AUTOMATIC PROCESS CONTROL

DEVIATION
SET POINT SIGNAL OUTPUT
M.V
SIGNAL
CONTROLLER SIGNAL FINAL CONTROL
S.V ELEMENT
P.V CORRECTIVE
CONTROLLED VARIABLE SIGNAL

ACTION

MEASURING PROCESS
MEANS
AUTOMATIC PROCESS CONTROL

AUTOMATIC FLOW CONTROL LOOP

S.V.
FLOW INDICATING CONTROLLE.
FIC
P.V.
F.T.

M.V
PIPE LINE
F.E (ORIFICE PLATE) CONTROL FLOW OUT
FLOW IN
VALVE
Field transmitter

Junction Marshalling
Barrier 4 - 20 mAT
box rack
4 - 20 mA 4 - 20 mA O
4 - 20 mA 4 - 20 mA

S
Y
S
T
I/P Junction Marshalling
Barrier
box rack E
4 - 20 mA 4 - 20 mA 4 - 20 mA 4 - 20 mA M

3 - 15
PSI

Control
Valve
MODES OF OPERATION :
• MANUAL
• AUTO
• CASCADE
• SPC
• DDC
 ENG. SUPERVISORY
OPERATOR COMPUTER
STATION STATION
GATEWAY UNIT

DATAHIGHWAY (OPTION)

(OPTION)
GATEWAY UNIT
CONTROL DAS
STATION
PLC

MINIMUM CONFIGURATION OF DCS

 GEOGRAPHICALLY AND FUNCTIONALLY

DISTRIBUTED DIGITAL CONTROL SYSTEM

I/O Wires I/O Wires I/O Wires

Remote Remote Remote

E
Processor-1 Processor-2 Processor-3
X
T
E
Data Highway
CRT CRT CRT CRT
N
Operator Station
D
E
Supervisory
D
Computer
 GEOGRAPHICALLY CENTRALISED
FUNCTIONALLY DISTRIBUTED
DIGITAL CONTROL SYSTEM

I/O Wires I/O Wires I/O Wires

Controller-1 Controller-2 Controller-3

Data Highway
CRT CRT CRT CRT

Operator Station
Supervisory
Computer
 DISTRIBUTED CONTROL SYSTEM

✽ Controller Sub -System

✽ Operator Interface
✽ Supervisory Computer
✽ Data Highway

CONTROLLER DESIGN :

- Single Loop Programmable

- Multi-Loop Programmable
- Multi Function
- Function Block Concept
- Programs using High Level Languages
- Advanced Control Algorithms
- Communication Interface
• Can talk to each other
• Can talk to higher order systems
- Scan Time as high as 20 times / sec.
 CONSOLE SUB-SYSTEM
✽ MAN - MACHINE INTERFACE FOR THE
TOTAL SYSTEM
✽ DISPLAY HIERARCHY

1. OVERVIEW DISPLAY

2. AREA DISPLAY

3. GROUP DISPLAY

4. ALARM SUMMARY DISPLAY

(PIONT DISPLAY)
MAN - MACHINE INTERFACE
• Intelligent , CRT based
• Operation by Exception
• Virtual Panels
• Faster Up-dates & Call-Ups
• Multi-Window
• Top- Down Approach
• Touch - Screens
• User - Definable Keys
• Voice Output
• Print Outs for
- Alarms
- Devices failure
-
 ADVANTAGES OF DCS
• Tighter Control Reduces Off-Spec Products
• Flexibility in Changing Control Strategy
• Better Operator Interface
- Monitoring and Control by Exception
- Colour Graphic Facility

• Reliability Through redundancy

• Trend and Historical Record facility
• MIS
• Integrated Operation
• Self - Diagnostics
• Reduced Maintenance
• Control Functions require no calibration

• Better Documentation due to self documentation option

• Modularity ensures expandability
• Can cope up with changing Technology: no obsolesce
• Provides scope for advanced Controls and Optimization
 Cost Report
Generation

Set-point Control MIS

Optimization Supervisory
Computer
MAN-MACHINE
INTERFACE Supervisory Monitoring

Controllers

Process

HIERARCHY IN DCS
 PROCESS :
Conversion
Raw Material Product

ELEMENTS IN A PROCESS :

Feed Preparation Reaction Product

Purification
VARIABLES :
Those Parameters which change with time and cause some
variations in the Process itself.

• Flow
• Temperature
• Pressure
• Level
• Composition
What is a process
What are variables in a process
What are the effects of these variables on the process
How are these variables regulated.

