Unit - 1 Icpc29

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ICPC29 LOGIC AND DISTRIBUTED

CONTROL SYSTEMS
Unit - 1
Course Objectives
1. To introduce the importance of process automation techniques.

2. To impart knowledge in PLC based programming.
3. To introduce distributed control system and different
communication protocols.
ICPC29 Logic and Distributed Control Systems 2
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COURSE CONTENT
Review of PC based control design for process automation: Functional Block diagram
of Computer control of process - Mathematical representation – Sampling
Consideration- Data Acquisition system and SCADA, Hybrid, Direct Digital Control
System, Distributed Control system architecture and Comparison with respect to
different performance attributes.
Programmable logic controller (PLC) basics: Definition, overview of PLC systems,

Block diagram of PLC. General PLC programming procedures: ON/OFF instruction,
Timer instruction sets, Counter Instruction sets -Design, development and simulation
of PLC programming using above instruction sets for simple applications.
PLC Data manipulation instruction - Arithmetic and comparison instruction- Skip,

Master Control Reset (MCR) and Zone Control Last state (ZCL) instruction – PID and
other important instruction set. PLC Installation, troubleshooting and maintenance.
Design of alarm and interlocks, networking of PLC – Case studies using above
instruction sets.
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ICPC29 Logic and Distributed Control Systems
COURSE CONTENT
Distributed Control system: Local Control Unit (LCU) architecture - Comparison of

different LCU architectures – LCU Process Interfacing Issues: - Block diagram,
Overview of different LCU security design approaches, secure control output design,
Manual and redundant backup designs.
LCU communication Facilities - Communication system requirements – Architectural

Issues – Operator Interfaces – Engineering Interfaces. Development of Field Control
Unit (FCU) diagram for simple control applications. Introduction to HART and Field
bus protocol. Interfacing Smart field devices (wired and wireless) with DCS controller.
Introduction to Object Linking and Embedding (OLE) for Process Control, Automation
in the cloud with case studies.
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Course Outcomes
On the completion of this course, the students will be familiar with,
1. familiar with process automation technologies.

2. able to design and develop a PLC ladder programming for simple
process applications.
3. able to apply different security design approaches, engineering and
operator interface issues for designing of Distributed control system.
4. familiar with latest communication technologies like HART and Field bus
protocol
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TEXT BOOKS
1. John W. Webb and Ronald A Reis, Programmable Logic Controllers -

Principles and Applications, Prentice Hall Inc., New Jersey, 5th Edition, 2003.
2. Lukcas M.P Distributed Control Systems, Van Nostrand Reinhold Co.,

New York, 1986.
3. Frank D. Petruzella, Programmable Logic Controllers, McGraw Hill, New

York, 5th Edition, 2016.
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REFERENCE BOOKS
1. Deshpande P.B and Ash R.H, Elements of Process Control

Applications, ISA Press, New York, 1995.
2. Curtis D. Johnson, Process Control Instrumentation

Technology, Pearson New International, 8th Edition, 2013.
3. Krishna Kant, Computer-based Industrial Control, Prentice

Hall, New Delhi, 2nd Edition, 2011.
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SYLLABUS
Unit-1
Review of PC based control design for process automation:

Functional Block diagram of Computer control of process -
Mathematical representation – Sampling Consideration- Data
Acquisition system and SCADA, Hybrid, Direct Digital Control
System, Distributed Control system architecture and
Comparison with respect to different performance attributes.
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PC based control design for process automation

Introduction:
• Transmitters (1950) gave a standard signal (3-15 psi, 4-20
mA) which could be sent over long distances, and thus, allow
controllers to be grouped together for supervision.
Krishna Kant, 2011

Historical development 9

Centralized computer system:
• Required to bring process signals to centralized computer
system and return the control signals to the field.
Krishna Kant, 2011

Centralized computer system 10
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Distributed digital computer system
• Computer languages such as, Real-Time Fortran, Pascal,
ADA and C have become most popular with distributed
computer control systems. This is coupled with rapid strides
in the developments in fibre-optics technology for wide-band
communications between different computers in the system.
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Krishna Kant, 2011 Distributed digital computer system

