Distributed Control System

DEVLOPED AT RELIANCE INDUSTRIES

Prepared by : -
Chirag Chavda
Haresh Patel
Evolution of discrete control
(relays)
 More recently relays has been used for control and
early electrical control was based on relays.

 These relays allow power to be switched on and off

without a mechanical switch.

 It is common to use relays to make simple logical

control decisions.

 Modern control systems still include

relays, but these are rarely used for
logic. A relay is a simple device that
uses a magnetic field to control a
switch.
 Contd..
 When a voltage is applied
to the input coil, the
resulting current
creates a magnetic field.
The magnetic field pulls
a metal switch (or reed) towards
it and the contacts touch,
closing the switch. The contact
that closes when
the coil is energized is called
normally open. The normally closed
contacts touch when the input coil
is not energized. When the input coil
is not energized the normally closed
contacts will be closed (conducting).
 What is Relay ?
 A relay is a simple device that uses magnetic field
to control a switch.
 In the fig.1 we see a 4 - pin relay. Relays have two
circuits: A control circuit (shown in GREEN) and a
load circuit (shown in RED). The control circuit has
a small control coil while the load circuit has a
switch. The coil controls the operation of the
switch. Fig, 1
 Current flowing through the control circuit coil (pins
1 and 3) creates a small magnetic field which
causes the switch to close, pins 2 and 4 as in fig.2.
The switch, which is part of the load circuit, is used
to control an electrical circuit that may connect to it.
Current now flows through pins 2 and 4 shown in
RED, when the relay is energized.

Fig, 2
 Contd..
ACTUAL RELAY DESIGN
Current flows through the
control coil, which is
wrapped around an iron
core. The iron core
intensifies the magnetic
field. The magnetic field
attracts the upper contact
arm and pulls it down,
closing the contacts and
allowing power from the
power source to go to the
load.
 Contd..

INSTRUMENT

TASK 1 TASK 2 TASK 3

(RELAY 1) (RELAY 2) (RELAY 3)
PLC evolution
 PLC was developed keeping the limitations
of the relay based control.
 In the late 1970s with the introduction of µp
the basic capabilities of PLC were greatly
expanded and improved. They were able to
perform sophisticated math and data
manipulation functions, which greatly
increased the use of programmable
controllers in more complex control
applications.
PLC Defined
 The National Electrical Manufacturers
Association (NEMA), USA, defines
programmable controller as a digital
electronic apparatus with a programmable
memory for storing instructions to
implement specific functions, such as logic,
sequencing, timing, counting and
arithmetic, to control machines and
processes.
Advantages of PLC
 Smaller physical size than hard-wire
solutions.
 Cost effective for controlling complex
systems.
 Easier and faster to make changes.
 PLCs have integrated diagnostics and
override functions.
 Diagnostics are centrally available.
 Applications can be immediately
documented.
Contd..
 Applications can be duplicated faster and less
expensively.
 Computational abilities allow more
sophisticated control.
 Trouble shooting aids make programming
easier and reduce downtime.
 Reliable components make these likely to
operate for years before failure.
 Ability to communicate with computer
Application
 Sequence control, timing, counting, data
calculation
 Batch or continuous process control.
 Open loop or feedback process control,
process data acquisition and display.
 Precise motion / position control.
 Safety and Interlocks
 Alarm handling
 Sequence Of Events (SOE)
 Components of PLC Systems
INPUTS POWER
I/O SYSTEM SUPPLY
OUTPUTS

PROCESSOR

PROGRAMMING MEMORY
DEVICE
 How PLC’s Work ?

All PLC’s contain a Central Processing Unit (CPU), Memory, Power supply,
Input / Output modules and programming device.
 PLC Operation

A PLC works by continually scanning a program. We can think of this scan

cycle as consisting of 3 important steps. There are typically more than 3 but we
can focus on the important parts and not worry about the others. Typically the
others are checking the system and updating the current internal counter and
timer values.

Step 1-CHECK INPUT STATUS-First the PLC takes a look at each input to
determine if it is on or off. In other words, is the sensor connected to the first
input on? How about the second input? How about the third... It records this
data into its memory to be used during the next step.
Contd..
Step 2-EXECUTE PROGRAM-Next the PLC executes your program one
instruction at a time. Maybe your program said that if the first input was on
then it should turn on the first output. Since it already knows which inputs
are on/off from the previous step it will be able to decide whether the first
output should be turned on based on the state of the first input. It will store
the execution results for use later during the next step.
Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the status of the
outputs. It updates the outputs based on which inputs were on during the
first step and the results of executing your program during the second step.
Based on the example in step 2 it would now turn on the first output
because the first input was on and your program said to turn on the first
output when this condition is true.
 After the third step the PLC goes back to step one and repeats the steps
continuously. One scan time is defined as the time it takes to execute the 3
steps listed above.
 A Level Application

Let's consider the following application:

We are controlling lubricating oil being dispensed from a tank. This is possible
by using two sensors. We put one near the bottom and one near the top, as
shown in the picture.
Here, we want the fill motor to pump lubricating oil into the tank until the high
level sensor turns on. At that point we want to turn off the motor until the level
falls below the low level sensor. Then we should turn on the fill motor and
repeat the process.
 A Level Application

•Here we have a need for 3 I/O (i.e. Inputs/Outputs). 2 are inputs (the sensors)
and 1 is an output (the fill motor). Both of our inputs will be NC (normally
closed) level sensors. When they are NOT immersed in liquid they will be ON.
When they are immersed in liquid they will be OFF.
•We will give each input and output device an address. This lets the plc know
where they are physically connected. The addresses are shown in the following
tables:

