This workshop will cover the practical applications of the modern Distributed Control System (DCS). Whilst all control systems are distributed to a certain extent today and there is a definite merging of the concepts of a DCS, Programmable Logic Controller (PLC) and SCADA and despite the rapid growth in the use of PLC’s and SCADA systems, some of the advantages of a DCS can still be said to be Integrity and Engineering time.
Abnormal Situation Management and Intelligent Alarm Management is a very important DCS issue that provides significant advantages over PLC and SCADA systems.
Few DCSs do justice to the process in terms of controlling for superior performance – most of them merely do the basics and leave the rest to the operators. Operators tend to operate within their comfort zone; they don’t drive the process “like Vettel drives his Renault”. If more than one adverse condition developed at the same time and the system is too basic to act protectively, the operator would probably not be able to react adequately and risk a major deviation.
Not only is the process control functionality normally underdeveloped but on-line process and control system performance evaluation is rarely seen and alarm management is often badly done. Operators consequently have little feedback on their own performance and exceptional adverse conditions are often not handled as well as they should be. This workshop gives suggestions on dealing with these issues.
The losses in process performance due to the inadequately developed control functionality and the operator’s utilisation of the system are invisible in the conventional plant and process performance evaluation and reporting system; that is why it is so hard to make the case for eliminating these losses. Accounting for the invisible losses due to inferior control is not a simple matter, technically and managerially; so it is rarely attempted. A few suggestions are given in dealing with this.
Why are DCS generally so underutilised? Often because the vendor minimises the applications software development costs to be sure of winning the job, or because he does not know enough about the process or if it is a green-field situation, enough could not be known at commissioning time but no allowance was made to add the missing functionality during the ramp-up phase. Often the client does not have the technical skills in-house to realise the desired functionality is missing or to adequately specify the desired functionality.
This workshop examines all these issues and gives suggestions in dealing with them and whilst not being by any means exhaustive provides an excellent starting point for you in working with a DCS.
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A CASE STUDY ON CERAMIC INDUSTRY OF BANGLADESH.pptx
Practical Distributed Control Systems (DCS) for Engineers and Technicians
1. Practical Distributed Control Systems
(DCS) for Engineers and technicians
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2. Learning Objectives
In this chapter we will learn the following:
• Introduction to computer based measurement and control systems
• Role of computers in process control
• Basic components of computer based measurement and control system
• Architecture of computer based control
• Human Machine Interface (HMI)
• Hardware of computer based process control system
• Interfacing computer system with process
• Economics of computer based system for industrial application
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3. Use of computer for measurement and control (in real-time)
application were conceived as early as 1950
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4. Digital computer application in process
industry may be:
Passive or Active
• Passive application involves only acquisition
of process data (data acquisition / data
logging)
• Active application involves acquisition and
manipulation of data and uses it for (real
time) process control.
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5. Set-
Point
+v
Digital computer used for process control; use of ADC and DAC for
computer to Input and output matching is necessary
Computer System
Controller Eq.
(Digital
Algorithm)
Digital -to -
Analog
Converter
(DAC)
e u u(t)
Analog -to -
Digital
Converter
(ADC)
Final
Control
Element
(Control
Valve)
Process
u(t)
y(t)
Controlled
Variable
Sensor
(Measuring Element)
Measured
Variable
_
(a) Schematic Diagram
Digital Computer
Set-
Point
+
v(t)
Digital
Algorithm
e u(t)
Hold Device Process
u(t)
y(t)
_
(b) Block Diagram
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6. Control of hot air blower – system interfaced with digital
computer for control purpose
COMPUTER
Digital
Input ADC DAC Digital Output
Air Inlet
Opened
Amplifier
Heater
Control
Direction On/Off
Reversible
Motor
Control
Air Inlet
Position
Fully
Close
d
Fully
Open
Variabl
e Air
Inlet
Air Flow
Air Inlet
Closed
Air Inlet
Position
Sensor
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7. Centralized computer based process control system –
Large computer system with huge space and power consuming type magnetic
core memory,
Wired-in arithmetic and logical functions (gate logics)
Expensive due to high cost of core memory and additional electronics used in
the system.
Expensive communication system
Single computer system used primarily to justify high cost; popularly known as
central or mainframe computer.
Had high electrical noise problems
Sudden computer stoppages led to complete stoppage of plant/process
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8. Tasks of computer control system
• Monitoring large number of variables operating under a wide
range of process dynamics.
• The computer based system develop large number of complex
functions which work on a large number of widely scattered
actuators of various
• These are based on multiple inputs to the computer as process
parameters.
• In conclusion - to meet the production demands while
ensuring the quality of the products and safety of the plant’s
resources
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9. Task listing of computer based control
system
LELEV 4; Management Level
LEVEL 3; Plant Level
LEVEL 2; Supervisory Level
LEVEL 1; Control Level
LEVEL 0; Field Level
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10. Human Machine Interface (HMI)
Plant mimic diagram of plant/process overview
Alarm overview presenting information on the alarm status of
large areas of the plant
Multiple area displays presenting information on the control
system
Loop displays giving extensive information on the details of a
particular control loop of group of control loops
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11. HMI components
Display unit (CRT)
Keyboard
Input unit
Printing unit
Control Panel/desks, mimic
board/panel
Recorders
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12. Hardware for Computer based process
control system
• A general purpose digital computer with adequate
hardware provisions can be used as an industrial process
(real-time) computer control.
