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PLC FUNCTION BLOCK CREATION FOR MINIMIZING DATA LINK LIMITATION ON CC-LINK-BASED CONVEYOR HANDLING SYSTEM
(2022-07-01)
Pongswatd, Sawai
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Niyomtamarat, Patipak
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Kummool, Sart
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Thepmanee, Teerawat
In order to solve a facing network capacity problem when improving an existing conveyor handling system controlled by programmable logic controllers (PLCs) on master-slave control and communication link (CC-Link) network at a wooden pallet manufacturer, this article presents a software technique for short-term solution. For new requirements to upgrade a pallet sortation to be automated by installing new robotic handling unit, a slave PLC using an interface module modeled FX2N-32CCL (or slave PLC1) cannot receive all specified data of pallet production models from an existing master PLC using intelligent module modeled QJ61BT11N in one communication cycle due to limited data links. To overcome this limitation, a PLC function block creation based on data sorting approach is proposed. Two new function blocks named FB SEND and FB RECEIVE are created based on IEC61131-3 standard for adding to the existing ladder diagrams, which execute on the master PLC central processing unit (CPU) and slave PLC1 CPU, respectively. Experimental results verify that the created function blocks can provide data transfers correctly between the specified sources and destinations. The data received at the slave PLC1 CPU are similar to the data sent from the master PLC CPU. With the proposed solution, the desired conveyor handling system can be upgraded according to user’s requirements.
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AVAILABILITY THROUGH FIELD DEVICE DIAGNOSIS IN FEEDFORWARD CONTROL: A CASE STUDY OF FOUNDATION FIELDBUS-BASED TEMPERATURE CONTROL
(2022-02-01)
Kummool, Sart
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Suwanmanee, Ittimon
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Weerathaweemas, Songchai
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Julsereewong, Amphawan
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Sittigorn, Jirasak
For endusers, requiring an action to enable a fieldbus-based process control that is not hazardous to continue its operation in the event of transmitter failures, it is essential to understand how diagnostic capability of field instruments is helpful in availability enhancement. In order to effectively implement a feedforward control strategy with increased availability, this article presents a control configuration method when utilizing a Foundation Fieldbus (FF)-based temperature feedforward control as an illustrative case study. Four function block assignment options for configuring the studied control strategy during engineering phase are described. The ‘Uncertain’ measurement status provided by temperature transmitters is treated as ‘Good’ measurement status in all control configuration options for availability goal by reducing process downtime. In addition, based on experimental results, a simplified Petri net model for logical behavior representation of the interested FF-based feedforward is also proposed.
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Safety enhancement for basic process control using 4-20 milliampere signal transmission
(2021-08-01)
Julsereewong, Amphawan
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Muangmool, Phongphiphat
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Thepmanee, Teerawat
To enhance safety of basic process control using traditional 4-20 mA current loops with/without transmitting a return signal of actual actuator position back to a host, this article presents a useful technique to provide fault-state and fault-recovery actions in four patterns. The proposed technique is a design of control drawings configured in a distributed control system (DCS) host for conventional proportional-integral-derivative (PID) loops with/without feedforward path to improve actions of the control loops in response to sensor and actuator failures. The configuration design based on functions of failure status propagation and failure mode shedding for eight control drawings that contain software function blocks for running on the DCS host modeled CENTUM VP is described. Simulation results by employing the DCS virtual test function verify that all designed control drawings can successfully perform the desired fault-state and faultrecovery actions for process safety enhancement.
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Process safety enhancement of feedforward control using foundation fieldbus
(2020-04-01)
Julsereewong, Amphawan
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Kummool, Sart
This paper presents a practical technique in engineering phase for enhancing safety of Foundation Fieldbus (FF)-based feedforward control through propagation of measurement validity and status information in the loop using function block language to prevent hazards in the presence of a transmitter failure. The proposed technique is based on fault diagnosis of FF devices to increase the safety beyond that found in basic control loops using traditional technologies. For hybrid architecture by assigning basic and advanced function blocks to execute in H1 field instruments and H1 interface module, respectively, all possible cases for configuring parameter options not only to shut the loop down when the failure occurs but also to resume the loop to normal when the failure disappears are described. The feedforward on temperature control of H1 segment configured and operated on the DeltaV integrated host is used for experimentally testing the correctness of the defined parameter options to provide function block interlocks and failsafe actions as well as fault recovery mechanisms. In addition, the Petri net model to represent the control loop behaviors for comparing the process safety enhancement in different scenarios from five cases of parameter configurations is also included.