Reasons for Automation :
• To increase labor productivity

• To reduce labor cost
• To reduce or remove routine manual and clerical tasks
• To improve worker safety
• To improve product quality
• To reduce manufacturing lead time
• To accomplish what cannot be done manually
• To avoid the high cost of not automating
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 Computers
 Controllers
 Actuators
 Sensors
 Software
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Introduction:
• PC-Based Automation combines the features of PLC-Control

and open PC-Architecture on one industrial device
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Evolution of PC based:
• Plants with high requirements on processing speed,
• Example : measurement and quality control systems, benefit

from the computing power and openness of PC technology.
• Plants often operate continuously and in a harsh industrial

environment, the PCs must also be designed to run under
these conditions.
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Advantages of using PC based control :
• Ease of implementation because of easily available

programmer base
• Ease of configuration, maintenance as PC know-how is
easily available.
• Networking of different controllers is possible.
• Feature to communicate the automation/production data to
other PC
• Ability to store production data of a longer period of time.
• Generate different graphs and reports for visualization
• Graphically rich user-interface environment.
• Multitask capability.
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PC based automation basics :
• Fewer functional components needed for use in an
application-Eg: an IPC can consolidate such elements as
the PLC itself, plus its HMI
• Integration of non-PLC functionality with traditional PLC

control logic- Eg: oil and gas industry would be to integrate
a monitoring and control application in a driller’s cabin with a
producer’s enterprise resource planning (ERP) system back
at headquarters
• Large data storage capacities on-board or connected -

storage area networks) for various black-box applications that
generate large amounts of data or in order to collect high-
speed data from process applications 19

PC based automation applications:
• open-loop and closed-loop control in mechanical

engineering,
• visualization in the food & beverage industry,
• measuring and testing in the automotive industry,
• data processing and communication in the semiconductor
and electronics industry,
• intellectual property protection in emerging markets
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Requirements :
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PLC with PC based automation:
• Which is better for industrial control, PLC or PC?
logical answer is both.
• With PACs, the flexibility, multifunctionality, and speed of PCs
running control software are combined with the reputation for
robustness, reliability, and installed base of PLCs.
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PC-Based Controls
• PC-based controls are programmed on a Windows computer
and used to communicate with and monitor an entire material
handling system or specific material handling equipment.
PLC-Based Controls
• A programmable logic controller (PLC) is a small computer,
often located inside a larger electrical control panel,
programmed to run an entire system or specific equipment.
• Unlike a typical computer, a PLC can only be used to handle
programming language for machine automation.
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PC based controllers:
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PC based controllers:
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SYLLABUS
Unit-1

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Computer control of process

Introduction:
• Advances in instrumentation and control contributed to the
development of larger and more complex processes, bringing
numerous technological and economical benefits to the
operator.
Use of Computer in measurement and control 29

Computer based control:
• Objective of computer based measurement and control is to
acquire the information from field devices (input), and
compute a logical decision to manipulate the material and
energy flow of given process in a desired way to get optimal
output.
• Digital computer control applications in the process industries
may be of passive or active type.
• Passive application involves only acquisition of process data

(data acquisition / data logging).
• Active application involves acquisition and manipulation of

data and uses it for (real time) process control.
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Centralized Control:
• Centralized control is used when several machines or
processes are controlled by one central controller.
• Control layout uses a single, large control system to control
many diverse manufacturing processes and operations.
• Each individual step in the manufacturing process is handled
by a central control system controller.
• One disadvantage of centralized control is that, if the main
controller fails, the whole process stops.
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Computer control

Distributive Control:
• Each machine is handled by a dedicated control system.
• Each dedicated control (PLC) is totally independent and

could be removed from the overall control scheme if it were
not for the manufacturing functions it performs.
• It involves two or more computers communicating with each

other to accomplish the complete control task.
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Distributive control
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Distributive Control:
• Type of control typically employs local area networks (LANs),
in which several computers control different stages or
processes locally and are constantly exchanging information
and reporting the status on the process.
• Communications among computers is done through single

coaxial cables or fiber optics at very high speed.
• Distributive control drastically reduces field wiring and

heightens performance because it places the controller and
I/O close to the machine process being controlled.
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Components of computer based measurement and control
• Measurement and Data Acquisition

