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SYSTEM OVERVIEW
Distributed Control System (DCS) refers to a control system used in process control or
continuous manufacturing which the controller elements are not centralized in a location but
are distributed throughout the system. Each components subsystems are controlled by one or
more controllers. The entire system of controllers is connected through a network for
communicating, controlling, and supervising.
In the fast changing industry of process automation, it is not just about technology and control,
but more importantly, it is about getting the job done correctly. There is a rising demand for
more critical advanced control system with greater management features to improve the entire
enterprises competitiveness and competence, to reduce energy consumption and pollution,
and to achieve sustainable development.
As a leading supplier in automation control industry in Egypt, PEP ARAB developed new
generation control system platform SMART DCS, based on international advanced
automation control technology. The SMART DCS brings you the next evolutionary step
providing better information visibility, critical control, performance, and operational agility.
It is an open system platform that is extremely reliable, flexible to configure by providing a
complete solutions to your plant automation needs.
SMART DCS is our new generation DCS, a hardware and software platform for the modern
automation industries demonstrating high state of art technology. Delivering the perfect
process control and overall enterprise level management, the SMART DCS platform is
developed to be used in the process industries. Examples of industries application are thermal
power, nuclear power, oil and gas, petrochemical, chemicals, pharmaceuticals, paper and
pulps, metals and minerals, cement, beverage, glass, metallurgical, water treatment, and
environmental protection.
System Philosophy
SMART DCS is a system at which intelligent existing every where, intelligent distributed in all
levels, from field, up to Man Machine Interface at control room.
It means that each part of system can perform its function directly without any need to send
data to masters for processing purpose. Ability to monitor, operate & diagnose from all levels.
Smart DCS philosophy based on important facts:
Fact 1: each end intelligent could work independently.
Fact 2: Possibility to process, monitor & operate from all levels.
industries.
SMART DCS Architecture divided into:
Operator Level
Process Level
Communication Level
These three basic levels support facilities from the tiny to very large and complex with up to
100,000 tags
SYSTEM ARCHITECTURE
SMART DCS has a simple and common architecture covers a variety of plant sizes and
ARCHITECTURE IN DETAIL
ardware
SMART DCS system hardware includes the following:
Engineer Station
Engineer Station consists of a high-performance computer with DCS configuration software.
It is used to perform DCS configuration and upload operational parameters to the field control
station and operator station.
Operator Station
Operator station consists of high-performance computer with optional touch screen HMI
display. It issued to monitor the production process, conduct controls, and check the running
status of the system network, controllers, and I/O modules in field control station.
Field Control Station
Field control station consists of the field controllers, I/O modules, power supply modules,
terminal modules resides in the control cabinets. It does signal collection, conversion, various
controls and interlock algorithm, field signal output, etc. It also performs self-diagnosis of its
operational status. SMART DCS offers SMART I/O series modules for flexible configuration.
System Server (optional)
High-performance server is used to fulfill the management, accessing, data processing, and
communication of real-time database and historical database. System server supports
redundancy and can be configured according to project scale.
ARCHITECTURE IN DETAIL
System Features
Flexible system architecture equips with wide I/O ranges from tens to hundreds of
thousands to adapt to different application.
Open system:
The system supports and provides OPC industrial standard interface based on
COM/DCOM technology to standardize software interfaces between equipment
and application programs from different suppliers.
Profibus-DP
In 1999, PEP ARAB utilized
the profibus-DP core
technology with physical
and link layer of the master
and slave stations
Sequence Control
Advanced Control
On/Off Switching
Graphic Displays
Group Displays
Loop Displays
System Diagnostics
Computational Functions
System Functions
SYSTEM HARDWARE
Lots of memory: all SMART DCS workstation come with sufficient memory to
handle SMART DCS applications.
Sounds alive: to provide the audible alarms for your automation project, 16-bit
sound is included on the motherboard of all workstations.
The Operator Stations are mainly used for operation and monitoring. It displays process
variables, control parameters, and alarms necessary for users to quickly grasp the operating
status of the plant. It also incorporates open interfaces so that the supervisory computers can
access trend data, message, and process data.
Operator Station Dual monitors support:
Operator station supports dual monitor operation, meaning that two monitors can be
used on single PC, operated using one mouse and one keyboard.
Dual Monitor Benefits:
Optimize operator interface for efficient use of the larger screen area.
