VALLIAMMAI ENGINEERING COLLEGE DEPARTMENT OF EIE

VALLIAMMAI ENGINEERING COLLEGE

Department of Electronics and Instrumentation Engineering

EI 2402– Logic and Distributed Control System

Question Bank

Year :III year (2015-16) ODD SEMESTER Prepared by:Z.Jenifer&S.Vanila

UNIT I: Programmable Logic Controller

PART-A (Q&A)

1. Briefly explain about timers in PLC

The operation of time-delay relays is provided in software. The contacts are shown as NO or NC
designations. Only the address to the relay coil shows that it is a timer contact. The timer is activated
by a condition in a rung that leads to the timer being energized. Then the indicated time delay (in
seconds or minutes) is inserted before the associated contacts change state.

2. How do you choose the PLC for a particular application?

The selection of PLC based on

i) The number of input and output used

ii) The control strategy

iii) Working environment of the system

iv) Cost factor.

What is the difference between PLC and Computer?

The major difference between PLC and computer are,

PLC can accommodate industrial environment that will stand relatively high temperature, humidity,
moisture etc.
Programming of PLC is easier than Computer.

All the field point inputs and outputs are directly connect to PLC. There is no need of signal
conditioning.)

What is latch? Where it is used?

Latch is a hardware or software device which uses to maintain the state unless the next state is
generated. In PLC operations the relay contact need not be placed directly over the coil symbol, but
can go anywhere in the program with associated them with a particular coil.

5.

What are the different methods in PLC programming?

The different methods of PLC programming are

i) Ladder program

ii) Functional block diagram

iii) Statement list.

6.

Briefly explain about counters in PLC.

The counter works in a similar fashion as timer expect that it is counting of events that determine
when the associated contacts change state. Thus, if the counter is loaded with the number 10, after
being energized 10 times the associated contacts will be changed. Counters can be configured to count
up, count down, count from preset values, and be reset before the count is finished.

7. What are the advantages and disadvantages of PLCs?

Advantages

a. Flexibility d. Lower cost

b. Implementing changes and correcting errors e. Simplicity of ordering control system

c. Large quantities of contacts components

f. Ease of changes by reprogramming

Disadvantages

a. Fail safe operation c. Environmental considerations

b. Fixed circuit and fixed program applications d. Newer technology

8.What is program scan?

During each operating cycle, the processor reads all the inputs, takes these values andenergizes or de-
energizes theoutputs according to the user program.This process is known as ascan. A single PLC
scan, which consists of the I/Oscan and theprogramscan.Because the inputs can change at any time,
the PLC must carry on this process continuously.

9.. What is PLC?

Programmable Logic Controller (PLC) is a user friendly electronic computer that carries out control
functions of many types and levels of complexity. It can be programmed, controlled and operated by a
person unskilled in operating computers.

10. What is ladder diagram?

Ladder diagrams are the most commonly used diagram for non-electronic control circuits.
They are sometimes elementary diagrams or line diagrams. Sometimes they are considered asubtype
of schematic diagrams. The PLC program is look like ladder in a way. The program starts at the top of
the ladder and generally works down as our requirement.

11. List the functions of PLC programming device.

The programming device is a device used to load the program into the processor. It can be a PC or a
dedicated piece of equipment made by the PLC manufacturer. It makes the PLC reprogrammable and
thus flexible.

12. What are the advantages of PLC timer?

The PLC timer the time may be programmable variable time as well as a fixed time. The variable time
interval may be in accordance with a changing register value. The PLC timer is that its timer accuracy
and repeatability are extremely high, since it is based on solid state technology.

13.Explain the function of optical isolator.

There are three main functions. They are

Separate the higher AC input voltage from the logic circuits.

Prevents damage to the processor due to line voltage transients.

Helps to reduce the effect of electrical noise, which can pass entire operation of the processor.

14.Mention any 2 differences between PLC’s and general purpose computers:

(i) PLC is designed to operate in the industrial environment with wide range of ambient
temperatures and humidity. A well-designed PLC is not affected by the electrical noise that is inherent
in most industrial locations.