• Data conversion and scaling and checking
• Data accumulation and formatting
• Visual display
• Comparing with limits and alarm raising
• Events, sequence and trends; monitoring and logging
• Data logging and Computation
• Control actions
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Analog and Digital I/O Module :
• Analog input signals are received from sensors and signal
conditioner and represent the value of measurand like flow,
position, displacement, temperature, etc.
• Signal conditioner takes as input the output of sensor and suitably

conditions them to be acceptable to real-time systems. The signal
may be amplified, filtered or/and isolated in signal conditioner
depending on the sensor type and its electrical characteristics.
• Digital input signals refer to the ON-OFF states of various valves,

limit switches, etc. one digital input signal represents status of the
limit switch or valve and is represented by on bit of information for
real-time systems. It is compatible to real-time systems and can be
inputted directly.
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Analog input module :
• Continuously scans the analog inputs signals in the pre-defined
order and frequency, converts them into the digital and then sends
these values to processor and memory module for processing.
• It also provide signal conditioning for some standard transducers

like thermocouples, LVDTs, strain gauges etc. in such cases,
analog input modules may be different for different types of
transducers.
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Analog input module
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Analog input module: Operates under the command from processor
in the following manner:
• The processor initiates multiplexer by sending the address of input

channel.
• The multiplexer connects the particular channel to the ADC.
• The processor sends the start convert signal to ADC. The ADC
converts the analog signal to digital, puts it at the output and
issues end of conversion signal.
• The processor on receipt of the end of conversion signal reads the
ADC output and stores in memory.
• The operation is repeated by processor by sending the address of
next channel to multiplexer.
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Digital input module:
• Digital inputs can be accepted directly by the processor. Thus no
analog to digital converter is required in digital input module.
• Each digital input channel consists of n bits which are transferred

in parallel.
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Digital input module
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Analog output module:
• To provide appropriate control signals to different control valves.
the structure of analog output module which is derived by reversing
the analog input module.
• The de-multiplexer switches the digital output received from the
master processor to the output channel whose address is
specified.
• The digital to analog converter of particular channel will convert the
input digital value to equivalent analog signal which is connected to
control valve, motor etc.
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Analog output module

Timer/counter module:
• Consists of a number of times/counters which may be cascaded or
used independently.
• Each timer/counter may be programmed in different modes in

which case the timer/counter output will be different.
• The modes may be interrupt on zero count, rate generator,

monoshot etc.
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Timer/counter module
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Timer/counter module:
• Processor loads the count in the form of data byte/words.
• The clock may be derived from processor clock or may be

provided externally.
• The gate signal is used to enable/disable the counter operation.
• The processor may read the current counter value at any instant
by stopping the counter using gate signal or read it on the Fly, i.e.,
without stopping the counter.
• The output may be used to interrupt the processor or in any other

way as programmed.
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Display counter module:
consists of following independent sub-modules.
• Manual entry sub-module

• CRT controller sub-module
• LED/LCD control sub-module
• Alarm annunciate sub-module
• Printer controller sub-module
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CRT controller module:
• Interfaces main processor to Visual Display Unit, which is used to
show the status of process by displaying transducers values,
present set points entered through manual entry sub-module,
historical trend of various parameters, mimic diagram of process,
alarm status etc.
• LED/LCD control sub- module interfaces array of LED/LCD to main

processor. It accepts data bytes/word from main processor and
displays it on LED/LCD.
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Computer controlled system:
• Controlled variable (output of the process) is measured as
before in continuous electrical signal (analog) form, and
converted into a discrete-time signal using device called
analog-to-digital converter (ADC).
• The value of discrete signal thus produced is then compared

with the discrete form of the set-point (desired value) inside
the digital computer to produce an error signal (e).
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Computer controlled system 45

Computer controlled system:
• An appropriate computer program representing the controller,
called control algorithm, is executed which yields a discrete
controller output.
• The discrete signal is then converted into a continuous

electrical signal using a device called digital-to-analog
converter (DAC), and the signal is then fed to the final control
element.
• This control strategy is repeated at some predetermined

frequency so as to achieve the closed- loop computer control
of the process.
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Computer based controlled system

