is that it can support two-way, multi node, bus type all digital communication. With the development of computer technology, communication technology, integrated circuit technology and intelligent sensor technology, fieldbus technology is a revolution in the field of industrial control, which represents a breakthrough control idea. It changes the traditional DCS structure - → FCS structure, and truly achieves "risk dispersion, control dispersion and centralized monitoring". The Profibus-DP technology of holly company is the first one in China, which has independent intellectual property rights. The physical layer and link layer of master station and slave station are developed independently. Its advantages are: it can directly connect PLC of other major manufacturers, such as Siemens, VIPA, GE, etc. at present, dozens of projects have benefited directly; It can be easily connected to PROFIBUS PA intelligent transmitter or actuator through coupler or connector; Centralized installation or distributed installation is still selected by users to save cables; Macs software is successfully independent of I/O devices, and it is very convenient to add hardware devices; I/O devices become standard DCS components that can be integrated. In the application and development of Profibus-DP fieldbus, Hollysys was appointed as the unit of the Standing Committee of the international Fieldbus Foundation in 2001. It independently developed the main controller and various types of I/O cards for Profibus-DP technology. It is the first system supplier in China to independently develop the physical layer and link layer products of master station and slave station. After using Profibus DP fieldbus technology, HOLLIAS-MACS system can easily communicate with intelligent instruments of other manufacturers and exchange data; I/O modules can be installed in a centralized or decentralized way to save a lot of cable costs; It can be easily connected to Profibus PA intelligent transmitter or actuator through coupler or connector; MACS software is successfully independent of I/O devices, and it is very convenient to add hardware devices; I/O devices become standard DCS components that can be integrated.

3.1.3. Hardware Introduction (take FM series as an example)

The cage unit is the installation cage of the main control unit FM801 and the power modules FM910 and fm920, which realizes the redundancy configuration of the main control unit and the power module and the current sharing between the power modules. The master-slave redundant FM801 and the redundant power modules FM910 and fm920 are inserted into the corresponding slots of the cage unit to form a complete redundant control structure.

There are 8 slots in one FM301 cage, and each slot has a 64 pin socket, which is connected to the corresponding module. Two master-slave redundant master control unit modules FM801 are inserted into the two leftmost slots. The remaining slots are inserted into the power module, which are defined as 1#  power supply, 2# power supply, 3# power supply, 4# power supply, 5# power supply and 6# power supply in turn. 1#  and 2# power supply is the system power supply, which provides 24 VDC and FM910 is selected; The back power supply is the field power supply, which provides 48VDC / 24VDC. According to different voltage requirements, FM920 or FM910 is selected.

Common IO modules:

FM801: main control unit (system core equipment)

FM910, 920: system power supply (24 V, 48 V)

FM301: 8-slot main control cage

FM131A: universal terminal module (base)

FM143: 8-channel thermistor input module

FM147A: 8-channel Thermocouple Input Module

FM148A: 8-channel large signal input module

FM151A: 8-channel analog output module

FM161D: 16 channel input module

FM171: 16 channel output module

 

3.2. MACSV system

After the successful development and application of HS-DCS-1000 system, HS2000 and SmartPro system, Hollysys systematically summarized the opinions and suggestions of users in various industries, fully investigated the latest developments of computer technology, network technology, application software technology, signal processing technology, etc., and also drew on the advantages of DCS system of other companies, Based on the most advanced technology and mature advanced control algorithm, the fourth generation DCS system HOLLIAS-MACS is introduced.

3.2.1 hardware architecture of HOLLIAS-MACS system

3.2.2. Concept of "station" in HOLLIAS-MACS system

           Is a component of the system structure

           It's a physically independent set of devices

           Is a communication node in the network

           In the system function to complete a specific type of processing tasks

3.2.3.  "Stations" in HOLLIAS-MACS system include

3.2.3.1. Engineer station

3.2.3.2. Operator station (station number 50-79)

3.2.3.3. Communication station

3.2.3.4. Server (station number is 0)

3.2.3.5. Field control station (Station No. 10-49)

3.2.4. Function of each "station" in HOLLIAS-MACS system

3.2.4.1. Engineer station

The engineer station runs the corresponding configuration management program to centrally control and manage the whole system. The engineer station mainly has the following functions:

① Configuration (including system hardware, database, control algorithm, graphics, reports) and related system parameter settings.

