INDUSTRIAL INSTRUMENTATION AND

CONTROL SYSTEMS

Assoc. Prof. Dr. BUI Dang Thanh

School of Electrical Engineering, Hanoi University of Science and Technology
1 Dai Co Viet road, Hà Nôi, Viêt Nam

9/28/2021 Buidangthanh.3i@gmail.com 1
 Chapter 1: Introduction

9/28/2021 Buidangthanh.3i@gmail.com 2
 Presentation Outline

❖ Historical Overview of II&CS

❖ Plant Bus Hierarchy of II&CS

❖ OSI Model

❖ System classification

❖ P&ID

9/28/2021 Buidangthanh.3i@gmail.com 3
 Historical Overview of II&CS

9/28/2021 Buidangthanh.3i@gmail.com 4
 Historical Overview of II&CS

• At the beginning of 1960, a digital computer was for the first time
applied as a digital computer

• 1960s, digital communication network for automation system

• 1970s SCADA

• 1980s DCS

• 2000s IIT, IoT

9/28/2021 Buidangthanh.3i@gmail.com 5
 Plant Bus Hierarchy of II&CS (Fieldbus)

9/28/2021 Buidangthanh.3i@gmail.com 6
 Plant Bus Hierarchy of II&CS

Office
network

TCP - IP
Ethernet

Plant Network
Ethernet, ControlNet

Fieldbus
intelligent field devices
FF, PROFIBUS, MVB, LON

Sensor Busses
simple switches etc.

CAN, DeviceNet, SDS, ASI-bus, Interbus-S

9/28/2021 Buidangthanh.3i@gmail.com 7
 What is a Fieldbus?

❑ A Fieldbus is an industrial computer network for real-

time distributed control.
❑ A complex automated industrial system usually
needs an organized hierarchy of controller systems
to function.
❑ Human Machine Interface (HMI) at the top,
Programmable Logic Controllers (PLCs) in the
middle, and the Fieldbus at the bottom.
❑ The Fieldbus links the PLCs to the components
which actually do the work such as sensors,
actuators, electric motors, console lights, switches,
valves, and contactors.

9/28/2021 Buidangthanh.3i@gmail.com 8
 What is a Fieldbus?

❑ Fieldbus is a generic term that describes a new digital

communications network that is being used in industry to
replace the existing 4-20 mA analog signal standard.
❑ The network is a digital, bi-directional, multi-drop, serial-bus
communication network used to link isolated field devices,
such as controllers, transducers, actuators and sensors.
❑ Bi-directional means it is a duplex port; the data can be
transmitted in two directions at the same time.
❑ Multi-drop is also referred to as multi-access and it can be
interpreted as a single bus with many nodes connected to
it.
❑ Serial-bus means the data is transmitted serially
according to RS232 or RS485 protocol. Profibus uses
RS485 protocol.
9/28/2021 Buidangthanh.3i@gmail.com 9
 What is a Fieldbus?

❑ Fieldbus works on network structures such as daisy-chain, star,

ring, branch, and tree network topologies.
❑ Previously computers were connected using RS-232 by which
only two devices could communicate.
❑ This is the equivalent of the currently used 4-20 mA
communication scheme which requires that each device has its
own communication point at the controller level
❑ The fieldbus is the equivalent of the current LAN-type
connections, which require only one communication at the
controller level and allow multiple (100's) of analog and digital
points to be connected at the same time.
❑ This reduces both the length of the cable required and the
number of cables required.

9/28/2021 Buidangthanh.3i@gmail.com 10
 History & Current State

❖ In 1999 a committee formed the IEC 61158 standard

with eight different protocol sets:

◼ FOUNDATION Fieldbus ◼ FOUNDATION Fieldbus

H1 HSE
◼ ControlNet ◼ Interbus
◼ PROFIBUS ◼ SwiftNet
◼ P-Net ◼ WorldFIP

9/28/2021 Buidangthanh.3i@gmail.com 11
 History & Current State

❑ Recent additions or planned additions to IEC 61158 include but

are not limited to:

❑ PROFINET IO

❑ EtherCAT

❑ Both FOUNDATION Fieldbus and Profibus technologies are now

commonly implemented within the process control field, both for
new developments and major refits. In 2006, China saw the
largest FF systems installations at NanHai and SECCO, each
with around 15,000 fieldbus devices connected

9/28/2021 Buidangthanh.3i@gmail.com 12
 Who uses Fieldbuses?