OPERATOR STATION
Operator Station
Main controller adopts high shock-proof and low power consumption CPU
working without fans for a longer and safer operational period. (CPU fans in
industry field usually last no more than 2 years) The long period power
consumption for the entire controller is less than 10 watts. All CPU and memories
inside the controllers adopt SMT or DIP insertion mode to improve its shockproof performance.
Power modules are small, light, and highly efficient, with powerful antidisturbance, wide input voltage ranges.
Isolation between field and electrical system, partial AIO inter-channel isolation,
DI optical coupling isolation, DO optical-coupling or relay isolation.
Automatic power-on for controllers and I/O modules with normal working
conditions status.
Main Controller and SMART I/O series modules have different features in terms of
structure and installation to meet the requirements of various industrial applications.
ardware Reliability
SMART DCS features the following reliability technologies:
Redundancy
Controller Redundancy
Controller's redundancy is used with one primary and the other standby. It is designed
with hardware redundancy, shift and fault self-detect circuit. Two controllers receive
network data and make calculation at the same time but only one output the calculated
results and updates the real-time data. Once the primary controller fails, the standby
unit will be shifted to work as the primary without any disturbances.
I/O Redundancy
AI/AO equipments are configured in redundancy.
Network Redundancy
Industrial Ethernet interfaces with redundancy are configured for the controller with
embedded Profibus-DP master station interface.
Easy Maintenance
Self-diagnosis
With embedded controller, each module is able to have periodic self-diagnosis,
including the following:
o DO channel: read-back, comparison, and self-diagnosis.
o AI channel: adopts special input channel fault-diagnosis technology, diagnoses
and checks open circuit, short-circuit and jump.
o AO channel: adopts special output channel fault-diagnosis and diagnoses output
channel and executor.
Status Indicators
There are LED indicators in all modules and controllers, including running indicator,
error indication and network communication indicator. The running status of all modules
HARDWARE RELIABILITY
HARDWARE RELIABILITY
is clear. At the operator station, operators can call the system status graphic to monitor
the running status of each station or each module.
pecification
A large-scale SMART DCS can include multiple groups of servers. System can be divided
into multiple domains. Each domain consists of certain number of engineer stations, operator
stations, system servers, and field control stations, to enable relatively independent data
collection and equipment control functions. Engineer station and operator station can operate
on different domains by login.
Maximum Capacity
Engineering domain
Server
Engineer station
Operator station
Controller
I/O Modules
System Margin
Controller CPU peak load rate
< 40%
Memory margin
Around 25%
< 20%
> 40%
Reliability
MTBF
50,000h
System availability
99.9%
Response Time
Minimum real-time data scan cycle
50ms
50ms
50ms
1s
System Network
Communication protocol
Network structure
Communication medium
Baud rate
100/1000Mbps
Control Network
Communication protocol
Profibus-DP
Network structure
Bus
Communication medium
Baud rate
SPECIFICATION
SPECIFICATION
System Precision
AI error
0.2%
AO error
0.2%
1ms
Signal Interface
AI signal type, I/O range
J, K, N, E, S, B, R, T
Pt100
AO signal type
DI signal type
Power Supply
AC input voltage
3000Vrms
EMC
Electrostatic discharge immunity test
0C ~60C
0C ~70C
Storage temperature
Controller
-15C ~ 65C
-40C ~ 85C
Working humidity
Storage humidity
Ingress Protection
Controller
IP40
IP20
Cabinet
Acceleration
Maximum 2.0g
PEP ARAB Control Systems incorporates powerful controllers for secure, mission-critical
operations such as those of power and water plants.
The SMDCS Controllers execute simple or complex modulating and sequential control
strategies, performs data acquisition functions, and interfaces to the Smart DCS Network
and various I/O sub-systems. It has the capability to originate up to 6,000 points.
The open architecture of the SMDCS Controllers uses a powerful real-time operating
system running on PCI bus PC architecture. This design allows rapidly advancing
technology to be easily integrated into the system - protecting your investment in software.
The SMDCS controllers are a family of rail-mounted modules, consisting of CPUs,
communication modules, power supply modules and various accessories. Several CPU
modules are available that vary in terms of processing power, memory size, and
redundancy support.
Each CPU module is equipped with Ethernet ports for communication with other controllers
and for interaction with operators, engineers, managers, and higher level applications.
The connectivity and expansion options make the SMDCS exceptionally open and
scalable, that is, easy to connect to the surrounding world of supervisory systems and
intelligent devices of all kinds - and adaptable to changing requirements as the process it
controls changes or expands.