② Installation and online debugging of field control station, installation of server and operator station.

③ After running the real-time monitoring program of the operator station on the engineer station, the engineer station can be used as the operator station.

3.2.4.2. Operator station

The operator station runs the corresponding real-time monitoring program to monitor and control the whole system. The main functions of the operator station are as follows:

① Display, query and print of various monitoring information, mainly including process flow chart display, trend display, parameter list display, alarm monitoring, log query, system equipment monitoring, etc.

② Through the keyboard, mouse or touch screen and other human-machine equipment, through the modification of commands and parameters, the system can be manually intervened, such as online parameter modification, control adjustment, etc.

3.2.4.3. Server

The server runs the corresponding management program to manage the real-time data and historical data of the whole system.

3.2.4.4. Field control station

The site control station runs the corresponding real-time control program to control and manage the site. The field control station mainly operates the control program installed in the engineer station to carry out engineering unit transformation, data acquisition and control output, control operation, etc.

3.2.5. The "network" in HOLLIAS MACS system includes:

Monitoring network MNET

System network SNET

Control network CNET

3.2.5.1. Monitoring network MNET

① Redundant high speed Ethernet link

② Connect each communication node to a central switch using a five class shielded twisted pair or fiber

③ The nodes include engineer station, operator station and service station

④ TCP/IP communication protocol

⑤ Each node on the monitoring network is identified with a fixed assigned IP address. In order to realize the redundancy of monitoring network, each node host in the network is equipped with two Ethernet cards. Generally, two Ethernet cards are connected to switches of 130 and 131 network segments respectively in the project. The first two IP addresses of the monitoring network are 130.0 and 131.0 respectively, and the latter two bits can be defined by themselves. For the computer of engineer station and operator station, we regard it as the same kind of computer and carry out unified numbering.

3.2.5.2. SNET of system network

① Redundant high speed industrial Ethernet

② Adopt HSIE communication protocol

③ Connect each communication node to a central switch using a five class shielded twisted pair or fiber

④ The nodes have service station and site control station

3.2.5.3. Control network CNET

① Located inside the site control station

② Profibus-DP Fieldbus

③ Use shielded twisted copper wire connection

④ The nodes are mainly DP master station (main control unit) and DP slave station (intelligent I/O unit)

⑤ Complete the transmission of real-time input / output data and diagnosis information of slave equipment

⑥ Station address is 0-125

The system I/O station bus adopts the advanced Profibus-DP bus, the main control unit of I/O station, such as fm801 as Profibus-DP master station, I/O input / output module such as FM series module as Profibus-DP slave station. The master / slave station and their connections form a complete Profibus-DP bus network. The optimization of network configuration (including the transmission distance of the number of primary / secondary stations) can greatly improve the stability of the system under the premise of ensuring the correct and fast operation of the system.

Because the engineer station is installed under the site control station through TCP/IP protocol, the site control station needs to set IP address. Generally, we call two redundant main control units in a field control station as a unit and B unit respectively. Their IP address setting is realized by a pair of dial switches. For details, please refer to the setting section of the code dial switch on the back of FM301 in hardware product introduction. When the engineer station is installed at the site control station, this address should be set in the configuration software. For the specific setting method, please refer to the controller algorithm configuration in the software introduction.

3.2.6. HOLLIAS - Macs system software composition

3.2.6.1. Offline configuration software of engineer station

3.2.6.2. Operation software of the industrial operator station

3.2.6.3. Operation software of industrial server

3.2.6.4. Operation software of control station on site

3.2.7. Hardware composition of HOLLIAS Macs system (taking SM series as an example)

SM series hardware mainly includes the following parts:

3.2.7.1. Macs system cabinet

3.2.7.2. Main control unit

3.2.7.3. Power module

3.2.7.4. Cage unit

SM cage is divided into main control cage and I/O cage according to function. Two power modules + 2 main control modules + 6 I/O modules are installed in the main control cage, and 2 power modules + 8 I/O modules are installed in the expansion cage.

