Chapter10 DCS FF July 08 v3 1 Oct
-
Upload
ggleichgesinnten -
Category
Documents
-
view
220 -
download
0
Transcript of Chapter10 DCS FF July 08 v3 1 Oct
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 1/58
Topic 3Topic 3 -- 11EEB5223/EAB4223 Industrial Automation & Control Systems
EAB4223/EEB5223EAB4223/EEB5223
Industrial Automation and Control SystemIndustrial Automation and Control System
• PART 3:DCS and Fieldbus
Assoc Prof Dr Nordin SaadDepartment of Electrical & Electronics EngineeringUniversiti Teknologi PETRONAS23.03.005Email: [email protected]: 05-368 7835
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 2/58
Topic 3Topic 3 -- 22EEB5223/EAB4223 Industrial Automation & Control Systems
This course cover topics related to measurements(PLTF) and automation in the process industry. Theseinclude a study on industrial sensors and actuators, industrialcontrollers such as computer-based control, PLC, DCS and FF.
This course cover topics related to measurements(PLTF) and automation in the process industry. Theseinclude a study on industrial sensors and actuators, industrialcontrollers such as computer-based control, PLC, DCS and FF.
Synopsis
SynopsisSynopsis Learning Outcomes
Learning OutcomesLearning Outcomes
that students are expected to achieved aftersuccessfully completing the course
that students are expected to achieved aftersuccessfully completing the course
The learning outcomes related to Industrial instruments and Measurements
• Have knowledge andunderstanding of the variousprocess industry instruments,concept of measurements,calibration and configuration
requirements and their applications.• Be able to design and develop a
control loop consisting the processinstruments, based on a prescribedrequirement.
The learning outcomes related to Automation and the implementation of Programmable logic controller
• Have knowledge andunderstanding of the PLCarchitecture and its importance inautomation.
• Be able to develop a PLC programto perform sequential, and batchcontrol.
The learning outcomes related to DCS and Foundation Fieldbus use in process industries.
• Have knowledge andunderstanding of a DCS and itsuse in process industries, andthe features and architecture of aFoundation Fieldbus system, andits improvement over theconventional DCS.
This topic covers the key and base areas of automation in the process industries.
Process , Industrial Instr.& Meas.
Process , IndustrialProcess , Industrial
InstrInstr
.& Meas.
.& Meas.Automation
AutomationAutomation
DCS and Foundation Fieldbus
DCS and FoundationDCS and Foundation
FieldbusFieldbus
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 3/58
Topic 3Topic 3 -- 33EEB5223/EAB4223 Industrial Automation & Control Systems
CONTENTSCONTENTSq DCS• Overview of DCS (also SCADA)• DCS Definition and Configuration• DCS Architecture
• Advanced Control Developmentq Fieldbus• What is Fieldbus? Features• Why Fieldbus? Advantages• Fieldbus – Function blocks, DD, Configurations,
Implementations
• Issues: Device Descriptions, Interoperability
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 4/58
Topic 3Topic 3 -- 44EEB5223/EAB4223 Industrial Automation & Control Systems
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 5/58
Topic 3Topic 3 -- 55EEB5223/EAB4223 Industrial Automation & Control Systems
Block Diagram of Process Contro l Loop
Block diagram of a process control loop
FINAL CONTROLELEMENT
PROCESS
MEASUREMENT
CONTROL
+
-
SETPOINT
PV
SP
OPCONTROLLED
VARIABLEMANIPULATEDVARIABLE
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 6/58
Topic 3Topic 3 -- 66EEB5223/EAB4223 Industrial Automation & Control Systems
Principle of Controller
Block diagram of a controller
PIDCONTROLLEDVARIABLE PV
SETPOINT SP
A
MMANUALADJUSTMENT OP
A AUTO M MANUAL
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 7/58
Topic 3Topic 3 -- 77EEB5223/EAB4223 Industrial Automation & Control Systems
Analog vs Digital in Field Signals
Signal
Time
Signal
Time
Continous variableDiscrete signal with onlytwo possible values or
position
Analog Digital
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 8/58
Topic 3Topic 3 -- 88EEB5223/EAB4223 Industrial Automation & Control Systems
- Data Logging
Computer used to store data forreviewing the data.