The electrical noise and extreme temperatures affect computers.

(ii) PLC’s execute a single program in an orderly and sequential fashion from first to last instruction,
whereas computers are complex computing machines capable of executing several programs or tasks
simultaneously in any order.

15. List the features of PLC.

The programmable controller has eliminated much of hand wiring associated with conventional relay
control circuits. It is small and inexpensive compared to relay based process control systems.
Programmable controllers also offer solid-state reliability, lower power consumption and ease of
expandability.

16.Name the programming methods used in PLC.The different methods of PLC programming are

Ladder Logic (LAD)

Functional Block Diagram ( FBD)

Statement List (STL)

17.

List out any four PLC input and output devices.

(May 2013)

Input: i) Push button, ii) Limit switches, iii) Toggle switches iv) Pressure limit switch.

Output: a. Control relay b. Pilot lamps c. Solenoid d. Alarm.

18.

Enlist the advantages of PLC over relay ladder logic.

(May 2013)
Relays

PLC

 They have to be hard-wires to perform a

No hard-wire requirement.

specific function.

 When the system requirements change,

Can be easily changed or expanded.

the relay wiring has to be changed or

modified.

Lower power consumption.

 Higher power consumption.

19.

List the advantages of a PLC system over the traditional hardwired control system.

(Dec 2013)

The programmable controllerhas eliminated much of the hard wiring associated withconventional
relay controlcircuits.Itis small and inexpensive compared to equivalent relay-

basedprocess control systems.

Increased reliability

More flexibility Lower costs

Communication capability

Faster response time

Easier to troubleshoot

20. Compare Tonand Tofftimers.

(Dec 2013)
Ton timers

Toff timers

 When the coil is energized, the timed

When the coil is de-energized, the timed

contacts are prevented from opening or

contacts are prevented from opening or

closing until the time delay period has

closing until the time delay period has

elapsed.

elapsed.

 When the coil is de-energized, the timed

When the coil is energized, the timed

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contacts return instantaneously to their contacts return instantaneously to their normal

normal state. state.

PART B

1. Draw the architecture of PLC and explain individual components.

(Dec 2013)

2.(i) Explain how to convert the fundamental relay schematic diagrams in to PLC ladder logic
diagram with an example. (8)

Design a PLC program to operate a light according to the following sequence

A momentary push button is pressed to start the sequence. 

The light is switched on and remains ON for 2 sec. 

The light is switched off and remains OFF for 2 sec. 

A counter is incremented after this sequence. 

 The sequence then repeats for a total of 4 counts.

(Dec 2013)

After fourth count, the sequence will stop and the counter will be reset to zero. (8) 
3. (i) With neat block diagram, discuss the various components of PLC.

(ii) Sketch and explain the functions performed by analog I/O module.

(May 2013)

(i) How timers and counters are programmed in PLC? Illustrate with an example. (6)

(ii) Develop ladder diagram for controlling the level of liquid in a tank between upper and lower

limit. (10)

(May 2013)

5.

(i) Explicate with neat block diagram power supply used for PLC (6)

(ii) Explain the architecture of PLC with neat diagram. (10)

(Nov 2012)

6.

(i) Write down the steps to be considered for designing a 16 analog input and 5 digital input, 5

analog output and 2 digital output PLC.

(ii) What is the purpose of input status table and output status table in PLC and write any PLC

program using timer and counter applications.

(Nov 2012)

(i) Comment on the advantages of PLC over relay logic.

Discuss analog input interface module.

With logic ladder program and a timing chart explain Retentive On-Delay Timer.

(i) Design a PLC program and prepare a typical I/O connection diagram and logic ladder program for
the following control specification

To fill the tank with the liquid

Heat the liquid to a particular temperature and stir the liquid.

Maintain the temperature for 15 minutes.

Empty the tank.

 (ii) With an example explain programming counters in Ladder Logic Diagram. 9.(i) Describe the architecture of a
PLC.

(ii) Draw a ladder diagram for a three-motor system having the following conditions:

Motor 1 (M1) starts as soon as the start switch is on; after 10 seconds, M 1 goes off and motor 2

(M2) starts. After 5 seconds, M2 goes off and M3 starts. After 10 seconds, M3 goes off. M1 starts and
the cycle is repeated.