3.2.7.5. Common I/O module

3.2.7.6. Terminal module

3.2.8. Characteristics of HOLLIAS Macs V system

3.2.8.1. Provide integrated management and control solution on a unified system platform

3.2.8.2. Standard client/server structure

3.2.8.3. Apply advanced Fieldbus Technology

3.2.8.4. Support OPC data processing

3.2.8.5. Open network system

3.2.8.6. Open operating system

3.2.8.7. Open hardware architecture

3.2.8.8. Standard configuration software function

3.2.8.9. Control software provides convenient system simulation, no disturbance down installation and data read back function

3.2.8.10. Convenience of system installation

3.2.8.11. Redundancy design of the system ensures the high reliability of the system

3.2.8.12. Fault monitoring and transfer capability of the system

3.2.8.13. Strong processing capacity of the system

3.2.9. Comparison of MACS V system and SmartPro system:

3.2.9.1. The control function of the maxv system is more powerful and the configuration is simple

3.2.9.2. The failure rate of mascvs is low and maintenance is simple

3.2.9.3. The control accuracy of MACSV is not as high as SmartPro

3.2.9.4. The configuration of MACSV is not as flexible as SmartPro, and relatively rigid

3.2.9.5. Because of its independent database support, maxvs have strong data processing ability, and online and offline installation is much safer than SmartPro.

3.3. HOLLIAS-MACS configuration

3.3.1. Definition of configuration

The process of defining the system through special software is configuration. The process of defining the arrangement position and type of each module in process station is called process station hardware configuration; The process of defining process station control strategy and control program is called control strategy configuration; The process of defining operator station monitoring program is called operator station configuration; The process of defining the system network connection mode and the address of each station is called network configuration.

3.3.2. Preparation before configuration

The preparatory work refers to that before entering the system configuration, we should first determine the measurement point list, control calculation scheme, system hardware configuration, including the system scale, IO unit configuration of each station and the distribution of measurement points, and also put forward the design requirements for flow chart, report, history library, memory library, etc. For example: measuring point list (including roll name, Chinese character description, upper and lower limits of measuring range, data unit, signal type, square root, redundancy, alarm, historical database point, module model, station number, equipment number, channel number, etc.).

3.3.3. Configuration process

3.3.3.1. SmartPro system

3.3.3.1.1. Control algorithm configuration

① New projects and related settings

② Hardware configuration and property setting

③ Add database

④ Programming for control algorithm configuration

⑤ Communication settings

⑥ Compile and debug

⑦ Downloading operation

3.3.3.1.2. Human machine interface configuration

① New projects and related settings

② Add database

③ Add alarm variable

④ Add a chemotactic variable

⑤ Report making trend

⑥ Drawing graphic pages

⑦ Compile run

3.3.3.2. Macs V system

3.3.3.2.1. New project (database control): before the formal configuration of the application project, a project name must be established for the application project. After the new project, the data directory of the project will be established

3.3.3.2.2. Hardware configuration (device configuration): define the hardware configuration of the application project in the new project

3.3.3.2.3. Database definition (database master): define and edit the point information of each station applied in the project, which is the basis of forming the whole application system

Basic compilation of database (database master control): on the basis of successful compilation of equipment configuration, the basic compilation of database can be carried out after the completion of database editing

3.3.3.2.4. Server control algorithm configuration (server algorithm configuration): it is used to program server algorithm

3.3.3.2.5. Controller algorithm engineering generation (database master control): after the server control algorithm engineering compilation and database basic compilation are successful, the database can be combined to generate controller algorithm engineering

3.3.3.2.6. Controller control algorithm configuration (controller algorithm configuration): it is used to compile controller algorithm program and download controller

3.3.3.2.7. Report making (report configuration): it is used to make the report reflecting the field process data

3.3.3.2.8. Drawing graph (graph configuration): used to draw process flow chart

3.3.3.2.9. Generate download project file (database control): generate download file

3.3.3.2.10. Log in the controller and install the project into the main control unit (controller algorithm configuration)

3.3.3.2.11. Download server and operator station (Engineer download online)

3.3.3.2.12. Run the program and debug online