Inputs Address Output Address Internal Utility Relay

Low 0000 Motor 0500 1000
High 0001
 A Level Application
Below is what the ladder diagram will actually look like. Notice that we
are using an internal utility relay in this example. You can use the
contacts of these relays as many times as required. Here they are used
twice to simulate a relay with 2 sets of contacts. Remember, these relays
DO NOT physically exist in the plc but rather they are bits in a register
that you can use to SIMULATE a relay.
Ladder Diagram (LAD)
 Scan time
Start cycle
Output scan Input Scan

Star output Start program

scan scan

Control program
scan
The input and output scans are normally very short relative to the time
required for the program scan
 Contd…..
1000 RELAYS=1 PLC

INSTRUMENT
(PLC)

TASK 1 TASK 2 TASK 3

(RELAY 1) (RELAY 2) (RELAY 3)
Triconex PLC
PLCs in the Market
 Triconex
 Allen Bradley
 Siemens
 Hitachi
 GE Fanuc
 Hima-Sella
 Modicon
 Mitsubishi
DCS
 CENTUM XL DCS
 BENEFITS - DCS
Information is compressed into area that the eye can scan without head
movement.
If economy permits, 2 to 3 CRTs are recommended.
One for overview display.
One for current interest group or graphics display.
One for alarm summary display.
More concentration of centralized information.
Ease of accessing display information through keyboard.
Direct overview of entire process.
Ability to anticipate incipient upsets.
Improved operator performance
Higher Degree of hardware standardization.
Greater Controllability of Process Variables.
 WHY DISTRIBUTED
CONTROL?
 MANAGEMENT
 Cost Reduction of Control Installation
 By Reducing Number of Wires for signal transmission.
 Inbuilt Algorithms in place of signal conditioning devices.
 Less No. of Panels.
 Panel Space Saving.
 Control Room Design.
 Cost of Heating, Ventilation, air conditioning.
 Cost of Future Expansion – Scalability of DCS Motor
Starters
 Servo motors
Contd..
CENTUM XL DCS
 HF BUS

EOPS EOPC

Access Control : Token Passing

Trans. Speed : 1 Mbps HF
Trans. Distance : 1 Km to 20km
Media : Coaxial/Optical Fibre
 STATION CAPACITY

Feedback Insts 255 Timers 511

Control Loops 80 Preset
Compu Expression 255 Counters
BSI 32 Code Inputs
Switch Instruments 255 Code Outputs
Valve o/p Monitoring 255 Annunciator 255
message
Sequence Tables 200
Relational Exp 255
Internal Switches 2048
Sequence 255
Contact Inputs 512
Mess
Contact Outputs 512
FCS Station display
STATION
ENGINEERING •SYSTEM GENERATION
ON STAND-ALONE
STATION
•OPERATOR STATION
BUILDER
MOUSE DRIVEN
ISA SYMBOLS
•CONTROL STATION
BUILDER
LOOP DIAG

•SELF DOCUMENTATION

•MULTI-WINDOW ENGS
 * 1 Second display update rate for operator
console display * Touch panel
* Basic language * Powerful
graphic display
* 16- color display panel
* Super window * Multi window
* Voice message output
EOPS Powerful man /
machine
interface

* Upto 300 graphic display

Compact size
Large application simplifies control
capacity room layout
* 16000 tags * 2,560 trend points * Compact * Support large screen CRT
MULTI-WINDOW EOPS
 EOPS CAPACITY
FUNCTION MEMORY
CAPACITY
NO. OF TAGS : max. 16000 MEMORY : 8 MB
NO. OF TREND POINTS: max HARD DISK : 80
2304 MB
GRAPHIC PABNELS : 300 pages
BASIC USER AREA : 5 MB
NO. OF CRTs : upto 4
NO. OF PRINTERS : upto 4
NO. OF HARD COPIER : max 1
Block diagram of DCS
Contd…
 The arrow shows how the process has been done?
 It’s a bi-directional process.
 It Controls the whole plant through control room.
 It’s a heart of a DCS system.
 It shows that the how DCS is actually working?
 In Diagram All diagrams have their own number.
 And according to their numbers Process has been
done.
 So, this type DCS can actually work. the detail
description of it is shown into the Closed loop.
EOPS PANEL
ORGANISATION
Trend Panel
 SECURITY KEY

64 ONE-TOUCH FUNCTION
KEYS
DISPLAY PANELS
START BASIC
LOGGING REPORT
Closed loop
Contd..
 For any Closed loop that are different parts as shown in
upper figure.
 In figure up to the junction box, that part is as the field side.
 While the other parts are at the control room.
 In control room, the whole wires are comes in to the terminal
box, then it goes into the Barrier & redundancy.
 Barrier provides 24V D.C. Supply, isolation, provide 4 to 20
mA current and also adjust its current.
 Then it goes into the Elco Board ,in this part 8 wires are
converted into 1 wire.
 That wires are gone into Processor & Controller part.
 And this is a Bidirectional System. So, after applying logic it
goes into field side, into similar manner.
 Table of other DCS systems
 Sr.no. Company name Models Year
1 Yokogawa Centum series 1975
2 Honeywell TDC-2000,3000 1975
 3 Taylor Mod III,Mod 300 1976
4 Hokushin 900/TX 1976
5 Foxboro SPECTRUM 1979
6 B.s.kent P4000(KELTRON) 1979
 7 Fisher & porter DCF4000 1979
8 Beckman MV8000 1979
9 Fisher controls FISHER PROVOX 1979
 10 Moore MYCRO 1980
11 Bailey NETWORK90 1980
 12 Leed & Northup MAX-1 1980
Any Queries????