Control Systems

Piu Ghosh Instrumentation And Control Department

Pneumatic Implementation:
In the early implementation of automatic control systems, information flow was accomplished by pneumatic transmission, and computation was done by mechanical devices using bellows, spring etc.

Problems associated with pneumatic implementation: Transmission. Calculation

Electron analog implementation:

Electrons are used as the medium of transmission in his type of implementation mode. Computation devices are still the same as before.

Same Problems associated with electron analog implementation.

 Digital

Implementation:

Transmission: Digital signals are far less sensitive to noise. Calculation: The computational devices are digital computers.

1. PC Control: Good for small processes such as laboratory prototype or pilot plants, where the number of control loops is relatively small

Display

Main Computer

Final control element

PROCESS

Data acquisition

2.Programmable Logic Controller

The

class of control systems which can be programmed to execute plant shutdown and / or interlock /sequence logics to the specified safety integrity levels. It uses a programmable memory to store instructions and specific functions.

Introduced in the late 1960s Developed to offer the same functionality as the existing relay logic systems Programmable, reusable and reliable

Could withstand a harsh industrial environment They had no hard drive, they had battery backup Could start in seconds Used Ladder Logic for programming

POWER SUPPLY
Provides the voltage needed to run the primary PLC components I/O MODULES Provides signal conversion and isolation between the internal logic-level signals inside the PLC and the fields high level signal. PROCESSOR Provides intelligence to command and govern the activities of the entire PLC systems. PROGRAMMING DEVICE used to enter the desired program that will determine the sequence of operation and control of process equipment or driven machine.
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Advantages of a PLC Control System

Eliminates much of the hard wiring that was associated with conventional relay control circuits. Increased Reliability: Once a program has been written and tested it can be downloaded to other PLCs. More Flexibility: Original equipment manufacturers (OEMs) can provide system updates for a process by simply sending out a new program.

Advantages of a PLC Control System

Lower Costs: Originally PLCs were designed to replace relay control logic. The cost savings using PLCs have been so significant that relay control is becoming obsolete, except for power applications. Communications Capability: A PLC can communicate with other controllers or computer equipment.

Advantages of a PLC Control System

Faster Response Time: PLCs operate in real-time which means that an event taking place in the field will result in an operation or output taking place. Easier To Troubleshoot: PLCs have resident diagnostic and override functions allowing users to easily trace and correct software and hardware problems.

Leading Brands Of PLC

AMERICAN 1. 2. 3. 4. 5. 1. 2. 3. 4. 1. 2. 3. 4. Allen Bradley Gould Modicon Texas Instruments General Electric Westinghouse Siemens Klockner & Mouller Festo Telemechanique Toshiba Omron Fanuc Mitsubishi

EUROPEAN

JAPANESE

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The new PLC standard IEC 61131

Since 1992, an international standard now exists for programmable logic controllers and associated peripheral devices (programming and diagnostic tools, testing equipment, man-to-machine interfaces etc.). The new IEC 61131 standard consists of five parts: Part 1: General information Part 2: Equipment requirements and tests Part 3: Programming languages Part 4: User guidelines (in preparation with IEC) Part 5: Messaging service specification (in preparation with IEC)

3. Distributed Control System:

Control system comprising of geographically and functionally distributed hardware and software, which not only performs the assigned control and monitoring function but also provides information, data from many subsystems to other subsystems over dedicated communication network.

A Control system which is functionally as well as geographically distributed.

Advantage of DCS over centralized: 1.System overloading reduced 2.Back-up/Redundancy available 3.More Computing power(parallel processing) 4.Improved reliability as plant can survive failure of one processor

CONTROLLER:
Control algorithms are configured by engineers through the engineering stations and executed in the controller. Controllers can be implemented in simplex or redundant configurations per user requirement.

I/O Module:
I/O modules shall communicate with processor modules serially either through back-plane or through I/O communication network. I/O network shall always be redundant.

I/O MODULE

 AI

(Analog Input Conventional/ Smart / HART / Foundation Fieldbus), AO (Analog output Conventional /Smart / HART/Foundation Fieldbus), DI (Digital Input), DO (Digital Output).

 Communication

Modules : Controls the communication of the control network and information network. Power Supply Modules Provides the power supply to various modules as required. Engineering console: Main Engineer interface device through which the system configuration and maintenance engineer can interface with the system.

Each station supports control, monitoring, and configuration of the entire system. This allows a uniform graphical interface for all plant operations.A set of standard system graphical displays are supplied with the system,including: Single point display for monitoring and control Real-time and historical trend display. Alarm status and history display.

 History

Module

-Like the harddisk of PCs - Store the configurations of the DCS as well as the configurations of all the points in the plant - Store the graphic files that are shown in the console and in most systems these days they are able to store some plant operating data
Data

Historian

- Software that are dedicated to store process variables, set points and output values - They are usually of higher scanning rates than that available in the history module.

- Group displays - Overview displays - Detail displays - Graphic displays - Trend displays

Shows the operating parameters of group of control loops such as four, eight, twelve, or sixteen control loops, arranged in rows so that they look like the faces of instruments on an instrument panel.