Small footprint with low power requirements and fan less operation
Overview
Managed by a commercial, real-time operating system which supports multitasking and preemptive task scheduling
SMDCS-CP series modules have different features in terms of structure and installation to
meet the requirements of various industrial applications.
SMDCS-CP
Controllers
are
Compact-PCI
standard CPU with feature Intel Mobile PentiumM processors and offer fast execution, larger
memory capacity and upgradeability to track
future technology growth. The SMDCS-CP CPU
is available with various processor speed,
memory sizes, and performance capabilities
and advanced Functionalities, such as software
configuration of data and program memory.
The SMDCS-CP Controllers deliver high PC
computing performance in a highly integrated
cost-effective design.
The SMDCS-CP Controllers Combining the low power/high performance features of
Intels Mobile Pentium processor with the 855GME chipset, the CPCI system controller
incorporates components commonly used in industrial and mobile applications.
Compact designed the single slot processor card integrates Intels latest I/O Controller
Hub technology. This all together results in lower levels of heat dissipation, which in turn
leads to lower system requirements and integration costs
Highly versatile the CPU can be used in a system or peripheral slot. With full hot swap
and IPMI functionality the CPU is an ideal solution for cost-effective, performanceoriented data and telecommunications applications, media gateways, networking and
switching applications, airborne and industrial automation systems and more.
All board versions are passive cooled with a heat sink within 4HP height.
Forced air cooling at a specific flow rate is required depending on the processor version.
Memory
Up to 2 GB DDR SDRAM
Supervisory Functions
Watchdog, software configurable, 125 msec to 256 sec
Generates IRQ, NMI or hardware reset, two stage configuration for NMI and
Reset
Hardware monitoring SCH3112 for thermal control, fan-sense/control and all
important onboard voltages
Compliancy
Designed to meet or exceed:
- Safety: UL 1950, UL 94, CSA 22.2 No 950, EN 60950, IEC 950
- EMI/EMC: EN 55022 / EN 55024, EN 50081-1 / EN 6100-6-2
Controller Rack
You should always attempt to use pairs of the same controllers for backup, to
ensure proper processing.
Benefits
Uninterrupted control operation: Using the capabilities of the SMDCS-CP Controller,
you can establish a safety net to protect your process from unexpected controller failures.
Automatic commissioning: The system automatically commissions a standby controller
as its installed. You dont need to bring the system down to add redundancy. Addressing
and configuration are automatic.
Bumpless transition: You can add redundancy to an existing system as your needs
grow. Redundancy adds minimal processing overhead to the system, allowing you to add
increased reliability without having to increase the processing capability.
Product Code
Product Description
SMDCS-CP-DPM-S
SMDCS-CP-DPM-R
Ordering Information
The modularity inherent within the ingenious design concept of SMARTI/O systems allows
an enormous flexibility in system configuration through the specific targeting of Fieldbus,
CPU or I/O modules to suit the application.
The open architecture of SMARTI/O Family guarantees availability for tomorrows demands
be it another fieldbus interface, I/O module or CPU [SMART2]
SMART I/O Modularity: a wide range of I/O modules for SMARTI/O Family is available to
interface the variety of process signals connected with industrial automation or process
control.
The comprehensive range of available modules covers digital I/Os, relay connections, analog
I/Os, serial communication and temperature processing interfaces.
With enough potential for up to 14 SMART modules, completely configured Family of SMART
I/O systems have enough driving force to equip even the most demanding industrial
application with up to 108 digital I/O points.
SMART2- Base
SMART2- CPU
Designing the CPU in the same manner as the pluggable
SMART-modules opens a new area of flexibility in the micro
controller market.
An obvious Spin OFF is the easy creation of made to measure
systems for improved cost efficiency of a given application and
the ability to easily exchange or upgrade the modules.
The CPU-Modules, SM2CPU is equipped with Motorolas power
full MC 68LC302 microprocessor. Operating at a comfortable 20
MHz, theses CPUs are complete with 1.5 Mbyte DRAM
respectively, application software and firmware are stored in
1Mbyte of service Free flash memory that may be programmed via an RS 232 serial
interface built into the front panel an additional 256 Kbytes of SRAM is provided for system
and application use. Beside the dedicated modem compatible RS232 interface for
programming, a second serial line can be utilized for the connection of an operator panel.
Finally a supervisor utility resets the system if the power supply falls be low 4.65W.