Hot air blower system:
• Centrifugal fan blows air over a heating element and into a
tube.
• The hot-air temperature at the output is measured and by

thermocouple, which, through signal conditioner, generates a
proportional voltage signal to temperature.
• The output temperature in this process may be increased or

decreased by varying the heater current. The air-inlet valve
opening and closing for flow of air into the blower is adjusted
by means of a reversible motor.
• The motor operates at constant speed and is turned on or off

by a logic signal applied to motor on / off control. 48
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Hot air blower system 49

Hot air blower system:
• Information regarding the measured value of air temperature
and fan inlet valve position is obtained in the form of analog
signal.
• An analog to- digital converter is used to convert the analog

signal into digital signal before it is fed to the computer.
• The status of fully open or fully closed position of the fan inlet
valve is obtained in the form of digital signals.
• For the output generated by the computer, digital -to- analog

converter is used to send control signal in analog form to the
motor control.
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Block diagram - Hot air blower system 51
Hot air blower system – controlled using computer 52

based system
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Advantages of computers in measurement and control:
• Ensure the repeatability in the product quality that is essential

in manufacturing plants.
• It permits flexibility to modify the sequencing and control
procedures.
• It helps in reduction in dead time of batch operation.
• Increases the productivity of the plant significantly by
ensuring greater plant availability.
• It maintains a data base containing the product recipe and
easy to change to a new recipe quickly and reliably.
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SYLLABUS
Unit-1

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Sampling consideration
Introduction:
• Digital computer used – controller, process of signal
conversion is essential
• Analog / Digital (A/D) – Output of analog device.
• Digital / Analog (D/A) – coded signal from controller
• Sample and Hold (S/H) device
Sampled data control system
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Sampled data control system
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Introduction:
• Generally signals are analog in nature (eg: speech,weather
signals).
• To process the analog signal by digital means, it is essential
to convert them to discrete-time signal, and then convert
them to a sequence of numbers.
• The process of converting an analog to digital signal is
– Analog-to-Digital Conversion
• The ADC involves three steps which are:
– Sampling
– Quantization
– coding
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Types of signals:
• Analog signals: continuous in time and amplitude
– Example: voltage, current, temperature,..
• Digital signals: discrete both in time and amplitude

– Example: attendance of this class, digitizes analog signals,…
• Discrete-time signal: discrete in time, continuous in amplitude

– Example: hourly change of temperature in Austin
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Sample and hold device:
• Sampler – converts an analog signal into train of amplitude
demodulated pulses.
• Hold device – maintains the value of the pulse for a

prescribed time duration.
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Sample and hold device
Sample and hold device:
• S-H circuit – capacitor, electronic switch, op-amp.
• Switch goes to logic 1 state (closed condition), capacitor

charges to Vin and Vout = Vin
• Switch goes to logic 0 state (open condition), capacitor retain

its charges and output holds the at Vin
• Fundamental parameter – Acquisition time, Aperture time,

Drop rate.
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Hold process :
• inverse of sampling process i.e conversion of sequence to a
continuous time function.
• Extracting the samples
• Holding the result fixed for one period.
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Sample and hold operation
Sampling :
• During sampling process, a continuous-time signal (analog)
is converted into discrete -time signals by taking samples of
continuous-time signal at discrete time intervals.
• x(nTs) = x(t)
T - Sampling Interval
x (t) - Analog input signal
Fs =1/T , sampling rate or samples per second
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Sampling theorem:
• Sampling theorem gives the criteria for minimum number of
samples that should be taken.
• Sampling criteria:- Sampling frequency must be twice of the
highest frequency.
Fs>2Fm
– Fs=sampling frequency
– Fm=higher frequency content
• Nyquist rate is defined as the minimum sampling rate for the

perfect reconstruction of the continuous time signals from
samples.
• Nyquist rate=2*highest frequency component (=2*W)
• Sampling rate must be greater than or equal to nyquist rate.
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Ideal Sampling :
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Ideal Sampling:
• In Time domain: Sampling results in conversion of continuous time
signal into discrete time signal.
• In Frequency domain: Sampling results in multiple translation of signal

spectrum (linear combination of shifted signal spectrum at integer
multiples of sampling frequency.
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Ideal Sampling : Reconstruction
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Aliasing :
• In case of under sampling
( s<2 m ), shifted versions of
signal spectrum shall overlap
resulting in spectral distortions.
• In such case, signal can not be