Monitor
LT
CPU
Printer
PV
SP
OP
Process
Use of Computer in Process Control
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 9/58
Topic 3Topic 3 -- 99EEB5223/EAB4223 Industrial Automation & Control Systems
LT
CPU
Monitor
Printer
- Set Point /Super visory Cont rol
Set Point
Process Variable
Computer used to performadjustments of loop setpoints
besides keeping records of
process parameters. Thecomputer using specifiedequations, calculates the setpointbased on the measured variable
Output
Process
Use of Computer in Process Cont rol
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 10/58
Topic 3Topic 3 -- 1010EEB5223/EAB4223 Industrial Automation & Control Systems
LT
CPU
Monitor
Printer
PV1
PV2PV3PV4 Out4
Out3Out2
Out1
- Direct Digital/Centralized Control
The function of controllers weresuperseded by the computer. Acentral computer monitor and
control all the process variables.
PV OP
Controller
Process
Use of Computer in Process Control
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 11/58
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 12/58
Topic 3Topic 3 -- 1212EEB5223/EAB4223 Industrial Automation & Control Systems
History and Development of DCS:History and Development of DCS:
•• In the 1940s…In the 1940s…o Mechanical and pneumatic controllers for
controlling a few process variables: T,P,F.o Coordinated process unit control system was
not possible.o Conservatively for stability rather than
economic performance.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 13/58
Topic 3Topic 3 -- 1313EEB5223/EAB4223 Industrial Automation & Control Systems
History and Development of DCS:History and Development of DCS:
•• In the 1950s…In the 1950s…o Electronic controllers introduced.
o Centrally located in the control roomand wired into the measuring devicesand actuators in the plant
o Provide feedforward dynamic models.o Small pneumatic instruments were also
used.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 14/58
Topic 3Topic 3 -- 1414EEB5223/EAB4223 Industrial Automation & Control Systems
History and Development of DCS:History and Development of DCS:
•• In the 1960s…In the 1960s…o Process computers made their debut.o Assembly of distributed, mutually
independent and dedicated controllers.
Smaller instruments (electronic)
Digital computer
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 15/58
Topic 3Topic 3 -- 1515EEB5223/EAB4223 Industrial Automation & Control Systems
History and Development of DCSHistory and Development of DCS
These dedicated controllers/computers hadwider applications in:
• Decentralised (not distributed) control operation ofprocess plant
• Monitoring and control by local operators• Small plant automation• Partial plant automation• Automation in the laboratory, etc.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 16/58
Topic 3Topic 3 -- 1616EEB5223/EAB4223 Industrial Automation & Control Systems
History and Development of DCSHistory and Development of DCS•• In the 1970s…In the 1970s…o Introduction of analog system architecture, specialized
computer interface devices and computers with highercapacity and speed of processing
o A centralized control structure was introduced. Itcontained process control computer as its central.
Management Information System
OperatorInterfaceSystem
SupervisoryComputerInterface
ProgrammableLogic Controller
Interface
Controller andData
AcquisitionSystem
Foreign DeviceInterface
(Analyzer etc.)
CommunicationSystem
A general DCS component
•Distributedcontrol system
•CRToperation
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 17/58
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 18/58
Topic 3Topic 3 -- 1818EEB5223/EAB4223 Industrial Automation & Control Systems
Evolution Man-machineinterface
1900
MechanicalMechanicalinstrumentsinstruments
[Field operation][Field operation]
Mechanical +Mechanical +pneumaticpneumaticcontrollerscontrollers
[Signal[Signaltransmission]transmission]
Pneumatic +Pneumatic +electronicelectroniccontrollerscontrollers
[Signal[Signaltransmission]transmission]
Electronic +Electronic +processprocess
computerscomputers[Digital computer][Digital computer]
DistributedDistributedcontrol systemcontrol system[CRT Operation][CRT Operation]
1930’s 1940’s 1950’s 1960’s 1970’s - now
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 19/58
Topic 3Topic 3 -- 1919EEB5223/EAB4223 Industrial Automation & Control Systems
Industrial Control System Evolution
DISCRETE ANALOGDEVICES
MECHANCIAL
DIRECT PNEUMATIC
PNEUMATIC TRANSMISSION
ELECTRIC ANALOG CONTROL
RELAYS
ELECTRONIC LOGIC
PROGRAMMABLE LOGIC
DISCRETESWITCHIN G
DEVICES
CENTRALIZEDINTEGRATED
SYSTEM
DCS
DIRECT DIGITAL CONTROL
SUPERVISORY CONTROL
198019701960195019401930
DISCRETEANALOGDEVICES
DISCRETESWITCHING
DEVICES
CENTRALIZEDINTEGRATED
SYSTEM
1990 2000
FIELDBUS
Industrial Control System Evolution
• Timeline of computer control of industrial processes:Ø Ferranti Argus 200Ø MicroprocessorØ SCADA - (I/Os of 1000 or less)Ø Distributed Control System (DCS) - (I/Os of more than 1000)Ø Communication protocol -Fieldbus/Profibus
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 20/58
Topic 3Topic 3 -- 2020EEB5223/EAB4223 Industrial Automation & Control Systems
PROCESS CONTROLEVOLUTION
1975 1985 1995
R O
I
1975 1985 1995
Analog Control
DCS
R e
t u r n o n
I n v e s
t m e n
t
Another dramatic change is required tocreate an acceleration of value from thecurrent DCS offering .