10.(i) Write about advanced PLC functions and alternative programming languages.

(ii) Assuming the process control applications where the input valve V in fills the tank till level-up
indicated by Lup is reached. Then start stirrer and keep it ON for 10secs. Open V out and empty the
tank till Le is reached. Develop logic ladder diagram.

UNIT II: Applications of PLC

PART-A (Q&A)

What is ladder diagram? How is it useful in a PLC?

Ladder logic is a graphical language. The programmer draws a schematic diagram of logic on the
screen. This diagram is called as the ladder logic diagram and determines the sequence of operation
and ultimate control of equipment or machinery.

Distinguish between relay based PLC and computer based PLC.

Relay based: Slower switching speeds, needs more power to be energized, subjected to contact

arcing or welding, cannot be completely sealed, immune to false trips from electrical noise.
Computer based: Faster switching speeds, needs less power to be energized, not subjected to contact
arcing or welding, can be completely sealed, not immune to false trips from electrical noise.
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3. List the sequence of operations carried out in PLC programming.

• Processor memory organisation. • Internal relay instruction.

• Program scan. • Programming examine ON and OFF

• PLC programming language. instructions.

• Relay type instruction. • Entering the ladder diagram.

• Instruction addressing. • Modes of operation.

Brach instruction.

List the conditions for drawing the ladder logic.

Contacts may be always inserted in the upper left.

Coils must be inserted at the end of a rung.

All contacts must run horizontally. (i.e.) No vertically oriented contacts are allowed.

The number of contacts per rung is limited.

Only one output may be connected to a group of contacts.

The contacts must be nested.

Flow must be from left to right.

Contact progression should be straight across.

What is meant by internal relay instruction?

Most PLCs have an area of memory allocated for what are known as internal storage bits. These

storagebits are also called internal outputs, internal coils, internal control relays are just internals. The
internal output does not directly control an output device.

6. What is fail safe circuits?

Some PLC circuits are programmed to be turned off by applying a signal voltage. For example the
latch-unlatch function requires an unlatch signal to turn the coil .If there is a loss control power,
pushing the stop button has no effect and coil remains on, since control power is needed for system
turn off, the emergency switch to stop machine where it is.
What are I/O scan and Program scan as applied to PLC’s

The execution cycle starts with the hardware I/O system gathering the latest values of all input

signals and storing them in a fixed region of memory. This process is called the I/O scan. During the
program scan, new values of physical outputs, as determined from the various ladder rungs are
initially written into the output memory region and when the program is completed; all output values
are written to the physical output by PLC hardware in 1 operation.

8. What are the advantages of sequencer programming over conventional programming?

The advantage of sequencer programming over the conventional program is the large savings of
memory words. Typically, the sequencer program can do in 20 words what a standard program can
doin 100 words. By setting up a sequence of events, sequencers make programming simpler and any
future changes easier to make.

The sequencer output (SQO) instruction can be used to control output devices sequentially. The
desired sequence of operation is stored in a data file, and this information is then transferred
sequentially to the outputs.

What is the main advantage of JUMP instruction?

The advantages to the jump instruction include:

The ability to reduce the processor scan time by jumping over instructions not pertinent to the
machines operation at that instant.

The PLC can hold more than one program and scan only the program appropriate to operator
requirements.

Sections of a program can be jumped when a production fault occurs.

For the program shown below what is the status of PL1.

The status of PL1 of will be denergized.
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Briefly explain the case study of PLC?

Bottle filling system is one of the applications of programmable logic control. It is possible for a

continuous control system to be part of a discrete-state process-control system. As an example, we

consider this experiment. The system consists of a conveyor on which the bottles are placed; the
conveyor motor is controlled by PLC. Periodically a bottle comes into position under the outlet valve
is opened and the bottle is filled. This requirement may be necessary to ensure a constant pressure
head during bottle filling.

Name the various sequence instructions used in PLC.

Mechanical cam operated sequencer, Mechanical drum operated sequencer, programmed

sequencer.