The CPU, complete with all firmware installed, is ready for programming and downloading of
application code. Using either the IEC1131-3 dedicated PLC programming languages or ANSI
C, application code can be easily constructed. Updating, customizing and maintaining the
firmware and software is a simple procedure that takes advantage of the integrated bootstraploader.
SM-ADC1 is a high-resolution and opt isolated A/D converter module that supports current or
voltage inputs. The six differential inputs offer high distortion immunity that is important for
industrial environments. An on-board EEPROM stores unique calibration and gain/offset data
required by the signal converter.
Overview
When a process upset occurs, events can take place very rapidly throughout your process
area. In order to correctly determine the cause of the upset, accurate recording and
sequencing of the events is essential. Sequence of Events provides a means of recording the
events associated with a process upset, and using highly accurate time stamps to determine
the precise order in which they occurred
System Description
The SMART DCS system is designed to capture and time stamp the events as close to the
source as possible, providing you with a much more accurate picture of the sequence of
events as they occurred.
The SMART DCS system receives process-upset signals using the Sequence of Events input
module. This module with 30 discrete input channels and each channel is configured as SOE
input.
Benefits
Captures process-upset events close to the source for faster recording:
Sequence of Events (SOE) input modules are used to capture process- upset events coming
directly from devices in the field.
Provides increased resolution of timestamps for more accurate event sequencing:
Events captured by an SOE input module are time stamped using a 1 millisecond resolution.
Additionally, the time stamps are resolved by the SMART DCS controller to ensure accuracy
across the SMART DCS network. Using a Network Time Protocol (NTP) server
The NTP server uses the Global Positioning System satellites for an accurate time reference.
As the controller reads events, they are time stamped using the NTP server as a reference.
This method of synchronization, along with the increased resolution, provides a much more
accurate and complete picture of the order in which the events occurred.
Easily integrates data with desktop applications for detailed analysis and reporting.
The Event Chronicle stores these events electronically, so that you always have easy, reliable
access to the data. A single Event Chronicle can capture system events spanning multiple
controllers and workstations, so that you can look in one place to find all the relevant data.
Additionally, multiple Event Chronicles can reside on the same Smart DCS network for
redundant event capturing. The events stored in the Event Chronicle can be easily viewed
using the Process History Viewer application, which displays the events in chronological order.
The Event Chronicle can automatically export data as well, so that it can be read using other
software packages such as the standard Microsoft Office applications.
Function
: 12V DC to +80V DC
Input Current
Input Frequency
: 20 kHz (max.)
Switching Level
Scan Rate
Switching Char.
Input Protection
Common
Isolation
Power Req.
Overview
Smart DCS provides user-friendly HMI, powerful programming and simulation software that
takes care of the configuration of all functions and data storing and processing capability that is
able to record important historical data and provide reports.
The power of all these functions lies in the software structure and technology. Client/Server
structure is adopted by Smart DCS operating level to guarantee data coherence,
completeness and safety, featuring good flexibility and expandability.
With COM/DCOM, middleware technology and OPC technology, Smart DCS software system
supports and provides OPC interface based on COM/DCOM technology. With standard OPC
interface, data communication between instruments of different suppliers becomes easier to
maintain and no special interface programming is necessary.
Human Machine Interface (HMI)
With Smart DCS HMI, the operators are able to get the whole process information, browse the
flow chart, quickly identify various events, and input the required control parameters to ensure
safe operation of the various equipments. In addition, with corresponding authorization,
operators, maintenance engineers, and managers are able to track the process, modify
process parameters, and obtain reports.
Engineering Flow Chart
All the measuring points monitored by the control system can be displayed using
graphics icons or symbols including digit, current value, dimension, value ranges
with upper and lower limits.
Software Tools
Software Tools
Alarms
Smart DCS alarm function helps and reminds the operator to
solve sudden in case of abnormal status or equipment failure
status during the production process. Alarms are categorized
into process alarm, equipment alarm and SOE signal alarm.
Reports
Smart DCS software provides integrated report system, which can print all the measuring
points in the database. The measuring points in the report can be printed in formats defined by
users. Automatic printing or manual printing is optional.
Logs
SMART DCS software provides logging functions which can automatically records, stores, and
checks all the sudden events in sequence and provides detailed evidence for managers to
analyze the events.
Logs can be classified into daily log, equipment log, operation log, SOE log and simplified log.
Logs can be displayed in track mode and historical mode. In track mode, the system will
automatically display the most recent information. In historical mode, historical event can be
displayed. All event information, operation parameter setting events, alarm monitor and timing
information are grouped into different logs.
