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Chapter10 DCS FF July 08 v3 1 Oct
Chapter10 DCS FF July 08 v3 1 Oct
• PART 3:
DCS and Fieldbus
Synopsis
Synopsis Learning
Learning Outcomes
Outcomes
This
Thiscourse
coursecover
covertopics
topicsrelated
relatedto
tomeasurements
measurements
(PLTF)
(PLTF) and automation in the processindustry.
and automation in the process industry.These
These that
thatstudents
studentsare
areexpected
expectedtotoachieved
achievedafter
after
include
include a study on industrial sensors andactuators,
a study on industrial sensors and actuators,industrial
industrial successfully completing the course
successfully completing the course
controllers
controllers such as computer-based control, PLC, DCSand
such as computer-based control, PLC, DCS and
FF.
FF.
Process
Process,,Industrial
Industrial Instr.&
Instr.& Meas.
Instr.& Meas. Automation
Automation DCS
DCSand
andFoundation
Foundation Fieldbus
Fieldbus
The learning outcomes related to The learning outcomes related to The learning outcomes related to
Industrial instruments and Automation and the implementation of DCS and Foundation Fieldbus use
Measurements Programmable logic controller in process industries.
• Have knowledge and
understanding of the various
• Have knowledge and • Have knowledge and
process industry instruments,
understanding of the PLC understanding of a DCS and its
concept of measurements,
architecture and its importance in use in process industries, and
calibration and configuration
automation. the features and architecture of a
requirements and their applications.
Foundation Fieldbus system, and
• Be able to develop a PLC program
• Be able to design and develop a its improvement over the
to perform sequential, and batch
control loop consisting the process conventional DCS.
control.
instruments, based on a prescribed
requirement.
SP +
- PV
OP CONTROL
CONTROLLED
MANIPULATED VARIABLE
VARIABLE
MEASUREMENT
PROCESS
FINAL CONTROL
ELEMENT
SETPOINT
SP
PID
CONTROLLED
VARIABLE
PV A
MANUAL
ADJUSTMENT
M
OP
A AUTO M MANUAL
Analog Digital
Signal Signal
Time Time
Discrete signal with only
Continous variable two possible values or
position
Monitor
Printer
SP
PV OP
LT
Process
Monitor
Printer
LT
Process
Monitor
Controller Printer
PV4
Out4
PV3
Out3 The function of controllers were
PV2 Out2
CPU superseded by the computer. A
PV1 Out1 central computer monitor and
control all the process variables.
PV OP
LT
Process
Monitor Printer
Network
IOP
PV OP
Process
LT
• In the 1940s…
o Mechanical and pneumatic controllers for
controlling a few process variables: T,P,F.
o Coordinated process unit control system was
not possible.
o Conservatively for stability rather than
economic performance.
• In the 1950s…
o Electronic controllers introduced.
o Centrally located in the control room
and wired into the measuring devices
and actuators in the plant
o Provide feedforward dynamic models.
o Small pneumatic instruments were also
used.
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-
3- 13
History and Development of DCS:
• In the 1960s…
o Process computers made their debut.
o Assembly of distributed, mutually
independent and dedicated controllers.
Digital computer
•CRT
Controller and
Data
Foreign Device
Communication
operation
Interface
Acquisition System
(Analyzer etc.)
System
PNEUMATIC TRANSMISSION
RELAYS
DISCRETE
DISCRETE
SWITCHING
SWITCHING
DEVICES ELECTRONIC LOGIC
DEVICES
PROGRAMMABLE LOGIC
SUPERVISORY CONTROL
RS3 by Rosemount
ROI
IA by Foxboro
DCS
Another dramatic change is required to
create an acceleration of value from the
current DCS offering.
Analog Control
Softw a re Hardware
(Monitor, (PLC or
Screen/ a n a lysis,
Transfer to
central com m ercial Plant
D isplay control) computer hardware)
Supervisory
control
Indirect control:
• For monitoring and indirect control based on certain set-points.
• Changes to a process would have to go through various levels
before being implemented – takes time and cannot be done
immediately.
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-
3- 21
SCADA System
Host control functions
are restricted to basic
overriding or
supervisory level
intervention.
The SCADA system
allows operators to
change the set points
for CVs, and enable
alarm conditions, such
as loss of flow and
high temperature, to
be displayed and
recorded.
The feedback control
PLCs control the
loop passes through
CVs of an the RTU or PLC, while
industrial process. the SCADA system
monitors the overall
performance of the
loop.
Centralized control
Ø Process Monitoring
Ø Data Acquisition
Ø Alarming and Logging
Ø Data Processing
Ø Process Control
Shared
Communication
Facility
Input Output
Monitoring Input
Control Loop
Primary & Control Alarms ( PV & SP )
Elements Trend , Log & Report
Execute Special
Programmed Logic.
25%
AUTO
0%
FIC21765
KLB/HR
FLOW 21
SP 42.9
PV 31.3
OP% CAS52.8
C O
0 100
HPM/APM
AI AO
I I
P P
Supervisory Programmable
Operator Computer Logic Controller
Interface System Interface Interface
OPERATOR
Processing Unit
Allows DAQ and control Display and
LCUs Operator
Station Man-machine
data-base
Engineering Interface
OTHER ENGINEER
Communication system
LCU- Local Control Unit
SYSTEMS System
Gate-
Communication configuration,
way
between other System
systems maintenance
Control Control
J21
WTT161
FTA-ID APM 1
WT301 WT301 TE61+1A1
+ 1 1 MU-TAIH02 NETWORK NO 01
WT302 WT302 TE61-1A1
- 2 2 01 TB2 03
NODE NO
TE61 01 TB3 MODULE NO 01
SLOT NO 01 DCS TAG NO
NODE NO 03
SLOT NO 04
CTLACN-REVERSE
J22
WTTV61
APM 1
FTA-ID
WT307 WT307 TCV61+1A0 NETWORK NO 01
3 3 MU-TAOX02
WT308 WT308 TCV61-1A0
4 01 TB1 NODE NO 03
4
02 TB1 MODULE NO 02
TCV61 SLOT NO 01
I/O SLOT NO 07
EU Low
0.00
0.00
0.00
% Low
0.00
0.00
Control
Station 2
Data Control
5 Highway Station 3
Comm.
1 I/O Module 4
Module
Controller
3 Module
LT
Points
FT 21442 TCV 21242 TT 21242
FCV 21442
Level 3
Process Model and Optimization
Level 1
Regulatory Control
PROCESS
§ Advanced Control
§ Management information system and interface
to Enterprise resource planning (ERP).