• Should have additional features like ability to
communicate efficiently and effectively with plant and
operating personnel
• Should also be capable of rapid execution of tasks
(algorithms) for real time control actions.
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13. Storage
Used to store data and instructions (programs).
Main storage or immediate access of storage (IAS)
Auxiliary or secondary memory storage
Cache memory
Picture of High Speed Random Access
Memory (RAM) used as main Memory
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14. The concept of cache memory
L1 Cache; built into
chip
L2 Cache; on SRAM
memory bank
Local bus
Local bus
(RAM)
Main Memory
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15. The input/output (I/O) interface:
Sub-system through which the CPU communicates
with the outside world
Devices like Human Machine Interface (HMI) for
communication between the CPU and displays and the
CPU and other peripheral devices such as printers,
external storage, keyboards, mouse
One of the most complex areas of a computer system
because of the wide variation in the rate of data transfer
and wide variety of devices which have to be
connected
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16. The I/O devices of process control
computers are divided into three types:
Operator IO
Process IO
Computer IO
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17. Schematic diagram showing
interfaces of computers for process
control applications system
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18. Bus Interface:
an electronic pathway (media) in computer based system that provides a
communication path for data to flow between the CPU and its memory and
peripherals and amongst the CPUs connected to the computer system
Diagram showing interface (communication) through Bus Interface
19. Following are the common expansion buses which were
introduced with IBM - compatible PCs
(personal computers):
S-100 bus
ISA (Industry Standard Architecture) bus
ISA-AT (Advanced Technology) bus
MCA (micro-channel Architecture) bus
EISA (Extended Industry Standard Architecture) bus
NU-bus
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20. Interfacing computer system with process:
• Wide variety of instruments and actuators (sensors/ transducers)
are connected to process or plant for measurement and control of
process parameters like temperature, flow, pressure, level, speed,
etc.
• The inputs to and output from computer may be:
Analog Quantities
Digital Quantities
Pulses or pulse rates
Telemetry
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21. Interface cards which have been developed and added to
the computer system to connect to different
measurements inputs of process parameters:
Analog interfaces
Digital interfaces
Pulse interfaces
Real-time clock
Standard (bus) interfaces
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22. Analog interfaces
Analog-to-digital converter (ADC)
Digital -to- analog converter (DAC)
Multiplexing devices
MODEM
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23. Analog-to-digital converter (ADC)
Binary Output Code
Fraction of Full
Scale
An 8-level (3-
bit) ADC
coding scheme
Normalized Analog Input Voltage
ADC Code
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24. LSB
Digital-to-Analog converter (DAC)
An 8-bit Digital to Analog Converter
(DAC) circuit using R-2R network
Buffer
Stage
88--bbiitt DDAACC
D7 D6 D5 D4 D3 D2 D1 D0
MSB Buffer
Stage
V1V1
V2 V2
Functional diagram of
an 8-bit Digital to
Analog Converter (DAC)
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25. Plant or Process
to be controlled
AAnnaalologg S Seennssoorsrs
AAnnaalologg S Seennssoorsrs
AADDCC
AADDCC
Diagram shows a typical application of ADC and DAC used for
interfacing analog signals to a digital computer controlled process Plant or Process
to be controlled
Digital
Computer
Digital
Computer
AAnnaalologg S Seennssoorsrs
AAnnaalologg A Acctutuaatotorr
AAnnaalologg A Acctutuaatotorr DDAACC
AAnnaalologg A Acctutuaatotorr
AADDCC
DDAACC
DDAACC
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26. Multiplexing (MUX)
• The process of sending multiple signals or streams of
information on a carrier at the same time in the form of a
single, complex signal
• Three different methods of multiplexing used for industrial
application:
Space Division Multiplexing
Frequency Division Multiplexing
Time Division Multiplexing
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27. Space Division Multiplexing (SDM)
• Method of providing multiple fixed bandwidth channels by multiple
physical paths (i.e., pairs of wires or optical fibers).
• AS an example, an SDM may use 25-pair cable to carry the
information of 25 individual sensors from the field premises to one
the local control station of the plant
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28. Frequency Division Multiplexing (FDM)
The higher bandwidth channel is divided into multiple individual
smaller bandwidth channels. Signals on these channels are transmitted
at the same time but at different carrier frequencies
FDM, with three signals to three users sharing the same bandwidth
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29. Time Division Multiplexing (TDM)
• Method of putting multiple data streams in a single signal by separating the
signal into many segments, each having a very short duration. Each individual
data stream is reassembled at the receiving end based on the timing.
CH1
CH2
CH3
CH1
CH2
CH3
Multiplexer
Demultiplexer
Multiplexer
Demultiplexer
T1 – Time Slice 1
T2 – Time Slice 2
Example of TDM showing three channels multiplexed / demultiplexed and
transmitted / received
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30. MODEM
• Device that transmits data between computers, workstations and
other peripheral devices; interconnected by means of
conventional communication lines supporting analog
transmission
Schematic diagram of modems connecting two remotely placed
computers via conventional telephone network.
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31. DO YOU WANT TO KNOW MORE?
If you are interested in further training or information,
please visit:
http://idc-online.com/slideshare
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