RS3 by Rosemount
PROVOX by Fisher
IA by Foxboro
Open SystemArchitecture
TDC is Introduced by Honeywell
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 21/58
Topic 3Topic 3 -- 2121EEB5223/EAB4223 Industrial Automation & Control Systems
SCADA System
Screen/Display
Sof tware(Monitor,analysis,control)
Hardware(PLC or
commercia lhardware)
Plan t
Supervisorycontrol
Collectinformation
Transfer tocentral
computer
Indirect control:
• For monitoring and indirect control based on certain set-points.• Changes to a process would have to go through various levels
before being implemented – takes time and cannot be doneimmediately.
Indirect cont rol is its m ain limit at ion
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 22/58
Topic 3Topic 3 -- 2222EEB5223/EAB4223 Industrial Automation & Control Systems
SCADA SystemHost control functionsare restricted to basicoverriding orsupervisory levelintervention.
The SCADA systemallows operators tochange the set pointsfor CVs, and enablealarm conditions, suchas loss of flow andhigh temperature, tobe displayed andrecorded.
The feedback controlloop passes throughthe RTU or PLC, whilethe SCADA systemmonitors the overallperformance of theloop.
PLCs control theCVs of an
industrial process.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 23/58
Topic 3Topic 3 -- 2323EEB5223/EAB4223 Industrial Automation & Control Systems
Development of DCSDevelopment of DCS
The following essential functions wereconcentrated in the central computer:
Ø Process MonitoringØ Data AcquisitionØ Alarming and LoggingØ Data ProcessingØ Process Control
Centralized control
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 24/58
Topic 3Topic 3 -- 2424EEB5223/EAB4223 Industrial Automation & Control Systems
Development of DCSDevelopment of DCS
The main concerns and disadv ant ages of acent raliz ed syst em are:
o Reliability : Very depended on proper functioning of the
central computer. System breakdown results indisruption of production and complete shutdown -prove to be extremely expensive.
o Programming effort and cost : Tailored to theuniqueness of each process and its control system.
o Cost of a centralized computer process control system:Mainframe and large minicomputers are very expensive.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 25/58
Topic 3Topic 3 -- 2525EEB5223/EAB4223 Industrial Automation & Control Systems
Development of DCSDevelopment of DCS
This creat ed t he need of fut ure sy st emsdevelopment.
The system should be such that data should bestored where they have been created and wherethey will be needed. Similar principles hold forthe functions also. Only the data requiredfor”other purposes” within the automationsystem will be distributed.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 26/58
Topic 3Topic 3 -- 2626EEB5223/EAB4223 Industrial Automation & Control Systems
Development of DCSDevelopment of DCS
These lead to the following data and functionsrequirements:
• Local control and supervision of plant should be locatednext to the plant instrumentation.
• Processing of data for higher purposes (optimization, setpoint value calculation, etc.) should be allocated in centralcontrol room.
• Production planning and plant management should besituated closer to the relevant plant management staff.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 27/58
Topic 3Topic 3 -- 2727EEB5223/EAB4223 Industrial Automation & Control Systems
Development of DCSDevelopment of DCS
o Hierarchical automation system structure was introduced popularlyknown as Distributed Control System.
o The operators console in the control room, is connected through ashared communication facility to several distributed local controlunits.