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Analysis of macrocycle schedules for an alternative of FF-based feedforward control
(2019-04-01)
Julsereewong, Amphawan
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Pannil, Pittaya
This paper focuses on analyzing the macrocycle schedules generated for an alternative implementation of Foundation Fieldbus (FF)-based feedforward control with hybrid architecture. The interested alternative control strategy is based on the use of the bias/gain (BG) function block to create feedforward summing function outside a proportional-integral-derivative (PID) function block for use to meet special operation requirements. An FF temperature control loop connected to the DeltaV distributed control system (DCS) providing built-in capability to execute function blocks in an H1 interface card is utilized as a case study to examine the effects of eight different configuration schemes on macrocycle schedules and function block synchronizations. Experimental results obtained from major configuration schemes by placing the PID block in the DCS host controller, the H1 interface card, and the temperature transmitter show that function block allocation affects the control performance to anticipate process disturbance effects.
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Integration of hart and ff h1 devices into distributed control system for feedforward control in revamping existing plants
(2019-02-01)
Thepmanee, Teerawat
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Julsereewong, Amphawan
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Pongswatd, Sawai
To revamp existing process plants that use Highway Addressable Remote Transducer (HART) communication technology, reusing the existing instruments which are still available in the market to combine with new Foundation Fieldbus (FF) H1 instruments in the same control system can become a cost-effective strategy for digital modernization. This paper aims at presenting an engineering method based on IEC 61804 standard for integrating a HART field device and FF H1 devices into a distributed control system (DCS) to operate together in a feedforward control loop. To verify the performance of the proposed method, the feedforward on temperature control configured and handled on the DeltaV DCS is employed as an illustrative case study. Moreover, how different analog-input (AI) function block assignments to the HART and FF transmitters for measuring the controlled variable and disturbance input as well as how different proportional-integral-derivative (PID) function block allocations to the DCS controller and FF field devices affect the H1 segment macrocycle schedules and network traffic loads is also analyzed. Experimental results obtained from some control configuration schemes demonstrate that the combined HART-FF H1 technique can maintain the controlled variable at the setpoint in the presence of disturbances for feedforward control.
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Comparative analysis between control in the host and control in the field in terms of safety and availability for foundation fieldbus-based process control
(2018-04-01)
Julsereewong, Amphawan
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Whatphat, Nopthawach
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Sangsuwan, Thaksin
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Chanwutitum, Jirasak
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Thepmanee, Teerawat
Design work of process control to provide necessary performance requirements must be based on capabilities and limitations of the technology used. This paper aims at analyzing possible safety and availability enhancements of basic process control based on Foundation Fieldbus (FF) technology in which the control function blocks can be assigned either in the host system controller, called ‘Control in the Host’ (CIH), or in the field devices, called ‘Control in the Field’ (CIF). Implementing the control loops with CIH and CIF strategies for water tank process is utilized as a case study to demonstrate the proposed analysis. The major configuration details of field devices, control strategies, and function blocks are described. Experimental results were analyzed for examining the parameter options as well as the control loop actions in response to invalid measurements to compare the safety and availability improvements between the CIH and the CIF. The proposed analysis can be useful to enable economical solutions for design phase of the FF-based control loops.
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Safety and availability of basic process control using foundation fieldbus with control in the field - An experimental analysis
(2017-08-01)
Sangsuwan, Thaksin
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Thepmanee, Teerawat
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Julsereewong, Amphawan
Detailed knowledge of how to balance between safety and availability for instruments is essential to successful design and implementation in fieldbus-based process control systems. The configuration correctness is crucial to actually obtain the benefits of digital fieldbus technology used. In actuality, a number of device parameters must be set to provide the required functionalities. This paper focuses on improving safety and availability for the proportional-integral-derivative (PID) and cascade control strategies using Foundation Fieldbus (FF) with control in the field. The aim of this paper is to analyze the logical behaviors of PID and cascade loops in two conflicting purposes for studying how different configuration options affect the interlocks between function blocks located in instruments as well as the initialization and fail-safe mechanisms in response to invalid measurements. For safety purpose, the interested control loops are configured to bring the process to a safe state in the presence of a fault. For availability purpose, the interested control loops are configured to keep the process running in the event of a failure. A water tank process is utilized as a case study for control loop implementations. Interactions between the status propagation and mode shedding for demonstrating the studied control loop behaviors are examined experimentally in Petri net models. In addition, the function block options for bumpless transfer and setpoint tracking are also described. The proved configuration method for proper operations in balancing the interests of safety and availability is proposed.

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