13. Write a simple program using PLC to implement the EXOR logic gate.
What are the functional areas in which the programmable controllers are used in many
industries?

The PLC has been successfully used in many industries includes steel plant, paper and pulp plants,
Chemical, automotive and power plants. PLC performs a great variety of control tasks, from repetitive
ON/OFF control of a simple machine to sophisticated manufacturing and process control.

What advantage is there to the nesting of subroutines?

Nesting subroutines allow you to direct program flow from the main program to a subroutine and

then to other subroutine. Nested subroutines make complex programming easier and program
operation faster because the programmer does not have to continually return from one subroutine to
enter another.

What are the limitations of using relay circuits for sequencing operation?

Separate hard wiring is required and one application can be adopted at a time.

What do you mean by relay logic?

The different symbols are followed for inputs and outputs unlike ladder logic.

18.Design a PLC ladder diagram to indicate light is to go ON when a count reaches 23 and go
OFF when a count reaches 31.
19.What is MCR instruction?

The master control reset (MCR) instruction can be programmed to control an entire circuit or to
control only selected rungs of a circuit. When the MCR instruction is false, or de-energized, all non-
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retentive (nonlatched) rungs below the MCR will be de-energized even if the programmed logic
foreach rung is true. All retentive rungs will remain in their last state. The MCR instruction establishes
a zone in the user program in which all non-retentive outputs can be turned off simultaneously.

Therefore, retentive instructions should not normally be placed within an MCR zone because the MCR
zone maintains retentive instructions in the last active state when the instruction goes false.

20. Mention any four real time applications of PLC.

(May 2013)

Sequence control, timing, counting, and data calculation. 

Batch or continuous process control. 

Precise position / motion control. 

Open loop or feedback control, process data acquisition and display. 

PART-B

1.

Describe the function of program control instructions and develop a program to illustrate their use.

(Dec 2013)

2.

Construct a PLC program to illustrate the bottle filling process.

(Dec 2013)

3.

Discuss the automatic bottle filling system with hardware and ladder diagram.

(May 2013)
Develop a ladder diagram for the case given. A switch will increment the counter on when engaged.
This counter can be reset by a second switch. The value in the counter should be

multiplied by five and then displayed as a binary output.

(May 2013)

5. (i) Develop the logic ladder diagram for liquid level control application. (10)

(ii) How to use a PC as a PLC? (6)

(Nov 2012)

(i) Mention the inputs and outputs used in a bottling application and write a program using RLL.(8)

Write a PLC ladder diagram for a process application of your choice.

Mention the I/Os. (8)

(Nov 2012)

(i) Discuss the use of math instructions of PLC for automatic control of upper and lower set point
limits.

With an example, explain function block programming for sequence control application.

(i) For the following problem develop PLC ladder logic diagram.

A bottling process for 10 bottles operates as follows: Bottles are counted until all 10 are in position for
filling, when in position in the carton the 10 bottles are filled simultaneously for 5 seconds. After filling
there is a pause for 2 seconds for foam to subside, the 10 caps are then put on and counted as they are
installed. A solenoid then pushes the completed carton of 10 on to a conveyor. The system is reset for a
new group (to be restarted manually) of 10 bottles by a limit switch that indicates that the carton is out
of the “fill” position and on the conveyor.

Comment on the use of PC as PLC.

(i) Discuss the various types of programming terminals and devices used in programmable controller
systems.

Write a detailed technical note on requirement of communication networks of PLC

10. (i) Explain how hardware-to-program interface and program-to-hardware interface are established in
PLC.

Propose and explain a safeguard technique for diagnosing failure in the I/O unit of a PLC

UNIT III: Computer Controlled Systems

PART-A (Q&A)

Define supervisory control.

When the computer is used to change only the SP’s or the values of adjustable control parameters

of local controllers, the resulting system is Supervisory control.

State differences between supervisory control and DDC.

When the digital computer has assumed all control actions of a conventional controller, it is called

as direct digital control. The only analog elements left in the process control are the measurement
functions and FCE’s. The computer is used to change the SP’s or the values of adjustable control
parameters of the local controllers in a supervisory control. This supervises many local DDC’s through
I/O interfaces.

