PcXSim
Dynamic Simulators for training purposes are very much in demand as the complexity and value of industrial plants increases. Such simulators allow the operator to manipulate the process controls without placing the production equipment at risk, during training sessions. The fundamental operating ability of the trainees can be developed earlier and quicker, resulting in highly skilled operators.
For example, the TDC LCN interface (LCNSIM) connects non-Honeywell products to Honeywell systems. To do so, this interface directly attaches to the network of the TDC 3000 industrial control system, and replaces physical modules with logical modules. Proconex has the experience of already producing and selling 150+ units of a version of the Honeywell interface for the Honeywell TDC 2000 system, and as technology has advanced, Proconex has provided its customers an interface to the more advanced Honeywell TDC 3000 system.
PcXSim
Skip to LCNSIM , SX006 , SX002 , SX004 , Other Bailey Options
DCS simulation of the respective control system has typically, in the past, been included as part of the process simulation provided by the respective simulation vendor. In this new approach, Proconex is performing the controller emulation in conjunction with the Interface to the operator console, as part of the application PcxSim. The Control Emulation provides a simulation of the Honeywell ExperionR PKS C300 controller blocks, while the interface provides the link between the PcSxim database and the Experion server. The two applications run on the same Windows]based CPU and communicate with each other through shared memory. The control emulation can run independently of the interface and the associated operator console.
Interface The interface provides the traditional Proconex communication functionality to transfer data to and from the associated operator consoles, via Ethernet. All requests for tag information received by the interface over the network are handled immediately with the PcXSim database. Protocols are available to emulate either the C300 or C200 (and associated FTE bridge module) controllers. The Interface allows for the emulation of up to 12 separate controllers.
Emulation The control emulation interfaces directly with the PcXSim database. The database is constructed, in part, by reading the ExperionR strategy export (XML) files. The process of reading these XML files also builds the respective executable blocks for control emulation, thereby creating a totally integrated solution.Proconex Interface and Control Emulation Overview
The associated XML files are parsed to extract:
. Parameter names
. Parameter values
. Block connection information
. Sequence (order of execution) at the CEE (Control Execution Environment) and CM (Control Module) levels
Under normal operating conditions, the execution of the control algorithms (blocks) becomes a slave to the simulation vendor's process simulator. In other words, simulation commands are expected to originate external to the control emulation. The emulation may also be run as a standalone simulation for testing and maintenance, independent of the interface and ExperionR server. Support is provided for the following simulation controls:
. Freeze/Run
. Initial Conditions e.g. store/restore (snapshot), backtrack
. Speedup
Additional functions include:
. Parameter value export/import
. Parameter edit and monitoring
. Basic PID]type block graphical interface
Simulation Communication Communication between the control emulation and the process simulation is via OPC server/client.
LCNSIM
Skip to PcXSim , SX006 , SX002 , SX004 , Other Bailey Options
The LCNSIM Interface connects a general purpose computer to the Honeywell TDC3000 LCN (Local Control Network). It was developed in 1993 as part of a simulation system for process operator training. The general purpose computer simulates the process and controls and communicates the results in the form of measurements, data and status words to the interface. Operators working with Universal Stations or Global Universal Stations view the simulated data as if it were from the real process.
An Exception Build File and graphics are taken from the actual plant configuration and loaded into the interface system unchanged, in the same way they would be loaded into an actual plant system.
The interface emulates the temporary data storage of a combination (maximum 4) of the following LCN devices: NIM, HG, or AM. The tags and parameters associated with these devices can be read and written by the simulation computer and by an operator console on the LCN. The link between the simulation computer and the LCNSIM is Ethernet or asyncrhnous RS232.
All requests for tag information received by the LCNSIM Interface over the LCN are handled immediately by the LCNSIM from its own database. The LCNSIM Interface updates its database as soon as any information is written to it by nodes on the LCN (usually the result of an operator action). The information updates are sent to an exception report buffer and transmitted to the host when it polls for exceptions.
In addition to the transfer of data to and from the LCN and to and from the host, the LCNSIM Interface does a limited amount of processing on each data point (point processing). Point processing generates alarm messages, does limit checks on data input, verifies that mode changes are permissible, and generates appropriate error responses if a change requested by an operator on a Universal Station is not permitted.
The LCNSIM is compatible with Honeywell's new TPS (Total Plant System) architecture.
SX006
Skip to PcXSim , LCNSIM , SX002 , SX004 , Other Bailey Options
The SX006 Interface connects a general purpose computer to the ControlNet, a multi-vendor network originally concieved by Allen-Bradley. It has been developed in 2002 as part of a simulation system for process operator training. The general purpose computer simulates the process and controls and communicates the results in the form of measurements, data and status words to the interface. Operators working with stations such as Honeywell PlantScape view the simulated data as if it were from the real process.
A data base and graphics are taken from the actual plant configuration and loaded into the interface system unchanged, in the same way they would be loaded into an actual plant system.
The interface emulates the temporary data storage of a combination (maximum 4) of the following (nodes) devices: C400, ControlLogix. The tags and parameters associated with these devices can be read and written by the simulation computer and by an operator console on the ControlNet. The link between the simulation computer and the LCNSIM is Ethernet.
