Process Control Concept

Process Control Hierarchy

Corporate Level Controls

(ERP)

Optimation
(Advance Process Control)

Advance Regulatory Control

(Ratio, Cascade, Feedforward, Override, Decoupling)

Basic Regulatory Control

(Feedback)

PROCESS
 Process Control
Manual With Off line Computer Assistance
OPERATING
INSTRUCTION

CONTROLLER

ANNUNCIATOR

RECORDERS
LOG

OFF LINE DELAY

PROCESS
 Process Control
Manual With On line Computer Assistance

RECORDERS
CONTROLLER

ON LINE

LOG

PROCESS
 Process Control
Automatic with Feedback

RECORDERS

ON LINE CONTROLLER

LOG

PROCESS
 BASIC CONTROL LOOP

TWO BASIC LOOPING IN SYSTEM MEASUREMENT

• OPEN LOOP – INDICATING, RECORDING ,

ALARM ANNUCIATING ONLY

• 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

DATA LOGGER

FIELD
ELEMENT
PRIMARY
ELEMENT

FINAL
PROCESS 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.

 Types of Automatic Control Loop
• OPEN LOOP is used to indicate or record a process fluid
without any control output
• CLOSED LOOP or Feedback Control uses the output of
controller to manipulate the final control element (e.g.
control valves)
• SPLIT RANGE CONTROL is used to split two outlet flow
within a range of controller output
• RATIO CONTROL: is used to ensure two or more flow
(mixed flow) are kept at the same ratio even if the flow
are changing
• CASCADE CONTROL: uses the output of primary
controller to manipulate the set point of the secondary
controller as if it were the final control element
• OVERRIDE CONTROL :is used to take control of an
output from one loop to allow a more important loop to
manipulated the output
Control Diagram of a Typical Control Loop

A c tu a to r
S y s te m
F1 F2

T 1
T 2

S en so r
S y stem
C o n tr o lle r TC
T
TT
Components and Signals of a Typical Control Loop

F1 F2

T 1
T 2

T h e r m o w e ll
3 -1 5 p s ig
T
A ir 4 -2 0 m a
I /P D /A T h e r m o c o u p le
m illiv o lt s ig n a l

T DCS 4 -2 0 m a
O p e ra to r sp
C o n tro l A /D T r a n s m itte r
C o n s o le
C o m p u te 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
Process
Controller Manipulated Process
Input Output
 Cascade Control Loop

T T T C T sp

R 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
Process
Controller Manipulated Process
Input Output
 Ratio Control Loop
FIELD CONTROLLER FIELD

OUT1
MLD-SW

A
OUT
PID SPLIT

OUT2
MLD-SW

MV MV

100 100

50 50

0 PV 0 PV
50 100 50 100
 Pneumatic Controller

• Introduced in the 1920’s

• 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 1930’s.
• 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 F2

T 1
T 2

T h e r m o w e ll
3 -1 5 p s ig
T

A ir T h e r m o c o u p le
m illiv o lt s ig n a l

T A ir
sp P n e u m a tic 3 -1 5 p s ig
T r a n s m itte r
C o n tr o lle r
 Electronic Analog Controller

• Became available in the late 1950’s.

• Replaced the pneumatic tubing with wires.
• Used resistors, capacitors, and transistors based amplifiers to
implement PID action.
• Out sold pneumatic controllers by 1970.
• Allowed for advanced PID control: ratio, feedforward, etc.
 Electronic Analog Controller

F1 F2

T 1
T 2

T h e r m o w e ll
3 -1 5 p s ig
T
A ir 4 -2 0 m a
I /P T h e r m o c o u p le
m illiv o lt s ig n a l

T E le c tr o n ic 4 -2 0 m a
sp
A n a lo g T r a n sm itte r
C o n tr o lle r
 Computer Control System

• Based upon a mainframe digital computer.

• Offered the ability to use data storage and retrieval, alarm functions,
and process optimization.
• First installed on a refinery in 1959.
• Had reliability limitations.
Computer Control System

V id e o D is p la y A la r m in g
P r in te r
U n it F u n c tio n s

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 D a ta S to r a g e
In te r fa c in g
C o n tr o l A c q u is itio n
H ardw are
S u b sy tem S y stem

...
Evolution - Microprocessor Base Controller

PC PLC

Multi Loop Continuous Multi Loop

& Discrete Controller Programmable Controller

Field Instrument Field Instrument

Evolution - Direct Digital Control (DDC)

CPU PC

RS 232

SEGREGATED
I/O RACK

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
Evolution – Programmable Controller (PLC)

PC

BUS

SEGREGATED
I/O RACK (See Detail)

HARD WIRED

FIELD INDTRUMENTS
PLC System - Rack/Card Configuration

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

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

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
 DCS

• Introduced in the late 1970’s.