recovered from its samples.
This effect is known as
ALIASING.
• To avoid aliasing effect due to

spurious frequencies, a pre
alias filter is applied before
sampling
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Types of sampling:
• Periodic sampling
• Multiple-order sampling
• Multiple rate sampling
• Random sampling
• Shannon’ sampling theorem
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Types of sampling:
• Periodic sampling – samples are obtained uniformly at
interval of T seconds.
• Multiple-order sampling – Particular sampling pattern is

separated periodically.
• Multiple rate sampling – two simultaneous sampling

operations with different time periods are carried out on the
signal to produce the sampled output.
• Random sampling – sampling instants are random.

Sampling frequency is selected based on shannon’s
theorem.
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Shannon’s sampling theorem :
• A band limited continuous time signal with highest frequency
(fm) hertz can be recovered from its samples. Sampling rate
is greater than or equal to 2 fm samples per second.
Fs >2 Fm, Fs=1/T
• Used for choosing the sampling frequency
• Conversion process of sampled signals by digital signal

consists of two process.
– Quantization
– Coding
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Shannon’s sampling theorem :
• Quantization – converting a discrete-time continuous valued

signal into discrete-time discrete valued signal.
• Coding – representing each discrete value by n-bit binary

sequence or code.
• Quantization error – difference between the unquantized

sample and quantized output.
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Mathematical modeling of sampling process

Introduction:
• Sampling operation in sampled data and digital control
system is used to model either the sample and hold operation
or the fact that the signal is digitally coded.
• If the sampler is used to represent S/H (Sample and Hold)

and A/D (Analog to Digital) operations, it may involve delays,
finite sampling duration and quantization errors.
• On the other hand used to represent digitally coded data the

model will be much simpler.
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Finite pulse with sampler:
• Sampler is the one which converts a continuous time signal

into a pulse modulated or discrete signal.
• The most common type of modulation in the sampling and

hold operation is the pulse amplitude modulation
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Finite pulse with sampler (a) Symbolic representation

(b) Block diagram (c) Operation
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Finite pulse with sampler:
• Pulse duration is p second,
• sampling period is T second
• p(t) – unit pulse train with period T
• Uniform arte sampler – satisfies the principle of
superposition.
• Us(t) – unit step function, leading edges of the pulse, t=0,
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Frequency domain characteristics:
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Ideal sampler:
• Carrier signal is replaced by a train of unit impulses.
• Sampling duration p approaches 0, i.e., its operation are

instantaneous.
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Zero order hold:
• Higher the order of the derivatives to be estimated is, larger
will be the number of delayed pulses required. Since time
delay degrades the stability of a closed loop control system,
using higher order derivatives of f(t) for more accurate
reconstruction often causes serious stability.
• Accuracy of zero order hold (ZOH) depends on the sampling

frequency. When output of ZOH approaches the continuous
time signal. Zero order hold is again a linear device which
satisfies the principle of superposition
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Impulse response of ZOH
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Zero order hold:
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Zero order hold:
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SYLLABUS
Unit-1

Data acquisition system (DAS)

Introduction:
• Data acquisition systems (DAS) interface between the real
world of physical parameters, which are analog, and the
artificial world of digital computation and control.
• With current emphasis on digital systems, the interfacing

function has become an important one; Digital systems are
used widely because complex circuits are low cost, accurate,
and relatively simple to implement.
• Industries that presently employ such automatic systems

include steel making, food processing, paper production, oil
refining, chemical manufacturing, textile production, cement
manufacturing, and others.
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Block diagram of Data Acquisition System

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Introduction:
• Industries that presently employ such automatic systems include
steel making, food processing, paper production, oil refining,
chemical manufacturing, textile production, cement manufacturing,
and others.
• The devices that perform the interfacing function between analog

and digital worlds are analog-to- digital (A/D) and digital-to-analog
(D/A) converters, which together are known as data converters.
• Some of the specific applications in which data converters are

used include data telemetry systems, pulse code modulated
communications, automatic test systems, computer display
systems, video signal processing systems, data logging systems,
and sampled data control systems.
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PC-based DAQ system:
• