Agenda
Alarm & Trip System
DCS
PLC
Ashwani Kansal
Sr. Engineer – Instrumentation
23/1/2006
Shut Down System Intervention - ESDS
Mechanical Intervention - PRVs
Human Intervention – Alarm System
Control System Intervention (DCS)
Normal Operation (LOCAL CONTROL)
Layered Protection
• Control System: System compensates for minor
disturbances, adjusting the process as needed.
• Alarm System: This alerts the operator to problems
beyond the capabilities of the control system to
enable human intervention.
• Relief System: If changes are beyond human
intervention or too fast for intervention, relief
systems energy to prevent unsafe condition from
occurring.
• Shut Down System: If the plant continues in to an
unsafe region, independent shut down system should
stop operation.
Basic Concepts of Control System
Evaluation History and benefits of
DCS
Basic Concepts of DCS
What is a Control?
• Measurement of a Process Variable
• Processing of measured data with
other information
• Cause a control action
Process Variable
• Pressure
• Temperature
• Flow
• Level
• Relative Humidity
• Current
• Voltage, ETC.
Types Of Control
Two Position Control
Floating Control
Analog Control
Proportional Control
PI Control
PID Control
Digital Control
Two-Position Control
In a two-position control sequence, the controller
compares an analog or variable input with instructions
and generates a digital (two-position) output. The
instructions involve definitions of upper or lower limits.
The output changes value as the input crosses the
limits.
Floating Control
A floating control response produces two digital
outputs based on changing variable input. One
output increases the signal to the controlled device
while the other output decreases the signal to the
controlled device. The control response also
involves an upper and lower limit with the output
changing as the variable input crosses these limits.
Proportional Control
A proportional control response produces an
analog or variable output change in proportion to
a varying input. A linear relationship exists
between input and output. A set point, throttling
range, and action normally define this
relationship.
PI Control
PI control measures offset or error over time. The
error is integrated, and a final adjustment is made
to the output signal from a proportional part of
this model. PI control response will work the
control loop to reduce the offset to zero.
PID Control
PID control adds a predictive element to the control
response. In addition to proportional and integral
calculation, the controller will compute the
derivative or slope of the control response. This
calculation dampens a control response that is
returning to set point so quickly that it would
overshoot the set point.
Digital Control
Based on pre defined control logics and status of
digital input signals, digital control signals are send
as output for control. These types of control are
normally used in on/off control , shutdown
systems, etc.
INPUT A
OUTPUT X
INPUT B
AND
INPUT C
Evaluation of Control Systems
• 1930s – Machine type instrument, manual
control
• 1940s – Large size pneumatic control
instrument
• 1950s – Small size pneumatic control
instrument
• 1960s – Small size analog instrument
• 1970s – Distributed control system, CRT
operation
• 1990s – Microprocessor based DCS, PLC, etc.
• Now – Compact systems, PC based systems,
Open connectivity, MIS, etc.
Control Techniques
• Manual Operation
• Pneumatic Controllers (Phase - I & Phase -
II)
• Electronic Analog Controllers
• Supervisory Control Computers
• Distributed Control System (DCS)
• Field Bus Technology
Advantage of Pneumatic
Controller over Manual Controller
• Improved Reliability
• Centralized System
• Improved Operator Efficiency
• Auto Operation
• Reduced Manpower
Problems of Pneumatic Control
System
• Failures due to moving parts
(Baffles & Nozzles assembly)
• Signal Loss due to long travel
• High Maintenance cost
Advantage/Disadvantage of
Electronic Control
• Improved Reliability (No moving Parts)
• No signal Loss
• Better representation of Process
• No data storage and retrieval ability
Distributed Control System - DCS
• Introduced in late 1970’s.
• The concept behind the DCS was to use
microprocessor technology for implementing
control.
• Control loops were distributed among many
smaller controllers each with its own Central
Processor Unit.
• Controllers were linked together along with
Operator Console and Engineering Station
through a Communication Highway.
