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PROCESS
CONTROLLER
ANNUNCIATOR
RECORDERS
LOG
OFF LINE
DELAY
PROCESS
RECORDERS
CONTROLLER
ON LINE
LOG
PROCESS
RECORDERS
ON LINE
CONTROLLER
LOG
PROCESS
OPEN LOOP
CLOSE LOOP CONTROL TO FINAL ELEMENT PLUS CAPABILITY ON INDICATING, RECORDING, AND ALARM ANNUNCIATOR
OPEN LOOP
INDICATING
DATA LOGGER
RECORDING
ALARM
OPERATOR WILL ACTUATE THE VALVE BASE ON DEMAND SHOWN BY PANEL DISPLAY
PROCESS
CLOSE LOOP
SET POINT
CONTROLLER
CONTROL ELEMENT
PRIMARY ELEMENT
PROCESS
FINAL ELEMENT
Control System
ON-OFF Control System Example : Motor Control, ESD Valve, Interlock System Variable (Regulatory) Control System Feedback Control Loop, Cascade Control, Ratio Control
Automatic Control
FIELD ELEMENT: Orifice, RTD, T/C, etc PRIMARY ELEMENT: Transmitter CONTROLLER: Manipulated device CONTROL SIGNAL: 3-15psig, 4-20 mA, HART/ Fieldbus CONTROL MODE: Proportional, Integral and Derivative SET POINT: value to be given to any controller FINAL ELEMENT: Control valves, switches etc.
A c tu a to r S y s te m F1 T
1
F2 T
2
S en so r S y stem C o n tr o lle r
TC TT
F1 T
1
F2 T 3 -1 5 p s ig
2
T h e r m o w e ll T
A ir
I /P
4 -2 0 m a
D /A
T h e r m o c o u p le m illiv o lt s ig n a l 4 -2 0 m a
O p e ra to r C o n s o le
sp
DCS C o n tro l C o m p u te r
A /D
T r a n s m itte r
Feedback
A feedback control configuration measures the error after the process as correction factor to be transmitted to controller in order to give signal input to final control element
Feedback Controller
Manipulated Input
Process
Process Output
T T
T C R SP
sp
P ro cess S tr e a m
F C F T G as
Feedforward
A feedforward control configuration measures the disturbance directly and takes control action to eliminate its impact on the process output.
Disturbance
Feedforward Controller
Manipulated Input
Process
Process Output
OUT1
M LD-SW
MV
PV 50 100
Pneumatic Controller
Introduced in the 1920s Installed in the field next to the valve Use bellows, baffles, and nozzles with an air supply to implement PID action. Provided automatic control and replaced manual control for many loops Transmitter type pneumatic controllers began to replace field mounted controllers in the late 1930s. Controller located in control room with pneumatic transmission from sensors to control room and back to the valve. Allowed operators to address a number of controllers from a centralized control room.
Pneumatic Controller
F1 T
1
F2 T 3 -1 5 p s ig
2
T h e r m o w e ll T A ir T h e r m o c o u p le m illiv o lt s ig n a l 3 -1 5 p s ig A ir T r a n s m itte r
sp
P n e u m a tic C o n tr o lle r
F1 T
1
F2 T 3 -1 5 p s ig
2
T h e r m o w e ll T
A ir
I /P
4 -2 0 m a
T h e r m o c o u p le m illiv o lt s ig n a l 4 -2 0 m a
sp
E le c tr o n ic A n a lo g C o n tr o lle r
T r a n sm itte r
V id e o D is p la y U n it
A la r m in g F u n c tio n s
P r in te r
S u p e r v is o r y C o n tr o l C o m p u te r
A n a lo g C o n tr o l S u b sy tem
In te r fa c in g H ardw are
D a ta S to r a g e A c q u is itio n S y stem
...
PC
PLC
Field Instrument
Field Instrument
CPU
PC
RS 232
HARD WIRED
FIELD INDTRUMENTS
PLC
A PLC (i.e. Programmable Logic Controller) is a device that was invented to replace the necessary sequential relay circuits for machine control PLC for safety
PC
BUS
HARD WIRED
FIELD INDTRUMENTS
PROGRAMABLE CARD
PROGRAMABLE CARD
PROCESSOR CARD
PROCESSOR CARD
COMMUNICATION
COMMUNICATION
POWER SUPPLY
POWER SUPPLY
I/O CARD
I/O CARD
I/O CARD
I/O CARD
I/O CARD
I/O CARD
I/O CARD
Note:: Normally a Rack can be filled in max. 16 Cards This Rack has redundancy in power supply , Communication and CPU/ Processor To Others Rack, or Others Devices
Field Instrument
I/O CARD
DCS
Introduced in the late 1970s. Based upon redundant microprocessors for performing control functions for a part of the plant. SUPERIOR RELIABILITY Less expensive per loop for large plants. Less expensive to expand. Facilitates the use of advanced control.
DCS
S y stem C o n so les H ost C o m p u ter D a ta S to r a g e U n it PLC
D a ta H ig h w a y (S h a r e d C o m m u n ic a tio n F a c ilitie s )
L ocal C o n s o le
L ocal C o n tro l U n it
..............
L ocal C o n tr o l U n it
L ocal C o n so le
P r o c e ss T r a n s m itte r s a n d A c tu a to r s
MMI
MMI
ETHERNET / BUS GATEAWAY SYSTEM INPU/ OUTPUT RACK PLC SYSTEM CONTROLLER RACK
FIELD INDTRUMENTS
SCADA
Basic concept: Definition, Automation or remote, SCADA Architecture Communication Field Device RTU MTU Data communication
SCADA
SCADA : A system for monitoring and controlling for geographically dispersed process from a central location. Acquires Data Supervisory Control
Field Devices
Master Station
Master Station
DCE
Master Station
RS 232 LINK
DCE DCE
DCE
DCE
DTE
Work Station
Work Station
ETHERNET NETWORK
DCE
DCE
DCE DCE
DCE
DCE
DCE
DCE
DTE
DCE
DCE
DCE DCE
FieldBus Technology
The open, nonproprietary all-digital, serial two-way, multi-drop communication link among intelligent field devices and automation systems. Based upon smart valves, smart sensors and controllers installed in the field. Uses data highway to replace wires from sensor to DCS and to the control valves. Less expensive installations and better reliability. Can mix different sources (vendors) of sensors, transmitters, and control valves. Now commercially available and should begin to replace DCSs.
P la n t-W id e N e tw o r k
L ocal A rea N e tw o rk
.................
Sm art S en so rs
L ocal A rea N e tw o r k
Sm art S en so rs
S m a r t C o n tr o l V a lv e s a n d C o n tr o lle r s
S m a r t C o n tr o l V a lv e s a n d C o n tr o lle r s
F ie ld b u s N e tw o r k a
F ie ld b u s N e tw o r k
Fieldbus Vs Conventional
Field wiring Information flow Quantity of information Information type Control functionality Maintenance location Maintenance type
Conventional 4 to Point-to-point 20 mA
Unidirectional
Fieldbus
Multi-drop
Bidirectional
Various data types Optimally From a remote allotted to controllocation system and/or field devices
Predictive maintenance
Fieldbus Control
PID
Controllers and Fieldbus Modules
Fieldbus
Fieldbus
AI
AO
AI
PID
AO
Integrated Fieldbus/Host Control Fieldbus Control on the Wire
Foundation Fieldbus
Foundation H1 Foundation Ethernet
Fondation H1
Intended primarily for process control, field-level interface and device integration. Running at 31.25 kbit/s, The technology interconnects devices such as transmitters and actuators on a field network. Twisted pair instrument cabling with power and signal on the same wire. Fiber optic media is optional. It also supports Intrinsic Safety (IS) applications.
Foundation HSE
Ideally suited for use as a control backbone. Running at 100 Mbit/s, Designed for device, subsystem and enterprise integration. Fieldbus capabilities: including standard function blocks and Device Descriptions (DDs), Flexible Function Blocks (FFBs) for advanced process and discrete/hybrid/batch applications Supports complex logic functions, such as those performed by Programmable Logic Controllers (PLCs), or data-intensive process devices, such as analyzers and gateways to other networks. HSE enhances access to H1 fieldbus technology via linking devices, while providing expanded capabilities for high-speed automation devices and hybrid/batch applications