Why is it very difficult to use a computer for process control without a real time clock?

Real-time clock keeps track of the real world’s time and allows the computer to schedule its

functions at time intervals in co-ordination with various needs of the real world. Thus it is the real time
clock that determines when the computer should take data from measuring sensors or change the
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values of the manipulated variables.

Write the function of DDC.

When the digital computer has assumed all control actions of a conventional controller, it is called

as direct digital control.

Name the functional units in computer control of processes.

CPU, Memory, Mass storage, Communication peripherals, I/O interface.

Why is the digital control necessary in industries?

Digital Control is a user friendly that carries out control functions of many types and levels of

complexity. It can be programmed, controlled and operated easily.

What is the need for watch dog timer in a process control computer?

WDT allows the computer to determine if control program is being executed smoothly or if the

program is hung up in a never-ending loop. In the second case an alarm alerts the operator that the computer
has lost control of the process, due to software problems.

Differentiate between analog controller and digital controller.

Analog controllers are faster than digital controllers, the later is preferred because the changes in

the parameter values are possible in digital controller while not in analog controller.

9. Draw the general block representation of a computer control system?

SP
ADC

Control

DAC
Control

Process

Equation

Valve
Measuring Element

Measuring Variable

Controlled Variable
10. Briefly explain about Data Acquisition System.

Data Acquisition System is generally a process of collecting input signal in analog or digitalform as rapidly,
as accurately, completely, and economically as necessary and possible. It is used for the measurement and
processing of plant signal data before it is displayed on the operator desk or permanently reordered. It can be
of two types: i) Analog data acquisition system and ii) Digital data acquisition system. Analog data
acquisition system deals with information in analog form where as digital data acquisition system handles
information in digital forms.

What is data logger?

A provision is made for assigning of a number of printers at the unit level for logging functions.

It is also possible to select any printer for any type of log that can be initiated on demand times.

12. Mention two algorithms used in DDC software?

There are two algorithms for programming a three mode PID control loop

 Position algorithm 
 Velocity algorithm 

13. What are the basic functions of computer control system?

The basic functions of computer aided process control system are:

Measurement and acquisition. 

Data conversion with scaling and checking. 

Data accumulation and formatting. 

Visual display. 

Comparing with limits and alarm raising. 

Recording and monitoring of events, sequence and trends. 

Data logging and computation. 

Control action. 

Briefly explain about Remote Terminal Unit (RTU).

The Remote Terminal Units (RTU) are basically distributed SCADA based systems used in

remote locations in applications like oil pipelining, irrigation canals, oil drilling platforms etc. they are
rugged and should be able to work unattended for a long duration. There are two modes in which Remote
Terminal Units work; i) Under command from central computer and ii) Stand alone mode.

15. What is CIMPLICITY?

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CIMPLICITY is a SCADA package. It is based on a client-server architecture consisting of servers and

viewers. Servers are responsible for the collection and distribution of data. Viewers connect into servers
and have full access to the collected data for viewing and control actions.

16.

List various SCADA manufactures.

Allen Bradly

: RS View

KPIT

: ASTRA

Siemens

: win cc

Intelution

: Aspic

Gefanc

Wonderware

: Intouch
17.

Define DCS.

(Nov 2012)

DCS (Distributed

Control System) is a

computerized control system used to control the

production line in the industry. The entire system of controllers is connected by networks for
communication and monitoring. DCS is a very broad term used in a variety of industries, to monitor

and control distributed equipment.

18. Compare SCADA and DDC.

(Nov 2012)

SCADA: When thecomputer is used to change only the SP’s or the values of adjustable control
parameters of local controllers, the resulting system is Supervisory control.

DDC: When the digital computer has assumed all control actions of a conventional controller, it is
called as direct digital control.

19. Define SCADA.

(May 2013)

Supervisory Control And Data Acquisition (SCADA) system is computerized hardware and software based
project that provides a single integrated view of all control and information resources, enable engineers,
supervisors, managers, operators to view and interact with the working of an entire

operation through graphical representation of their product process.