• Those who plan complex

automated industrial
systems

9/28/2021 Buidangthanh.3i@gmail.com 13
 Where are Fieldbuses Used?

➢ In complex automated
industrial systems where an
organized hierarchy of
controller systems is needed.

➢ In manufacturing plants
where many instruments
need to be connected.

9/28/2021 Buidangthanh.3i@gmail.com 14
 What are Fieldbuses Used For?

❑ When fieldbuses work in the factory, the purpose has been to

reduce installation cost by moving the I/O interface from the
programmable logic controller (PLC) to a remote I/O unit
mounted close to the machine on the factory floor.

❑ Factory automation fieldbuses are fast and deterministic.

(Deterministic means the maximum worst-case time to obtain
data across the fieldbus is accurately predictable and is not
subject to chance.)

9/28/2021 Buidangthanh.3i@gmail.com 15
 Advantages of Fieldbus

❑ A major advantage of fieldbus is the CAPital EXpenditure

(CAPEX) savings associated with cable elimination; multiple
devices share wire-pairs in order to communicate over the bus
network and savings are also available through speedier
commissioning.

❑ On going maintenance and process control system performance

are significantly enhanced through fieldbus systems, which
results in OPerations EXpense savings (OPEX).

9/28/2021 Buidangthanh.3i@gmail.com 16
 Disadvantages of Fieldbus

❖ Disadvantages of fieldbus compared to the 4-20 mA analog

signal standard:
➢ Fieldbus systems are complex, so more training needed
➢ The price of fieldbus components is higher
➢ Fieldbus test devices are more complex
➢ Device manufacturers have to offer different versions of
devices due to different fieldbus standards. This can add to
the cost of the devices and increases the difficultly of device
selection.
➢ Standards may predominate or become obsolete, increasing
the investment risk.

9/28/2021 Buidangthanh.3i@gmail.com 17
 Location of the field bus in the plant hierarchy

File
Edit
SCADA level Operator 23 12 Engineering
4 2 2
33

Plant bus

Programmable
Plant Level Logic Controller

Field bus

Field level

Sensor/
Actor
Bus
Sensor / direct I/O

9/28/2021 Buidangthanh.3i@gmail.com 18
 Expectations
✓ Reduce cabling
✓ Increased modularity of plant (each object comes with its
computer)
✓ Easy fault location and maintenance
✓ Simplify commissioning (mise en service, IBS =
Inbetriebssetzung)*
✓ Simplify extension and retrofit
✓ Large number of off-the-shelf standard products to build “Lego”-
control systems
✓ Possibility to sell one’s own developments (if based on a
standard)

9/28/2021 Buidangthanh.3i@gmail.com 19
 The original idea: save wiring
marshalling tray
I/O bar capacity dumb devices

PLC

(Rangierung,
tableau de brassage (armoire de triage)
COM

PLC
field bus

but: the number of end-points remains the same !

energy must be supplied to smart devices

9/28/2021 Buidangthanh.3i@gmail.com 20
 Marshalling (Rangierschiene, Barre de rangement)

❑ The marshalling is the interface

between the PLC people and the
instrumentation people.

❑ The fieldbus replaces the

marshalling bar or rather moves it
piecewise to the process
(intelligent concentrator / wiring)

9/28/2021 Buidangthanh.3i@gmail.com 21
 Distributed peripherals

✓ Many field busses are just

extensions of the PLC’s Inputs
and Outputs, field devices are
data concentrators.
✓ Devices are only visible to the
PLC that controls them

relays and fuses

9/28/2021 Buidangthanh.3i@gmail.com 22
 Field busses classes

Office
network
TCP IP
Ethernet

Plant Network
Ethernet, ControlNet

Fieldbus
intelligent field devices
FF, PROFIBUS PA, LON

Sensor Busses
simple switches etc.
CAN, DeviceNet, SDS, ASI-bus, Interbus-S

The fieldbus depends on:

