dcs presentation1
TRANSCRIPT
CONTROLLER FINAL CONTROL ELEMENT
MEASURINGMEANS
PROCESS
SET POINTSIGNAL
DEVIATIONSIGNAL
S.VP.V
OUTPUT SIGNAL
CORRECTIVE ACTION
M.VC
ON
TR
OL
LE
D V
AR
IAB
LE
SIG
NA
L
AUTOMATIC PROCESS CONTROL
AUTOMATIC PROCESS CONTROL
FLOW OUT
FIC
S.V.FLOW INDICATING CONTROLLE.
M.V
CONTROL VALVE
F.E (ORIFICE PLATE)
PIPE LINE
FLOW IN
P.V.
F.T.
AUTOMATIC FLOW CONTROL LOOP
Junction box
Marshalling rack
Barrier
Field transmitter
Junction box
Marshalling rack
Barrier
Control Valve
I / P
4 - 20 mA
4 - 20 mA 4 - 20 mA
4 - 20 mA 4 - 20 mA 4 - 20 mA
4 - 20 mA 4 - 20 mA
3 - 15 PSI
T
O
S
Y
S
T
E
M
4 - 20 mA
MODES OF OPERATION :
• MANUAL
• AUTO
• CASCADE
• SPC
• DDC
OPERATORSTATION
ENG. STATION
SUPERVISORYCOMPUTER
GATEWAY UNIT
CONTROLSTATION
DAS
GATEWAY UNIT
PLC
(OPTION)
(OPTION)
DATAHIGHWAY
MINIMUM CONFIGURATION OF DCS
RemoteProcessor-1
RemoteProcessor-2
RemoteProcessor-3
CRTCRT CRT CRT
Operator Station
SupervisoryComputer
Data Highway
I/O Wires I/O Wires I/O Wires
GEOGRAPHICALLY AND FUNCTIONALLY
DISTRIBUTED DIGITAL CONTROL SYSTEM
E
X
T
E
N
D
E
D
Controller-1 Controller-2 Controller-3
CRTCRT CRT CRT
Operator Station
SupervisoryComputer
Data Highway
I/O Wires I/O Wires I/O Wires
GEOGRAPHICALLY CENTRALISED FUNCTIONALLY DISTRIBUTED
DIGITAL CONTROL SYSTEM
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
MIS
Supervisory Computer
Supervisory Monitoring
Controllers
Process
HIERARCHY IN DCS
Cost ReportGeneration
Set-point Control Optimization
MAN-MACHINEINTERFACE
PROCESS :
Raw MaterialConversion
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
IEC/CENELEC/EUROPE
STANDARD
NORTH AMERICA
PRESENT CONT.>1000HRS/ANNUM
INTERMITTENTLY>10<1000 HR/ANUUM
ABNORMALLY<10HR/ ANUUM
ZONE 0 ZONE1 ZONE 2
DIVISION 1 DIVISION 2
CURRENT LIMITORFUSE
INPUT
SUPPLYOUT PUT
TO XMITTER
Multiplexertransmitter
Multiplexerreceiver
Intrinsicallysafe
interface
N inputsHazardous area Safe area
Data Highway
N outputs
Hazardous area Safe area
X 16
MTL821transmitter
MTL825receiver
MTL3052Isolator
Data Highway
MTL switch multiplexer system
GUS 01
NIM 12
GUS 03 GUS 04 GUS 05 GUS 06 GUS 07 GUS 08 GUS 09
AM 25CG 22
GUS 02
NIM 11 HM 21 AM 26
LOCAL CONTROL NETWORK
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.
Displaying and printing information required during troubleshooting
Diagnosing system problems
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 17 18 FSC 21 22HPM 15 16 FSC 23 24 FSC 25 26
UNIVERSAL CONTROL NETWORK
NIM
NIM
LCN
HPM’s dual 68040 platform offers a wide ranges of capabilities for present and future process requirements.
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.
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.
HPMs capabilities include peer to peer communications and compatibility with industrial standard communication protocols.
Junction box
Marshalling rack
Barrier
Field transmitter
Junction box
Marshalling rack
Barrier
Control Valve
I / P
4 - 20 mA
4 - 20 mA 4 - 20 mA
4 - 20 mA 4 - 20 mA 4 - 20 mA
4 - 20 mA 4 - 20 mA
3 - 15 PSI
T
O
S
Y
S
T
E
M
24 V DC 4 - 20 mA
MTLMUX
1372B
MTLMUX
1372B
TO SI CARD
CH 1
CH 2
CH 15
CH 16
H1
MTLMUX
1372B
MTLMUX
1372B
TO SI CARD
CH 1
CH 2
CH 15
CH 16
H1....
.
.
..
mV
1 0 0 1 1 0 0
1 0 0 1 1 0 0
1 0 0 1 1 0 0
1 0 0 1 1 0 01 / 0