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Distributed Control System (DCS): ABB Freelance

Course Overview

This 5-day training program is designed to provide a thorough understanding of the Emerson DeltaV DCS, focusing on its architecture, configuration, programming, and operational capabilities. The course combines theoretical knowledge with hands-on exercises to prepare participants for real-world applications in industrial process automation and control.

Course Objectives

By the end of this course, participants will:

  1. Understand the architecture and components of the DeltaV DCS.
  2. Develop and deploy control strategies using DeltaV Control Studio.
  3. Configure Human-Machine Interface (HMI) displays using DeltaV Operate.
  4. Set up alarms, trends, and event logging for effective plant monitoring.
  5. Integrate field devices using communication protocols and troubleshoot system issues.

Target group: Automation engineers and technicians, Process and instrumentation engineers and Control system operators and maintenance personnel.

Prerequisites: Basic understanding of control systems and process automation and familiarity with industrial processes and instrumentation.

Duration: Five (5) days

Methodology: Hands-on sessions with DeltaV software and hardware simulators.

Contents

Module 1: Introduction to DeltaV DCS

  • Overview of Distributed Control Systems
  • Key concepts and advantages
  • DCS vs. PLC/SCADA
  • DeltaV System Architecture
  • Components: controllers, I/O cards, operator stations
  • Network and communication infrastructure
  • DeltaV Software Overview
  • DeltaV Explorer, DeltaV Control Studio, DeltaV Operate
  • Hands-On: Setting up a DeltaV system, navigating DeltaV Explorer.

Day 2: Control Strategy Development with Control Studio

  • Control Studio Basics
    • Interface overview and navigation
    • Creating and managing control modules
  • Control Logic Development
    • Function Blocks: AI, PID, AO, DI, DO
    • Advanced functions: logic blocks, math blocks, and sequence blocks
  • Downloading and Testing Control Strategies
    • Module configuration and deployment
  • Hands-On: Developing basic control loops (e.g., level and flow control) using PID blocks.

Day 3: HMI Configuration with DeltaV Operate

  • DeltaV Operate Overview
  • Designing operator graphics and layouts
  • Configuring dynamic elements for real-time data display
  • Alarm and Event Configuration
  • Setting alarm priorities and thresholds
  • Implementing effective alarm management practices
  • Trend Display Setup
    • Configuring historical and real-time trends
  • Hands-On: Designing an HMI screen with process graphics, alarms, and trends.

Day 4: Field Device Integration and Communication

  • I/O and Device Configuration
    • Setting up hardware: I/O cards, terminal blocks
    • Adding and calibrating field devices in DeltaV Explorer
  • Communication Protocols
    • HART, FOUNDATION Fieldbus, Modbus, and Ethernet/IP
  • Advanced Features
    • Redundancy setup for controllers and networks
    • Integration with third-party systems
  • Hands-On: Configuring and testing field device communication and diagnostics.

Day 5: Maintenance, Troubleshooting, and Advanced Topics

  • Maintenance and Diagnostics Tools
    • DeltaV Diagnostics and Alert Monitor
    • System backup and recovery procedures
  • Troubleshooting Techniques
    • Identifying and resolving common issues
    • Testing and simulation tools in DeltaV
  • Advanced Topics
    • Batch management and recipe configuration
    • Cybersecurity in DeltaV systems
  • Hands-On: Diagnosing and resolving simulated faults, creating a batch configuration.