Central ControlRoom (several
computers)
SharedCommunication
Facility
LocalProcessControlUnits
LocalProcessControl
Units
LocalProcessControlUnits
LocalProcessControlUnits
A Distributed Control System (DCS)
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 28/58
Topic 3Topic 3 -- 2828EEB5223/EAB4223 Industrial Automation & Control Systems
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 29/58
Topic 3Topic 3 -- 2929EEB5223/EAB4223 Industrial Automation & Control Systems
DCS Definition and ConfigurationDCS Definition and Configuration
The definition of DCS has changeddramatically over its history. The informationprocessing role of DCS has expanded fast, adding
Advanced Process Control, InformationAnalysis tools, Intelligent Systems andBusiness System Integration capabilities.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 30/58
Topic 3Topic 3 -- 3030EEB5223/EAB4223 Industrial Automation & Control Systems
DCS Definition and ConfigurationDCS Definition and Configuration
DCS has three (3) essential qualities:o DCS distributes its functions into smaller sets of
semi-autonomous subsystems covering specificprocess or geographic areas of the plant complex.The functions generally are:
• Process Analysis and Supervision• Data Collection• Process Control• Storage and Retrieval of Information• Presentation of Information and Reports
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 31/58
Topic 3Topic 3 -- 3131EEB5223/EAB4223 Industrial Automation & Control Systems
DCS Definition and ConfigurationDCS Definition and Configuration
DCS has three (3) essential qualities (cont…):o To automate the manufacturing process by integrating
advanced regulatory control logic and procedurallanguages with advanced application packages, expertsystems, including information to support suchmanufacturing enterprise application as:
Ø Production scheduling and dispatchingØ Preventive and predictive maintenance schedulingØ Information exchanges with business and logistics application
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 32/58
Topic 3Topic 3 -- 3232EEB5223/EAB4223 Industrial Automation & Control Systems
DCS Definition and ConfigurationDCS Definition and Configuration
DCS has three (3) essential qualities (cont…):o The third characteristic is the system aspect of the
DCS, which organizes information flow betweenthe constituent parts so as to have a single
automation system unifying the semi-autonomoussubsystems.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 33/58
Topic 3Topic 3 -- 3333EEB5223/EAB4223 Industrial Automation & Control Systems
Basic DCS function
Input Output
Primary & ControlElements
Monitoring InputControl LoopAlarms ( PV & SP )Trend , Log & ReportExecute SpecialProgrammed Logic.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 34/58
Topic 3Topic 3 -- 3434EEB5223/EAB4223 Industrial Automation & Control Systems
Conventional Controller Vs DCS
Conventional Vs DCS
AUTO
MAN
OC
0
200 ton/hr
0 100
AI AO
HPM/APM
100%
75%
50%
25%
0%
SP
PV
OP%
FIC21765KLB/HR
FLOW21
42.9
31.3
52.8CAS
IP
IP
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 35/58
Topic 3Topic 3 -- 3535EEB5223/EAB4223 Industrial Automation & Control Systems
DCS Definition and ConfigurationDCS Definition and ConfigurationIn DCS, the functions of control system are distributed into
different work areas of a process plant:o Central control room : Operator operation and monitoring
functionso Distributed control stations : Distributed at various plant
locations throughout the process facility, perform thefollowing functions at each location-ü Generation of input signals based on analog
variables and discrete inputsü Generation of output signals to control the actuators
to change the process conditions.o Communication system interfacing – the information is
communicated between the central control room andremote control stations.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 36/58
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 37/58
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 38/58
Topic 3Topic 3 -- 3838EEB5223/EAB4223 Industrial Automation & Control Systems
DCS System ConfigurationDCS System Configuration
o DCS Configuration comprises of (cont…):
o Comm unication sy stem – Interconnects various systems over whichthey can communicate with each other to meet all functionrequirements. Performs the function of transmitting and receiving ofdigital information from all the systems. consists of one or moreoperator consoles for monitoring and controlling process parametersand performing other process related functions.
o Management Information System : Interconnects various othersystems to extract plant-wide management information withoutaffecting or disturbing plant operations.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 39/58
Topic 3Topic 3 -- 3939EEB5223/EAB4223 Industrial Automation & Control Systems
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 40/58
Topic 3Topic 3 -- 4040EEB5223/EAB4223 Industrial Automation & Control Systems
DCS ArchitectureDCS Architecture
A physical arrangement of the hardware modules and theselection of software options to satisfy system requirements.