• Provides Redundancy
IPB1A/1B IPB2A/2B
AS160OS DAS/MMI
1.02
1.01 2.02
Diagnostic Station
2.01
1.04 SOE
2.04 1.10
HRSG 1
1.11
Aux. Boiler 1
1.12
GT 1
1.13
BoP-HP
1.14
Nitrogen
2.15 HRSG 2
2.16 Aux. Boiler 2
2.17 CW / IAPA
2.18 BoP-MP
2.19 AB 1/AB 2 Inputs
Procontrol P13/42 DCS System – O&U
Basic Layout of DCS
Control Room
Programmable Controller Input / Output
Bus Controller BUS MMI
Input Output
DCS
Analog / Digital Signals
Field / MCC
Example of Analog Signal Flow From Field To DCS
PV SET POINT
INPUT PV
4-20 mA
1-5 VDC
1- 5 VDC A/D
DIGITAL SIGNAL
INPUT SIGNAL CONDITIONER
PID
Sensor MMI
Bus
I/P MV
ISOLATOR
D/A DIGITAL SIGNAL
I/O Card Signal
Processing
Signal Conversion Control Room
Field & Isolation DCS
Example of Digital Signal Flow From Field To DCS
DIGITAL
TERMINAL INPUT
BOARD CARD
Sensor
SEQUENCE
MMI
CONTROL
BUS
RELAY DIGITAL
BOARD OUTPUT
CARD
I/O NEST PROCESSOR
Field Marshalling DCS C/R
Outline Of Control System
• Input module
• Output Module
• Processing Module
• Communication Module
• Bus Controller Module
• Bus System
Function Of Input Module
• Supplies power to Transmitters or
transducers
• Signal Verification
• Digitization, Parallel/Serial Conversion
• Storage of Measured value
• Address allocation
• Module can be Analog or Digital
Function Of Output Module
• Conversion of digital values in to
Analog/Binary signals
• Storage of signal for Output
• Address allocation
• Power supply for the driven end
• Module can be Analog or Digital
Function Of Processing Module
• Accept Input data from the Bus
• Executes Control/Logical/Arithmetic
functions as per written program
• Data Simulation
• Diagnostic Functions
• Checks the Redundancy
Function of Bus Controller & Bus
System
• Provides Hardware path for travel of
information
• Clock Generation
• Address generation
• Data Transmission
• Data Reliability Checking
Advantages of DCS
• Superior reliability due to Redundancy
• Improved Effectiveness
• Improved Operation Efficiency
• Better Diagnosis of Problem
• Facilitates the use of advanced control
• Alarm generation capabilities
• Modular System
• Less expensive per loop
• Less expensive to expand
• Data storage and retrieval features
• Easier modification
• Minimum Down time
• Ease of Maintenance (less
Complexity)
• Reduction in cost
• DCS can be placed away from Control
Room (Reduces Cable Cost)
ABB Procontrol – P13 DCS
DCS Systems in CFCL
Ammonia / Urea – I: Yokogawa Centum XL
Ammonia / Urea – II: Yokogawa Centum CS
Offsite & Utilities: ABB Procontrol P13/42
Ammonia / Urea – I: Yokogawa Centum XL
System hardware Configuration
Terminology
• EOPS : OPERATOR STATION
• EOPC : OPERATOR CONSOLE
• ENGS : ENGINEERING STATION
• EFCD : DUPLEX FIELD CONTROL STATION
• EFMS : FIELD MONITORING STATION
• EFGW : FIELD GATEWAY UNIT
• EPRT : PRINTERS
• HF BUS : BUS FOR INTER CONNECTING CONTROL
STATIONS AND OPERATOR STATIONS
• ECHU : COLOUR HARD COPY UNIT
Salient Features Of Control Station
Processor : Dual redundant
Communication : Dual redundant
Control cards : Dual redundant
Battery backup : 72 hours
Bus Transmission : 1 Mbit / sec
Transmission distance : Upto 1 km
No of stations : Upto 63
Self diagnostics
PHASE I – AMMONIA PLANT
MAN MACHINE INTERFACE
CENTUM CS3000
YOKOGAWA
SALIENT FEATURES OF OPERATOR STATION
CPU : MC68030 (25 MHz, 32 bit)
Memory : 8 MB
Hard Disk : 80 MB
Touch screen operation
Self Diagnostics
Application Capacity
No. of tags : Upto 16000
Trend points : Max 2300
Graphics pages : 300
Alarm Messages : Max 7680
Functions of MMI System
• Display of Process Data
• Trending
• Recording
• Control Function
• External System Connectivity
• Sequence of event recording
DCS Configuration – Ammonia II
Terminology
FCS : Field control station
ICS : Information & command station
EWS : Engineering work station
ACG : Advance Gateway unit
ABC : Bus converters
V-NET : Bus for connecting FCS & ICS real time
control network
E-NET : Communication network EWS to ICS and
Gateway to secondary system.