its function in the hierarchy
the distance it should cover
the data density it should gather
9/28/2021 Buidangthanh.3i@gmail.com 23
 Geographical extension of industrial plants
1 km .. 1000 km Transmission & Distribution
Control and supervision of large distribution networks:
• water - gas - oil - electricity - ...
1 km .. 5 km Power Generation
Out of primary energy sources:
• waterfalls - coal - gas - oil - nuclear - solar - ...
50 m .. 3 km Industrial Plants
Manufacturing and transformation plants:
• cement works - steel works - food silos - printing - paper
pulp processing - glass plants - harbors - ...
500m .. 2 km Building Automation
• energy - air conditioning - fire - intrusion - repair - ...
1 m .. 1 km Manufacturing
flexible manufacturing cells - robots
1 m .. 800 m Vehicles
• locomotives - trains - streetcars - trolley buses - vans -
buses - cars - airplanes - spacecraft - ...

9/28/2021 Buidangthanh.3i@gmail.com 24
 Fieldbus over a wide area: example wastewater
treatment

✓ Pumps, gates, valves, motors, water level sensors, flow meters,

temperature sensors, gas meters (CH4), generators, … are spread
over an area of several km2
✓ Some parts of the plant have explosive atmosphere.
✓ Wiring is traditionally 4..20 mA, resulting in long threads of cable
(several 100 km).
9/28/2021 Buidangthanh.3i@gmail.com 25
 Fieldbus over a wide area: Water treatment plant
Japan Control Room source: Kaneka, Japan
LAS

Remote
Malaysia SCADA Ethernet
Maintenance
System Bus Monitor

H1 Speed Fieldbus

JB Segment 1 Segment 3 JB
Sub Station

AO
AI
PID
PLC
AO
PID
AI AI AI AI AI AI AI AI PID AO
AO AO
DI M.C.C.
FB Protocol
Converter

JB Segment 2 JB Segment 4 Digital Input/Output

AI AI
S S S S S

AI AI AI PID AI PID AI AI AI AI
AO AO

Numerous analog inputs (AI),

low speed (37 kbit/s) segments merged to 1 Mbit/s links.
9/28/2021 Buidangthanh.3i@gmail.com 26
 Fieldbus application: Building Automation
Source: Echelon

low cost, low data rate (78 kbit/s), may use power lines (10 kbit/s)
9/28/2021 Buidangthanh.3i@gmail.com 27
 Fieldbus Application: locomotives and drives

radio power line

cockpit

diagnosis Train Bus

Vehicle Bus

brakes power electronics motors track signals

data rate 1.5 Mbit/second

delay 1 ms (16 ms for skip/slip control)
medium twisted wire pair, optical fibers (EM disturbances)
number of stations up to 255 programmable stations, 4096 simple I/O
integrity very high (signaling tasks)
cost engineering costs dominate

9/28/2021 Buidangthanh.3i@gmail.com 28
 Fieldbus Application: automobile

- 8 nodes
- 4 electromechanical wheel brakes
- 2 redundant Vehicle Control Unit
- Pedal simulator
- Fault-tolerant 2-voltage on-board power supply
- Diagnostic System

9/28/2021 Buidangthanh.3i@gmail.com 29
 Application: Avionics (Airbus 380)

9/28/2021 Buidangthanh.3i@gmail.com 30
 Networking busses: Electricity Network Control:
myriads of protocols
Inter-Control Center Protocol
SCADA
control IEC 870-6 control ICCP control High
HV Voltage
center center center

Modicom IEC 870-5 DNP 3.0 Conitel RP 570 serial links (telephone)

RTU RTU RTU RTU Remote Terminal Units

COM RTU

substation substation
MV Medium
Voltage

FSK, radio, DLC, cable, fiber,... RTU

RTU

houses RTU RTU

Low
LV Voltage
low speed, long distance communication, may use power lines or telephone modems.
Problem: diversity of protocols, data format, semantics...
9/28/2021 Buidangthanh.3i@gmail.com 31
 OSI Model

9/28/2021 Buidangthanh.3i@gmail.com 32
 The OSI Model
– The OSI model defined a standard, or set of rules, for
manufacturers of networking components that would allow these
networking components to communicate in dissimilar
environments.
– The model made up of seven layers.
– Network communication starts at application layer and works its
way down through the layers to the physical layer to receiver
computer.

9/28/2021 33
 The OSI Model
• Layer 7: The Application Layer
– The application layer is the OSI layer closest to the end user,
which means that both the OSI application layer and the user
interact directly with the software application.
– The application layer services facilitate communication
between software applications and lower-layer network
services so that the network can interpret an application's
request and, in turn, the application can interpret data sent
from the network.

9/28/2021 34
 The OSI Model
• Layer 6: The Presentation Layer
– The presentation layer provides a variety of coding and
conversion functions that are applied to application layer data.
– These functions ensure that information sent from the
application layer of one system would be readable by the
application layer of another system.
– Presentation layer services also manage data encryption (such
as the scrambling of passwords) and decryption

9/28/2021 35
 The OSI Model
• Layer 5: The Session Layer
– The session layer establishes, manages, and terminates
communication sessions.
– Communication sessions consist of service requests and
service responses that occur between applications located in
different network devices.
– Among the session layer's functions are establishing and
keeping alive the communications link for the duration of the
session, keeping the communication secure, synchronizing
the dialog between the two nodes, determining whether
communications have been cut off, and, if so, figuring out
where to restart transmission, and terminating
communications

9/28/2021 36
 The OSI Model
• Layer 4: The Transport Layer
– The transport layer accepts data from the session layer and
manages the end-to-end delivery of data.
– Generally, the transport layer is responsible for making sure that
the data is delivered error-free and in the proper sequence.
– Flow control generally occurs at the transport layer.
– Some Transport layer protocols take steps to ensure that data
arrives exactly as it was sent.
– To ensure data integrity further, connection-oriented protocols
such as TCP use a checksum.
– A checksum is a unique character string that allows the
receiving node to determine if an arriving data unit matches
exactly the data unit sent by the source.
9/28/2021 37
 The OSI Model
• Layer 4: The Transport Layer (Cont.)
– A connectionless protocol does not establish a connection
before transmitting and makes no effort to ensure data is
delivered error-free.
– These protocols are more efficient than a connection-oriented
protocol and are useful in situations in which data must be
transferred quickly, such as live audio or video transmissions
over the Internet.
– Transport layer protocols break large data units received from
the Session layer into multiple smaller units, called segments.
– In some cases, segmentation is necessary for data units to
match a network's MTU (maximum transmission unit), the
largest data unit it will carry.
– Reassembly is the process of reconstructing the segmented
data units.
9/28/2021 38
 The OSI Model

• Layer 3: The Network Layer

– The primary function of protocols at the network layer, is to
translate network addresses into their physical counterparts
and decide how to route data from the sender to the receiver.
– Addressing is a system for assigning unique identification
numbers to devices on a network.
– Each node has two types of addresses:
• Network address
• Physical address

9/28/2021 39
 The OSI Model

• Layer 3: The Network Layer (Cont.)

– Network addresses follow a hierarchical addressing scheme
and can be assigned through operating system software.
– Network address formats differ depending on which Network
layer protocol the network uses.
– Network addresses are also called network layer addresses,
logical addresses, or virtual addresses.

9/28/2021 40
 The OSI Model
• Layer 2: The Data Link Layer
– The primary function of the data link layer, is to divide data
received from the network layer into distinct frames that can
then be transmitted by the physical layer.
– A frame is a structured package for moving data that includes
not only the raw data, or payload, but also the sender's and
receiver's network addresses, and error checking and control
information.

9/28/2021 41
 The OSI Model

• Layer 2: The Data Link Layer (Cont.)

– Error checking is accomplished by a 4-byte Frame Check
Sequence (FCS) field, whose purpose is to ensure that the
data at the destination exactly matches the data issued from
the source.
– When the source node transmits the data, it performs an
algorithm (or mathematical routine) called a Cyclic
Redundancy Check (CRC).
– CRC takes the values of all of the preceding fields in the frame
and generates a unique 4-byte number.

9/28/2021 42
 The OSI Model
• Layer 2: The Data Link Layer (Cont.)
– The data link layer is divided the Data Link layer into two
sublayers.