The complexity of a DCS can vary. In the simplest form it
could only be a CRT display and keyboard in the controlroom and a local control unit in the process area connected bycommunication cables.
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 41/58
Topic 3Topic 3 -- 4141EEB5223/EAB4223 Industrial Automation & Control Systems
OPERATOROperation and
monitoringfunctions
OTHERSYSTEMS
Communicationbetween other
systems
ENGINEERSystem
configuration,System
maintenance
Display andoperationfunctions
Man-machinedata-base
Gate-way
Control data-base
Controlfunction
Control data-base
Controlfunction
Process Process
Control Station
Communication system
OperatorStation
Process Interface
Man-machine Interface
E n g
i n e e r i n g
I n t e r f a c e
I n t e r f a c e
t o o
t h e r
s y s
t e m s
Various configurations are possible
LCU- Local Control UnitUsually dedicated to specificunit operations of a process.
If CPU or communicationsystems fails, LCU can keepcontrols of the plant.
LCU controller moduleinterfaces with fieldinstruments
CPU – CentralProcessing UnitAllows DAQ and controlfunctions to be performed viaLCUs
DCS ArchitectureDCS Architecture
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 42/58
Topic 3Topic 3 -- 4242EEB5223/EAB4223 Industrial Automation & Control Systems
Single control loop diagram
I/O SLOT NO 07
WTTV61
APM 1
01NETWORK NO
SLOT NO
03
02
01
02
FTA-ID
MU-TAOX02
J21
+
-
1
2
FTA-ID
2
1 MU-TAIH02
01
01
WTT161
APM 1
01NETWORK NO
NODE NO
MODULE NO
SLOT NOI/O SLOT NO
DCS TAG NO
WTTIC61
REGCLNIM
NODE NO
SLOT NO
CTLACN-REVERSE
03
01
0106
NODE NO
MODULE NO
TB2
TB3
01 TB1
TB1
03
04
3
4 4
3
WT301
WT302
WT301
WT302
TE61+1A1
TE61-1A1
WT307
WT308
WT307
WT308
TCV61+1A0
TCV61-1A0
J22
TE61
TCV61
FIELD JUNCTION BOX TERMINAL PT FTA(DCSCABINET) DCS(CONSOLE)
Control loop diagram of DCS
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 43/58
Topic 3Topic 3 -- 4343EEB5223/EAB4223 Industrial Automation & Control Systems
- Point Trend Display with Four Trace
0.000.000.000.00
EU Low
150.00150.00100.00200.00
EU High % High
100.00
% Low0.00
R-AXIS
AddTrace
ScrollBack
ScrollFwrd
TIC 21741PV
DEG. C73.99
TIC 21741OP
DEG. C28.00
20 MIN HM HM HM
Parameter :EU Desc :
RT Value :
TIC 21741SP
DEG. C71.00
FIC 21741PV
KLB/HR39.00
Function of DCS
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 44/58
Topic 3Topic 3 -- 4444EEB5223/EAB4223 Industrial Automation & Control Systems
0.000.000.00
EU Low
150.00150.00100.00
EU High % High
100.00
% Low0.00
R-AXIS
AddTrace
ScrollBack
ScrollFwrd
TIC 21741PV
DEG. C73.99
TIC 21741OP
DEG. C28.00
20 MIN HM HM HM
Parameter :EU Desc :
RT Value :
TIC 21741SP
DEG. C71.00
Time Base
- Real Time Control
Time Base1 = 1 min2 = 2 min3 = 5 min4 = 10 min5 = 20 min6 = 1 hr7 = 2 hr8 = 8 hr9 = 16 hr10 = 24 hr11 = 48 hr12 = 96 hr13 = hourly14 = shift15 = daily16 = mnthly17 = user
Enter Time Base (1 - 17)
Function of DCS
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 45/58
Topic 3Topic 3 -- 4545EEB5223/EAB4223 Industrial Automation & Control Systems
DCS General Architecture
LT
Printer
ControlStation 1
ControlStation 2
ControlStation 3
DataHighway
User
Interface
Comm.ModuleI/O Module
ControllerModule
I/O Bus
Link
1
2
3
6
5
4
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 46/58
Topic 3Topic 3 -- 4646EEB5223/EAB4223 Industrial Automation & Control Systems
Example of DCS Architecture-Yokogawa DCS Architecture
PF(K)SB's DCS system is segregated into 4domains as shown below :
Domain 1
Amonia andMethanol
Plant
Domain 2Urea,Urea
Granulation andformaldehyde
plant
Domain 3
UtilitySection
Domain 4
Urea ExportTerminal(located at
Butterworth)
PF(K)SB
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 47/58
Topic 3Topic 3 -- 4747EEB5223/EAB4223 Industrial Automation & Control Systems