Detail Displays
- Specific to a single loop or control function - Includes additional information defining constants, limits, and other characteristics of the function

Graphic Displays
Graphic display capability allows a picture to be drawn on the screen so that the operator can look at a portion of the process more realistically than by watching a row of bar graphs

Trend Displays
- Trend displays are the distributed control system equivalents of chart records. - Shows change in process value that have taken place over a period of time

The working of DCS can be divided into two parts .

1. Hardware Flow

The flow of signal passes from sensors/ transmitters to a local field junction box. From field junction box through a multi core cable it goes to the main junction box. Again from main junction box it comes to a marshalling cabinet where the wires enter into the control panel. After signal entering the panel, the signal wire goes into the input card connected to the controller. Controller processes the data according to the logic created and gives output to the Final Control Element through output cards, following the same route.

2. Software
There is a scan cycle which needs to be completed for the execution of an instruction needed to control the process.The following steps occur for each scan period: 1.The status of inputs from the process through the input card are checked. 2.Then the values are updated in the program and according to the logic prepared by the programmer output values are decided. 3.These outputs then go to the field through output cards. 4.The status is updated in the SCADA as well as the changes are stored for future reference in the historian. 5.Any alarms i.e. deviations in the process are there are also noted and stored.

Following functional requirements as a minimum should be met by DCS system:

Control Data Acquisition Alarming Logging and report generation Historical data storage Trending System diagnostics. System security

Access a large amount of current information from the data highway. Monitoring trends of past process conditions. Readily install new on-line measurements together with local computers. Alternate quickly among standard control strategies and readjust controller parameters in software. Digital DCS systems are more flexible. Control algorithms can be changed and control configuration can be modified without having rewiring the system.

Honeywell
Fisher-Rosemont Baily Foxboro Yokogawa

Siemens

Selecting the right technology and the right supplier can help a company respond quickly to changing market conditions minimize Total Cost of Ownership (TCO) over the life of your plant create a system which is easily maintainable/upgradeable for the longterm achieve its future goals and vision

 1.

What are you manufacturing, and how? 2. What is the value of the product being manufactured? and the cost of downtime? 3. What do you view as the "heart" of the system? 4. What does the operator need to be successful? 5. What system performance is required? 6. What degree of customization is required? 7. What are your engineering expectations?

Number of products manufactured: Single product or Multiple products Recipe parameters: Constant or Variable Procedures: Single procedure or Multiple (different) procedures Equipment utilization and arbitration: Fixed/none or Flexible/often Frequency of changes to formulas and recipes: Never or Often

Manufacturing or assembly of specific items.

Product is visible as it moves through the process.

Involves the combination and/or transformation of raw materials.

Often impossible to visually see the product as it moves through the process.

PLC

High-speed logic Regulatory/Analog control (such as motors) (loop) control Simple Batch control Complex Batch Control

DCS

2. What is the value of the product being manufactured and the cost of downtime?
Value of the individual component being manufactured is relatively low. The value of a batch can be very high.

PLC

Downtime mainly results in lost Downtime not only results in production. lost production, but can result in dangerous conditions. Downtime does not typically damage the process equipment. Downtime can result in process equipment damage (product hardens, etc.)

Return to steady state production after an outage is short and relatively straightforward

Return to steady state production after an unplanned outage can be long, expensive, and difficult

DCS

3. What do you view as the "heart" of the system?

Typically, the Typically, the heart of the system heart of the is the controller. system is the HMI

DCS

PLC

The operator's primary role is to handle exceptions.

The operators interaction is typically required to keep the process in its target performance range.

PLC

Exception-based alarming is Alarm management is key to key information for the operator. safe operation of the process and for responding effectively during plant upset conditions. Manufacturing might be able to Failure of the HMI could force run "lights-out. the shutdown of the process

DCS

Status information (On/Off, Run/Stop) is critical for the operator.

Faceplates and analog trends are critical to see what is happening to the process.

Fast logic scan (approx. 10ms) is required to perform motor or motion control. Redundancy may not be cost justified.

Control loops require deterministic scan execution at a speed of 100 to 500 ms. System redundancy is often required.

PLC

System can be taken offline to make configuration changes.

Analog Control: Simple PID only. Diagnostics to tell you when something is broken.

Online configuration changes often required.

Analog Control: Simple to advanced PID control up to Advanced Process Control. Failure of the HMI could force the shutdown of the process

DCS

High level programming languages are available for creating custom logic. Customized routines usually required .

Custom logic created from existing function blocks. Many algorithms (i.e. PID) are complex and do not vary among applications. Standard application libraries are expected (function blocks and faceplates).

Standard libraries considered nice features.

Provisions must be available to integrate functions products into an integrated architecture.

Entire system is expected to function as a complete solution.

DCS

PLC

Program/configure individual components, integrate later (bottom-up). Desire customizable platforms to build upon.

Up-front design of complete system before implementation begins (top-down).

System designed to be flexible. System designed to make it "easy" to engineer process applications. Solution is generic in nature, to Use of pre-defined, pre-tested be applied on a wide variety of functions saves time. applications.
Use ladder logic to configure application. Use function block diagram to configuration application.

DCS

PLC

Looking for significant "outof-the-box" functionality.