All requests for tag information received by the SX006 Interface over the ControlNet are handled immediately by the SX006 from its own database. The SX006 Interface updates its database as soon as any information is written to it by nodes on the ControlNet (usually the result of an operator action). The information updates are sent to an exception report buffer and transmitted to the host when it polls for exceptions.
In addition to the transfer of data to and from the ControlNet and to and from the host, the SX006 Interface does a limited amount of processing on each data point (point processing). Point processing generates alarm messages, does limit checks on data input, verifies that mode changes are permissible, and generates appropriate error responses if a change requested by an operator is not permitted.
The SX006 is compatible with Honeywell's new Experion architecture and has an Ethernet link mode.
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SX002
Skip Down to PcXSim , LCNSIM , SX006 , SX004 , Other Bailey Options
This TDC 2000/3000 Hiway Interface Unit was developed in 1985 as part of a process operator's training system (simulation). The interface connects a host computer such as a desktop PC to the Data Hiway at the TDC 2000 level. The host simulates the process and process controls (regulatory and sequential) and communicates the results in the form of "measurements", "data" and "status words" to the interface. Either an Enhanced Operator Station or a Universal Station (through a gateway) accesses the Hiway and receives data as if it were from a real process. The process operator console can then be used as if it were connected to a real process.
The interface emulates up to 64 boxes on the imaginary Hiway. It does this by receiving all requests for data read/writes' and responding to all read requests with a data word drawn from the interface memory. Write requests are passed on to the host for action and there is usually a corresponding return message from the host, which is used to update the interface memory. Firmware in the interface cycles at the required frequency to answer requests relative to Hiway security and clock maintenance. The firmware supports READ and WRITE methods of access. The Hiway map in the interface is dynamically re-configurable form the host computer.
The SX002 has recently been converted to FPGA technology. A dedicated PC host is required and an operating system (DOS) is used only for program loading. It is feasible to upgrade the SX002 to an NT based system. With current, powerful PC's, the interface program could be run under NT, while still leaving processing time for other software. Our final decision to upgrade to NT will be based on customer demand.
The interface can co-exist with real boxes on a live Hiway.
SX004
Skip to PcXSim , LCNSIM , SX006 , SX002 , Other Bailey Options
The SX004 Interface connects Bailey consoles on an INFI-90 network to a host computer that is running a program simulating the process and controls of a plant. Up to 24 INFI-90 PCU (Process Control Unit) addresses can be assigned logically to one SX004 Interface card. The SX004 Interface can function as more than one node (PCU) for data messages. The SX004 Interface also has a serial communication port or an Ethernet port to connect it to a host computer. The SX004 was developed in 1996.
Here is a schematic drawing of the SX004 setup:
The SX004 has a tag database for the exception reporting function blocks assigned to the PCU's it is emulating. Parameters in the tag database are read or written to by the host computer or the Bailey Console.
The SX004 monitors changes in the tag database and generates appropriate exception reports to the Bailey console. The SX004 Interface updates its database as soon as any information is written to it over the INFI-90. The updates are recorded in an exception report buffer which is transmitted to the host when it polls for exceptions.
In addition to the transfer of data to and from the INFI-90 and to and from the host, the SX004 Interface does a limited amount of processing on each function block (point processing). Point processing generates the INFI-90 exception reports, sets alarm flags, and manages the Trend Blocks.
The SX004 Interface has a diagnostic console that can be used to examine and modify the tag database, save or load the database to/from the hard disk, view a summary of the SX004 Interface activity or the host serial line communication activity, enable or disable the transmission of data on the INFI-90, and scan the messages posted by the SX004 Interface.
Points are configured in the SX004 Interface tag database by extracting information from the EWS (Engineering Work Station) tag list using a small DBASE program. The tag database is saved on the SX004 Interface hard disk. The SX004 Interface does not support EWS operations, however, tune displays and trend displays of the Process Operator Station are supported.
The SX004 is compatible with Bailey's new Symphony Products.
Other Bailey Interface/Software Options
Skip to PcXSim , LCNSIM , SX006 , SX002 , SX004
This option is designed to use Bailey control modules as part of the simulation assembly. The connect point is at the I/O level for slave modules. One adapter board is required for every control module. Therefore, this option is attractive when Multi-loop controllers are used in the system. The control modules can be stopped as required in a training situation by setting their execution interval to infinity. Reconfiguration is not required. This model is called the XBIM.
This option does not require a Proconex hardware part, but does require the use of a software driver in the host. Multiple node addresses are not handled, except by reconfiguration. This method must have a "C" or Fortran program available. Reconfiguration of all DCS points is required.
This interface has been developed to connect a Bailey MCS or OIS12 operator console/keyboard to a simulation system for purposes of operator training. The MCS/OIS12 is directly connected to a simulation computer via a RS232C serial line operating at 19.2 KBaud. This serial line normally interconnects to a Bailey INFI-90 or Plant Loop for real-time operation. The simulation computer replaces the INFI-90 or Plant Loop and the associated control modules.
This option is the method used by Proconex in early installations. It uses a standard LIM/BIM module. The module serial bus is intercepted by a special circuit that is that is piggy-backed onto the LSI serial communications controller of the Bailey module. All the possible modules are emulated by the interface computer. This device works well for 1 node on the INFI-90 or Plant Loop, but requires DCS reconfiguration to handle multiple nodes.
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