GUS1
GUS2
GUS3
GUS4
GUS5
GUS6
GUS7
GUS8
GUS9
CCU
Utilities PlantManager'sOffice
Amonia Urea
Area 1 - Amonia Area 2 - Urea Area 3 -Utilities
UnitA1
UnitA2
UnitA3
UnitU1
UnitU2
UnitU3
UnitB1
UnitB2
Area 4
Point, Unit, Area and USRelationship
TT 21242TCV 21242FT 21442
FCV 21442
Points
Unit
Area
Terminal
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 48/58
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 49/58
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 50/58
Topic 3Topic 3 -- 5050EEB5223/EAB4223 Industrial Automation & Control Systems
ü Located in central control stationü Console deskü Keyboard – special functions for graphic and other
displays, programming and command.ü Displays on CRT – group displays showing a group of
control loops, in instrument panel like appearance.
§ Operator Interface :
DCS ArchitectureDCS Architecture
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 51/58
Topic 3Topic 3 -- 5151EEB5223/EAB4223 Industrial Automation & Control Systems
• Analog input modules:o 4 – 20 mA DC
o 1 – 5 volt DC
o Some DCS accept low level input fromthermocouples/RTDs.
• Discrete input modules (sense switch inputs):
o 24 volt DC, 48 volt DC
• Analog output modules:
o 4 – 20 mA DC
• Digital inputs and outputs modules:
o 24 volt DC, or 120 volt AC
§ Input/Output Modules :
DCS ArchitectureDCS Architecture
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 52/58
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 53/58
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 54/58
Topic 3Topic 3 -- 5454EEB5223/EAB4223 Industrial Automation & Control Systems
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 55/58
Topic 3Topic 3 -- 5555EEB5223/EAB4223 Industrial Automation & Control Systems
Advanced Control DevelopmentAdvanced Control Development§ Hierarchy of a DCS
Corporate Information System
Process Model and Optimization
Supervisory Control
Regulatory Control
Measuring Devices
PROCESS
Level 4
Level 3
Level 2
Level 1
Level 0
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 56/58
Topic 3Topic 3 -- 5656EEB5223/EAB4223 Industrial Automation & Control Systems
The system when specified along with a supervisorycomputer, could also meet the following requirements inaddition the basic process control.
§ Advanced Control§
Management information system and interfaceto Enterprise resource planning (ERP).
Note : ERP creates an enterprise-wide transactionbackbone and integrate manufacturing financial,
and other systems.
Advanced Control DevelopmentAdvanced Control Development
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 57/58
Topic 3Topic 3 -- 5757EEB5223/EAB4223 Industrial Automation & Control Systems
Advanced Process Control
DCSs and other types of digital control systems areenabling technologies. They provide the infrastructurethat allows substantial improvements in plantoperations.
To realize these improvements, the multivariablepredictive control (MPC), and other model-basedadvanced control technologies, and advancedcontrollers are incorporated.
Advanced Control DevelopmentAdvanced Control Development
8/8/2019 Chapter10 DCS FF July 08 v3 1 Oct
http://slidepdf.com/reader/full/chapter10-dcs-ff-july-08-v3-1-oct 58/58
T i 3 58
Management Information System
and Interface to ERPWhenever information network is specified, the system shallmeet any or all of the following requirements:o Centralised information system
o Statistical process control/statistical quality controlo Plant optimisation
o Plant planning and scheduling
o Computer integrated manufacturing (CIM) – to achieve functionslike production and preventive maintenance, scheduling and plantwide co-ordination, etc.
Advanced Control DevelopmentAdvanced Control Development