Historical Trend
SMART DCS software records all information of the measuring points in a database and
displayed either in the form of data or charts, featuring with
flexible modified time axis ranges or parameter axis ranges.
Trend curve provides monitoring platform for plant managers
or administrator to know if the production process is safe and
effective.
Various trends can be displayed such as general trend.
General trend deals with both analog and digital trend
query.
General trend can be displayed in track mode and historical mode. General trend can be
displayed in curve. Maximum of 16 measuring points trend can be displayed for analog and
digital trend. And the curve display range scope is real-time modified according to the curve
fluctuation displayed on the screen to easily identify the change of curve. The operator is
allowed to select or shield this function.
Powerful Configuration Software
Smart DCS provides user-friendly, powerful programming, and simulation software to configure
all system functions and collectively control and manage the whole project execution. The
software consists of system equipment, database, control calculation, graphic, report, off-line
simulation, and on-line management. It provides an integrated platform to design your
graphical Interface and control strategy.
Integrated Database
Integrated database stores all configuration data and settings. Database configuration is to
define and edit the measuring point information, including actual physical measuring points
and Mid-variables.
Large Graphical Libraries
SMART DCS HMI graphical layout and design software enables users to design a direct and
clear operational user interface. With the help of the large and
practical graphical libraries (ISA Symbols), users are able to
easily draw complex and beautiful graphic such as animation,
data, curves bar charts and real-time display of all the devices
and instruments or display complicated tables for any data type.
Smart DCS software also provides dynamic icons to indicate the
running status of equipment and parameter value as real-time
dynamic points. Users are also allowed to have personal graphic library and store frequently
used graphic in the library as icons for repeated usage.
Powerful Control Strategy Generation Tool
Software Tools
information. Digital trend takes care of digital trend information and functions as modification
Software Tools
Consist of control calculation editor and simulation debugger, the control strategy generation
tool allows you to write control algorithms through programming, downloading, and simulating.
Control Strategy Programming
Smart DCS control strategy generation tool provides rich function block calculation library, like
IEC operator, type transfer function, timer, trigger, counter function, emergency events
function, PID control, fuzzy control and sequence control. Users are also allowed to add selfdefined functions. Typical industrial control algorithms, like batch control, PID loop, complex
loop, logic loop, hybrid loop, advanced control calculation and special recipe control can be
fulfilled by using library function.
User Programmable Functions
Smart DCS control strategy generation system allows users to have further development on it,
providing self-defined functions and function blocks. Users are able to program complex
control modules with six programming languages and embed them to the system.
The control strategy configuration interface adopts an explorer-like window with tree-structures
to display the control solutions and set basic attributes, like solution name, used language,
calculation cycle, calculation switch and sequence.
On-line Download without Disturbance
All databases in SMART DCS system can be downloaded to the
controller. The system provides specific reminding and warning
information during the download. Modified incremental files can
also be downloaded to the controller without disturbing system
running.
Convenient Off-Line Simulation Environment
Smart DCS provides off-line simulation environment. Users are allowed to debug the control
algorithms configuration in non-field environments like at home or offices. Under the simulation
mode, program can run independently from the controller. Breakpoint, monitor variable, singlestep execution, single-loop execution, jump execution, call execution, call stack check, flow
control, value modification and forced output can be set during simulation.
On-line Modification
information like range without affecting the running system and process. Meanwhile, users are
also allowed to force output and input variables and cancel the forcing.
Breakpoint setting, monitoring variable, single-step execution, single-loop execution, jump
execution, call execution, call stack check and flow control can be applied.
Access Security
To prevent unauthorized access to database and configuration data, the smart DCS provide
several access levels under password or key-lock control
Smart DCS Access Level includes:
Supervisory Level: Supervisory have access for all functions listed for operator
level additionally have access to loop tuning parameters, process range,
operator alarms settings
View Only: The process may be viewed, while data entry or process changes
are not possible
Software Tools
The system supports on-line modification. Users can login the controller to modify auxiliary
Software Tools
Printing
-
HMI displays
Reports
System diagnostics
and
instructions,
like
symbols
(key
characters,
Software Tools
ST-Structural Text
SMART DCS
The contents of this publication are presented for informational purposes only, and while every effort is made to ensure their
accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services
described herein or their use or applicability. All sales are governed by our software licensing agreement, and terms and
conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our
product at any time without notice.
2009 PEP ARAB Control Systems CO.
The PEP ARAB logo is a trademark and service mark of PEP ARAB Control Systems Co.