– The upper sublayer of the Data Link layer, called the Logical Link
Control (LLC) sublayer, provides an interface to the Network layer
protocols, manages flow control, and issues requests for
transmission for data that has suffered errors.
– The Media Access Control (MAC) sublayer, the lower sublayer of
the Data Link layer, manages access to the physical medium.
9/28/2021 43
 The OSI Model

• Layer 1: The Physical Layer

– Protocols at the physical layer accept frames from the data
Link layer and generate voltage to transmit signals.
– When receiving data, physical layer protocols detect voltage
and accept signals, which they pass on to the data Link layer.
– Physical layer protocols also set the data transmission rate and
monitor data error rates.
– Connectivity devices such as hubs and repeaters operate at
the Physical layer.

9/28/2021 44
 The OSI Model

Identifying the function of each layer of the OSI model

9/28/2021 45
 II&CS Classification

9/28/2021 Buidangthanh.3i@gmail.com 52
 II&CS Classification

• Phân loại theo ứng dụng

– Hệ quan trắc môi trường khí thải
– Hệ SCADA trong khí tượng thủy văn
– Hệ SCADA điện lực
– Hệ DCS
• Phân loại theo quy mô
– Hệ thống nhỏ: vài tram I/O
– Hệ thống vừa: Vài ngàn I/O
– Hệ thống lớn: Hàng chục ngàn I/O

9/28/2021 Buidangthanh.3i@gmail.com 53
 P&ID

9/28/2021 Buidangthanh.3i@gmail.com 54
 P&ID Diagram

• Meaning:
– Piping & Instrumentation Diagram
– Process & Instrumentation Diagram
• Use standardized symbols:
– To represent different components of process:
• Specific to the process itself:
• Necessary to control the process:

55
 P&ID Diagram

• Use standardized symbols:

– To represent different components of process:
• Specific to the process itself:
– Static - Transport & Storage Operation
– Dynamic - Processing
• Necessary to control the process:

56
 P&ID Diagram

• Use standardized symbols:

– To represent different components of process:
• Specific to the process itself:
• Necessary to control the process:
– Measurements: mainly pressure, flow, level, temperature
– Measuring Instruments: local indicators, transmitters
– Controller: regulators
– Safety devices: alarms, automatic control systems
– Controlling Actuators: motorized shut-off valves, control valves, pumps,
fans
– Protection devices : valves

57
 P&ID Diagram

• Basic symbols:

28/09/2021 58
 P&ID Diagram

Indication – Control - Differential Pressure), loop

number 103.
Alarm – High - Temperature, loop number 104.

First letter: Variable or Initialization

Second letter: Support for the first letter

From the third letters: Indicating, Passive or Output
Function
T A H-104

28/09/2021 59
 P&ID Diagram
• Meaning of the Letters:
– First letter
– Succedding Letters

28/09/2021 60
P&ID Diagram
• Meaning of the Letters:
– First letter
– Succedding Letters

28/09/2021 61
 P&ID Diagram

• Line Symbols:
• Supply sources:
– AS (Air supply)
– ES (Electric supply)
– GS (Gas supply)

– HS (Hydraulic supply)
– NS (Nitrogen supply)
– SS (Steam supply)
– WS (Water supply)

28/09/2021 62
 P&ID Diagram

• Examples:
– Heat Exchanger

28/09/2021 63
P&ID Diagram

• Examples:
– Water Boiler

28/09/2021 64
 Thank you for your attention!

9/28/2021 Buidangthanh.3i@gmail.com 65
 Assessment

• What is a field bus ?

• Which of these qualities are required:
1 Gbit/s operation
Frequent reconfiguration
Plug and play
Bound transmission delay
Video streaming
• How does a field bus supports modularity ?
• What is the difference between a sensor bus and a process
bus ?
• Which advantages are expected from a field bus ?

9/28/2021 Buidangthanh.3i@gmail.com 66
 References

• http://en.wikipedia.org/wiki/Fieldbus
• http://www.isa.org/InTechTemplate.cfm?Section=Article_I
ndex1&template=/ContentManagement/ContentDisplay.cf
m&ContentID=60680
• http://www.us.profibus.com
• http://www.easydeltav.com/video/product/foundation_field
bus.asp
• http://www.fieldbus.org/images/stories/newsroom/newslett
er/200702/
• http://www.beckhoff.com/english.asp?embedded_pc/cx10
00_2.htm
• http://ethernet.industrial-networking.com/articles/
articledisplay.asp?id=79

9/28/2021 Buidangthanh.3i@gmail.com 67