DESIGN, CONFIGURATION AND IMPLEMENTATION OF FIELDBUS SYSTEM FOR CONTROLLING OF A PROCESS PLANT

The first process control systems used mechanical and pneumatic controllers, and
were run conservatively for stability rather than economic performance. In the 1950s,
the first electronic controllers were introduces that used analog signals with simple
devices, and later in the 1970s distributed control system (DCS) emerged, which is
the current standard for large control system. In DCS however, a central processor
controls all parameters and has limitation in terms of reliability and cost. This lead to
the introduction of fieldbus system: the digital communication and fieldbus system
replaces the DCS architecture by enabling distribution of control function to
equipment in the field such as sensors, controllers and actuators. This report discusses
the findings on the literature review of fieldbus system and the fundamental issues in
the development and implementation of a fieldbus system for controlling a simple
process loop using a fieldbus test rig. A configuration and implementation procedure
for the development of a fieldbus test rig is presented involving process variables that
are pressure, temperature and flow. A complete control system functions
implemented are the monitoring, measurement and control. The methodology towards
accomplishing the project includes the theoretical and technical research, the
installation and commissioning, the configuration of network, device and control
strategy, the troubleshooting, operation and maintenance, and the analysis on the
fieldbus savings and its benefits. Detailed design, configuration and implementation
for a temperature control are presented. The findings demonstrate the benefits of the
fieldbus system over the DCS in terms of signal conditioning, loop interconnection
and configurations and verify the qualitative characteristics of the fieldbus system in
terms of simpler and better controllability.