20.List out the task of computer control systems.

Field level (level-0)

Plant level (level-3)

Control level (level-1)

Corporate level (level-4)

Supervisory level (level-2)

PART-B

Distinguish between SCADA and DCS and explain the hardware architecture of SCADA. (Dec

2013)

Explain the Direct Digital Control structure with a neat diagram and compare the advantages of

DDC over conventional analog controllers.

(Dec 2013)

With neat block diagrams, explain the basic building blocks of computer controlled system. (May

2013)

(i) Explain any one supervisory control scheme.

(ii) Compare DCS and DDC.

(May 2013)

(i) Explain the need for a computer in a control system.

With the help of neat schematic diagram, explain the function of Direct Digital Control of a process.

(i) Explain the operation of SCADA.

Compare SCADA, DDC & DCS.

Explain with the block diagram and necessary hardware circuits the computer control with a typical
case study.

Describe one way that the scan rate for a single RTU could be increased beyond the scan rate for the
other RTUs.

(i) List the functional requirements of a distributed process control system.

Enumerate the advantages of digital computer control of processes.

Distinguish between SCADA and DCS. Explain the hardware architecture of SCADA.

UNIT IV: Distributed Control System

PART-A (Q&A)

1. What is the significance of DCS?

Used for interfacing and computing functions and also provides the means of communication between
the other devices. It consists of local control unit, low level interface, high level interface, shared
communication facility, etc.

2. Mention any two advantages of DCS

 More reliable Small expensive

 Cost is lower than centralized system which performs the same function. 
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3. What is LCU?

Local control unit is the small collection of hard ware in the system that can do closed loop control.
Local control unit interfaces directly to the process.

4. What is the significance of LLHI?

This is the device that allows the operator or instrumentation engineer to interact with the LCU to
change set point, control modes, control configuration, or tuning using a direct connection. LLHI can
also interface directly to the process.

5. What is the function of HLOI?

It has the functions similar to the LLHI with increased capacity and user with increased capability and

user friendliness. It interfaces to other devices only over the shared communication facilities. Operator
oriented program at this level is called HLOI. It is an instrument engineer oriented program.

6. What is shared communication?

One or more communication hardware and associated software that allow the sharing of data samong
all devices in the distributed system. Shared communication facilities do not include dedicated
communication channels between specific devices.

7. What is the need can be satisfied in designing an industrial grade LCU?

flexibility of changing the control configuration 



Ability to use the controller without being a computer expert. 

 Ability to bypass the controller in case it fails. So that the process still can be controlled
manually. 

 Ability of the LCU to communicate with other LCUs and other elements in

system. 

8. What is the architecture parameter to be considered while selecting LCU?

Size of Controller


Communication channels

out of

Functionality of controller

controller

Performance of controller

Controller

output

security.

9. What are the approaches in designing a redundant LCU architecture?

a) CPU redundancy

b) One-on-one redundancy

c) One-on-many redundancy

d) Multiple active redundancy.

10. Compare the configuration of the controller.

Architecture

Configuration A

Configuration B

Configuration C

parameter

Controller size

Number of function

Includes functions and

Equivalent to small

needed for single PID

I/O

DDC system

loop or motor
controller

Controller

Uses both continues

Uses both continues

Uses both continues

functionality

and logic function

and logic function

and logic function

Split between the

controller

Controller scalability

High degree of
Requires both

Not scalability

scalability

controller types

11. What are multiple active controllers?

In this case, several LCUs are active at the same time in reading process inputs calculating control
algorithms and producing control outputs to the process. The multiple active approaches is designed
so that a failure of one of the controllers does affect the automatic control function.

12.Mention the requirement of operator interface.

 Process monitoring   Process control 

 Process record keeping 

13.What are the motivations for using LLOI?

It provides an interface that is familiar to the operator trying to use panel board

instrumentation. 

Less expensive 

Provide manual back up in the case if high level operator interface fails. 

14Explain about different types of operator display.

 Plant display, Graphic display.

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Area display.

Trend display.

Group display.

Tabular display.