• 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
D a ta
S y stem H ost
S to r a g e PLC
C o n so les C o m p u ter
U n it

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 .............. L ocal
C o n tr o l
L ocal
C o n so le
U n it U n it

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
Evolution - Distributed Control System (DCS)

DATA BASE
RACK
MMI MMI
DAT LOGGER

ETHERNET / BUS

GATEAWAY INPU/ OUTPUT CONTROLLER

SYSTEM RACK PLC SYSTEM RACK

FIELD INDTRUMENTS
 DCS VERSUS PLC SYSTEM

DCS PLC
• Small “controlled area” • Small “limited I/O”
• Distributed, no master • Originally Programmable
• High capacity only
• Low capacity
• Microprocessor - base
• Microprocessor - base
• Continues & discrete
control • Batch and Discrete
• Dynamic system Control
• Dynamic System
• Medium speed, 100
mSec • High speed, less 10 mSec
• Bus, Ring and Star • Star Topology
topology • Mostly programmable
• Mostly configurable • Connectable to other
• Connectable to other system
system • Peer to peer
• Peer to peer communication
communication • SIL – 3 (IEC 60518)
• SIL – 2 (IEC 60518) • AK5 & AK6 (TUV Class)
 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
 SCADA SYSTEM – CONFIGURATION

MASTER Point to Multipoint

Station Topology

Half-Duplex
Transmission Mode

Sub Master Sub Master

Station #.1 Station #.2

REMOTE REMOTE REMOTE

Station #.1 Station #.2 Station #.3

Field Devices
   
 
  SCADA SYSTEM – COMPONENT
 
 
 
 
Master Master
  Station Station
 
 
 
  VAX-BASE COMPUTER
MASTER STATION
 
  DCE
 
 
  Point-to Multipoint, Half
  Duplex, PSTN, TCP/IP
  Protocol, Telemetry
  Network
 
 
 
ANALOG DIAL UP
  DCE MODEM
 
  ANALOG DIAL UP
  MODEM
 
  Pipeline Remote
DCE Shutdown Valve

C
 MASTER STATION – Personal Computer

Master
Station

RS – 232 LINK

DCE DCE

DCE
DCE

DTE
DTE

REMOTE REMOTE
STATION #.1 STATION #. 2
MASTER STATION – VAX- or UNIX or Windows - Base Computer

VAX OR UNIX-BASE
Work Work SERVER
Station Station

ETHERNET
NETWORK

CONTROLLER AND
I/O MODULE

RS – 232 LINK

DTE

DCE DCE

DCE
DCE

DTE
DTE

REMOTE
REMOTE
STATION #. 1
STATION #. 2
 SUB MASTER STATION – PLC BASE

COMMUNICATION
WITH
MASTER STATION

DCE

ETHERNET

PROGRAMMABLE
CONTROLLER BASE

DCE DCE

DCE DCE

DTE DTE

REMOTE REMOTE
STATION #. 1 STATION #. 2
 REMOTE STATION – PLC BASE

PUMP STATION

MMI

MASTER DCE
STATION
DCE

ETHERNET
DCE DCE DCE DCE

WASTE WATER
TREATMENT PLANT
DCE

DCE

PUMP STATION
GAS METERING
STATION
 DCS VERSUS SCADA SYSTEM

DCS SCADA
• Small “controlled area” • Big & wide “controlled
• Distributed, no master area”
• Centralized, master -
• High capacity
slave
• Microprocessor - base
• Low capacity
• Continues & discrete
• Microprocessor - base
control
• Remote, supervisory
• Dynamic system
control
• Medium speed, 100
• Static, shutdown
mSec
purposes
• Bus, Ring and Star
• High speed, less 10 mSec
topology
• Point to point/multipoint
• Mostly configurable
• Mostly programmable
• Connectable to other
system • Limited capability
• Peer to peer • Peer to peer
communication communication
• SIL – 2 (IEC 60518) • SIL – 3 (IEC 60518)
 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.
 Field Bus Configuration

P la n t-W id e N e tw o r k

.................
L ocal L ocal
A rea A rea
N e tw o rk N e tw o r k

Sm art S m a r t C o n tr o l Sm art S m a r t C o n tr o l
S en so rs V a lv e s a n d S en so rs V a lv e s a n d
C o n tr o lle r s C o n tr o lle r s

F ie ld b u s N e tw o r k F ie ld b u s N e tw o r k
a
 Fieldbus Vs Conventional
Field wiring Information flow Quantity of Information type Control Maintenance Maintenance type
information functionality location

Conventional 4 to Point-to-point Unidirectional Single data value Measurement Centered on a Mainly in the field Corrective
20 mA numerical value control system maintenance

Fieldbus Multi-drop Bidirectional Multiple data Various data types Optimally From a remote Predictive
values allotted to controllocation maintenance
system and/or
field devices
 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
Typical Fieldbus Network