APS : Application Station
ACS : Advance Control Station
RIO BUS : Remote I/O Bus
NIU : Node interface Unit
HARDWARE SPECIFICATIONS & MODEL CODES
• Processor : RB3000 (25 MHz)
• Memory size : 8 Mb (Enhanced type - 16 Mb)
• Battery backup time : 72hrs max.
• Recharging time : 48hrs or longer
• Communication : V-NET Duplex or Single
: RIO bus Duplex or Single
• Power Supply: 100 to 120 AC
: 50 0R 60HZ +/- 3HZ
Connectivity to LAN - Overview
V-Net Bus
V-Net Bus
ACG10S
ACG10S Ammonia
Ammonia Ethernet Switch Gateway
Ammonia DCS Gateway
Urea DCS
TCP/IP
Citect
Server
LAN Switch
Citect Citect Citect Citect Citect
Client Client Client Client Client
User-1 User-2 User-3 User-4 User-5
Salient Features Of Centum - CS
DUAL REDUNDANT V-NET SUPPORTS
•MAX. NO. OF STATIONS : 256/SYSTEM
•MAX. NO. OF DOMAINS : 16/SYSTEM
•STATION NO. ICS :1 TO 64
•STATION NO. FCS : 1 TO 64
•MAX. NO. OF ICS/DOMAIN : 16
•MAX. NO OF NIU/FCS :8
•MAX. NO. OF I/O UNIT/FCS : 40
•MAX. NO. OF NEST/IOU :5
•MAX. LENGTH OF V - NET : 20KM
(WITH OPTICAL FIBER)
•MAX. LENGTH OF RIO BUS : 20KM
(WITH OPTICAL FIBER)
O&U Plant
Procontrol P13/42 DCS
ABB
IPB2A/2B
AS160OS DAS/MMI
1.02
2.02
1.01
Diagnostic Station
2.01
1.04
SOE
2.04 1.10
HRSG 1
1.11
Aux. Boiler 1
1.12
GT 1
1.13
BoP-HP
1.14
Nitrogen
2.15 HRSG 2
2.16 Aux. Boiler 2
2.17 CW / IAPA
2.18 BoP-MP
2.19 AB 1/AB 2 Inputs
ABB Procontrol P-13/42 DCS System – O&U
Salient Features of DCS System
Modular System
Multi Processor System
Expandable System
Processor : Dual Redundant
Bus Traffic Director: Dual Redundant
Intra Plant Bus : Dual redundant
Cycle Time: 5, 10, 20, 40 mSec (User Selectable).
Programming Language: Procontrol P10
Bus Transmission (Local Bus): 0.2 Mbits/Sec.
Bus Transmission (IPB): 0.27 Mbits/Sec.
Transmission distance : Upto 1 km (2 Km with amplifier card)
No of stations : Upto 64
Max. No. of addresses on Local Bus: 256 word address (FF)
Total No. of addresses: 16384
O&U Plant
Man Machine Interface
Advant AS160OS DAS
ABB
Configuration Diagram
Control Room
Printer # 2 Printer # 3
Printer # 1
19”
19” 19” 19” 19”
Engineering
Station
AS 160OS Operator Station Information Network
Hub (TCP/IP)
AS 160OS
Server
IPB 1A/1B
IPB 2A/2B
Features Of ABB ADVANT AS160OS
MMI System
Direct integration with Procontrol P13 DCS
System structure – modular, flexible, open
Easy operation – point and click
Object oriented
Safe operation
Efficient navigation
User authorization and security levels
Easy to engineer
Task Performed by Server
Data acquisition and processing
Data management, archiving and retrieval
Interface to P13 DCS bus
Interface to LAN
Time synchronisation
System diagnostics
Overview of DAS Functions
Database
Analog inputs – 1200
Binary inputs – 3000
Analog drives – 50
Binary drives – 100
Reports
Daily reports – 24 nos
Monthly reports – 7 nos
Overview Of DAS Functions Used
Mimic displays – 85 pages
Real time trend displays – 42 pages
Historical trend displays – 42 pages
Group displays – 62 pages
UFF criteria displays – 19 pages
Characteristic curves display – 12 pages
Profile displays – 12 pages
Alarms – process, system, operator actions
System configuration display