What is a control system

What is digital control system
What is advanced control and Optimization
 MEASUREMENT OF

PROCESS PARAMETERS

TRANSMISSION &

CONTROL

• Flow
• Temperature
• Pressure
• Level
• Composition
 SAFETY
• Flammable Materials in Industrial Processes
• Spillage may give rise to an Exp..ATM.
• Precautions to Protect both Plant and Personnel
• The ‘ HAZARDOUS’ and ‘ SAFE’ Areas classification
• What is IS ? (INTRINSIC SAFETY)
Restricting the Electrical Energy available in
Hazardous Area circuits such that any sparks or Hot
Surfaces that may occur as a Result of Electrical faults
are too weak to cause Ignition
•To Limit the Energy supplied to the Hazardous
areas we use Interface BARRIERS between the Safe
area and the Hazardous Area.
 AREA CLASSIFICATION

PRESENT INTERMITTEN ABNORMAL

STANDARD CONT.>1000 TLY>10<1000 LY<10HR/
HRS/ANNUM HR/ANUUM ANUUM

IEC/CENELEC ZONE 0 ZONE1 ZONE 2

/EUROPE

NORTH
DIVISION 1 DIVISION 2
AMERICA
 CURRENT
FUSE LIMITOR

INPUT OUT PUT

SUPPLY TO
XMITTER
 Hazardous area Safe area
N inputs N outputs
Data
Multiplexer Highway Intrinsically Multiplexer
transmitter safe receiver
interface

Hazardous area Safe area

Data
Highway MTL3052
X 16 Isolator

MTL821 MTL825
transmitter receiver
MTL switch multiplexer system
GUS 01 GUS 02 GUS 03 GUS 04 GUS 05 GUS 06 GUS 07 GUS 08 GUS 09

LOCAL CONTROL NETWORK

NIM 11 NIM 12 HM 21 CG 22 AM 25 AM 26
The GUS is the primary TPS human interface. It provides a single window to
the entire system, whether the data is resident in one of the LCN modules or
in one of the devices in UCN or HIWAY.

Monitoring and manipulating continuous and discontinuous operations.

Annunciating and handling alarms
Displaying and printing trends, logs, journals, and reports
Monitoring and controlling system status and diagnostics.

Network configuration.
Building process database, custom graphics

Designing reports, Preparing control language programs.

Diagnosing system problems

Displaying and printing information required during troubleshooting
The HM is available with redundant drives , makes possible storage of, and
quick access to large quantities of data.

History of process alarms, operator changes, operator messages, system

status changes, system errors and system maintenance.

System files of all types, load images, and other data required anytime
modules are reloaded or personalities are changed.

Checkpoint data for maintaining up to date device setting in the event a

device is taken out of service.

Continuous process history to support logs and trends.

The computer gateway is a fully integrated node of TPS system , enabling it
to exchange information with all other nodes on the same LCN

Its function is to serve as a communication link between the host computer

and the LCN.

Its hardware components include an LCN interface, MCPU, memory, a

power supply, and a Computer Network Interface.

The GC memory contains the standard TDC 3000 node environment

software along with CG Specific application software and a user defined
database.
The AM permits the implementation of certain complex control calculation
and strategies that may not be practical or possible when using only
process connected devices .

A set of standard advanced control algorithms is included, and custom

algorithms and packages can be developed by using a process engineer
oriented control language.
 HPM 11 12 HPM 13 14 HPM 15 16 HPM 17 18 FSC 21 22 FSC 23 24 FSC 25 26

NIM

LCN UNIVERSAL CONTROL NETWORK

NIM
HPM’s dual 68040 platform offers a wide ranges of capabilities for present
and future process requirements.

It offers flexible I/O functions for both data monitoring and control .

Control functions including regulatory, logic, and sequencing control are

provided for continuous, batch, sequencing, and hybrid applications.

A toolbox of functions can be configured and programmed to meet the needs

of data acquisition and advanced control requirement in a highly secure and
performance intensive manner.

HPMs capabilities include peer to peer communications and compatibility

with industrial standard communication protocols.
Field transmitter

24 V DC Junction Marshalling
Barrier 4 - 20 mAT
box rack
4 - 20 mA 4 - 20 mA O
4 - 20 mA 4 - 20 mA

S
Y
S
T
I/P Junction Marshalling
Barrier
box rack E
4 - 20 mA 4 - 20 mA 4 - 20 mA 4 - 20 mA M

3 - 15
PSI

Control Valve
 m CH 1 H1 100 110 0 100 110 0
V
CH 2 TO SI CARD
MTL MTL
MUX MUX
1372B 1372B
CH 15

CH 16

. 100 110 0 100 110 0

CH 1 H1
. 1/ 0
. TO SI CARD
CH 2
.
MTL MTL
MUX MUX
1372B 1372B
.
. CH 15

.. CH 16