Loop display. 

15.What is the function of engineering interface?

System configuration

System documentation

Operator configuration

System failure diagnosis

 .

16.List the factors to be considered for types of communication in DCS.

There are many factors to take into account when choosing the best medium for particular application,
including speed and distance of data transmission, topology of the network, and target costs.

17.Define Distributed Control System? (May 2013)

DCS (Distributed Control System) is a computerized control system used to control the

production line in the industry. The entire system of controllers is connected by networks for
communication and monitoring. DCS is a very broad term used in a variety of industries, to monitor
and control distributed equipment.

18. Name few popular communication buses used in DCS.

(May 2013)

Control Bus

• Address Bus

IEEE 488 BUS

Data Bus

19. Compare individual, centralized and distributive control systems.

(Dec 2013)

Features

Individual

Centralized

Distributed

1. Scalability and
Good - due to

Poor –very limited

Good - due to

expandability

modularity

range of system size

modularity

2. Control capability

Limited –analog and

Full - digital control

Full - digital control

sequential control

capability

capability

hardware

3.Operator interfacing

Limited by panel board

Digital hardware

Digital hardware

capability

instrumentation

provides significant

provides improvement
improvement for large

for full range of system

systems

sizes

4. Integration of system

Poor - due to variety of

All functions

Functions integrated in

functions

products

performed by central

a family of products

computer

20.What is the role of communication interfaces in DCS?

(Dec 2013)

Communication interface reduce Cost of plant wiring (1000 of wires are replaced by the few

cables or buses used to implement shared communication system). Flexibility of marking changes
increases because of it is software configuration. Less time to implement large system since the wiring
labor is nearly eliminated, Configuration error reduced. Control is more reliable due to reduction in
physical connection. So failure is easily identified.

PART-B

“Communication plays a critical role in DCS” is it true? Justify with neat sketch.

(Dec 2013)

Describe the hierarchy of DCS with neat diagram.

Explain the architecture of distributed control system and its main sub-system. Compare it with
SCADA system.

(May 2013)

Describe the local control unit and communication facilities used in any process industry. (May

2013)

(i) Explain with neat diagram architecture of DCS. (12)

(ii) Explain the importance of local control unit in DCS. (4)

(Nov 2012)

(i) How to select topology and communication protocol of process control application? (8)

(ii) Explain any one popular communication protocol used in field level. (8)

(Nov 2012)

Discuss the different architectures of DCS with necessary diagrams.

(i) Explain the process interfacing issues in the petroleum industry.

Explain the communication facilities used in the petroleum process industry.

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(i) List the requirements of LCU.

Compare DCS and DDC.

Explain the display hierarchy in DCS.

UNIT V: Interfaces in DCS

PART-A (Q&A)

1. What are the problems which may occur in the power plant?

Requirement

Problem

Solution

System

Rapid load

To reduce steam

Predictive control

response

temperature error due to

Dynamic balancing

slow response of fuel loop

control

Reliable plant

To diagnose system

Decentralizing control

Totally

operation

condition and to continue

functions duplicating

distributed

plant operation in case of

main portions.

digital control.

fault.

Ease operation

To fully automate plant

Centralizing monitoring

operation and obtain quick

functions displaying fault

recovery from faults

portions

In a thermal power plant, how they are classified the control system?

 Semi-automatic system: – easy to understand and simple and economical. 

Full automatic system: – easy and reliable operation. What is semi-automatic system?

All continuous modulating controls during normal on-load operation and some start up

modulating controls, such as turbine run up controls, are handled automatically by individual sub-loop
controllers, whereas most start – up modulating and binary controls are executed manually.

What is fully automatic system?

Most start up modulating and binary controls are executed automatically. Significant

improvement of man machine communication with color graphic displays and voice communication. Most
plant control sub loop controllers are digital and connected to the unit computer with data busses comprising
a distributed digital control system.

What are the main processes of power station?

 Combustion, water / steam, electricity generation, cooling etc.   For the sub processes are feed water, mills, FD fans etc. 

What are the advantages of HIACS 3000 DCS?

The use of integrated controllers has reduced the required panel area by 40% Advance prediction control has
reduced the control deviation by 50% CRT plant operation reduction of hand/ auto / control station by 71%
by using plant communication networks, the number of cables interfacing with DAS was reduced by 75%

Mention the hardware’s of the power plant DCS and the buses of the power plant.

Field stations

 Unit level control station

 Sub group control stations

Manual control station.

Group control stations

Diagnostic station.

buses of the power plant DCS

Group bus


Peripheral bus

Plant bus

Back up bus

8. What are the basic models built for blast furnace?

Statistical models

 Material and energy balance

Thermo dynamical models

model.

9.In the steel process, which are all the things to be controlled?

 Time, for economical reasons, time element being critical. 

Temperature , with in the narrow limits 

Raw material mix- steel, sulphur, aluminium, manganese and dissolved gases. 

10.What are the main and sub process involved in iron and steel process?

Ore treatment plant

Electric arc furnace

Blast furnace

Continuous casing plant



Basic oxygen furnace

Rolling mill

Direct reduction plant 

11.What are the three modes of DCS?

Computer automatic

Manual

 Automatic and remote 

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12.Mention the applications of DCS in rolling mills

 Control process in multi-loop configuration

Interconnection of the number of processes

High speed control

Graphical display of fast changing analog

Fully digital drive control system with

variables

microprocessor control

13.List the some specific Process Record keeping requirements.

 Recording of short-term trending information. 

Manual input of process data 

Recording of alarms 

Periodic records of process variable information 

Long-term storage and retrieval of information 

Recording of operator control actions 

14.Mention the function of operator interface system.

The basic function of the operator interface system is to allow the operator to observe and monitor the current
state of the process. This function includes the current values of all process variables of interest in the system
must be available for the operator to view at any time. Each process variable is identified by a tag name.

15.. Mention the features provided in operator interfaces. (May 2013)

The operator interface in a distributed control system must allow the operator to perform tasks in the
following traditional areas of responsibility: Process monitoring, process control, process

diagnostics, and process record keeping.

16. State the main functions of computers in DCS.

(May 2013)

Process monitoring

Process control

Alarming

Process diagnostics

Trend in time

Process record keeping

17. Justify the need for operator interfaces in DCS.

(Dec 2013)

The operator interfaces in typical Distributed Control System are used to describe DCS capabilities, plant and
processes are accessed and controlled from the DCS controllers. Operator interface are used to

interpret control system diagrams into plant control loops, used to describe basic

Unit loading and control features.

18. Mention the significance of computers in modern control systems.

(Dec 2013)
Computer utilizes the same measurement information about the process used by human operators. Automatic
control strategy is composed of a sequence of control rules, describing the relationship

between process conditions and control actions.

19.Briefly explain process diagnostics.

Monitoring and controlling the process under normal operating conditions are relatively simple functions
compared to operation under abnormal or hazardous conditions caused by failures in plant equipment or in the
instrumentation and control system. The operator interface system must provide enough information during
these unusual conditions to allow the operator to identify the equipment causing the problem, take measures
to correct it and move the process back to its normal operating state.

20.List the some specific Process Record keeping requirements.

 Recording of short-term trending information. 

Manual input of process data 

Recording of alarms 

Periodic records of process variable information 

Long-term storage and retrieval of information 

Recording of operator control actions 

PART-B

Explain the different displays followed in industrial control systems.

Discuss the low level and high level operator interfaces in DCS.

(i) Discuss the features of high level operator interfaces in detail. (ii) Explain the hierarchy of operator display
used in DCS.

List the various engineering interfaces used in DCS. With neat diagram, explain the low and high level
engineering interfaces. Differentiate between them.

(i) Compare low level and high level operator interfaces. (6)
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Explain the operator displays used in any of process industry. (10)

(i) Compare low level and high level engineering interfaces. (6)

Explain the role of general purpose computers in DCS. (10)

Explain the automation of power plant using DCS?

8. Describe how DCS can be used for controlling Iron and steel plant .

Describe how DCS can be used for controlling Chemical Plants.

Describe how DCS can be used for controlling Cement Plants.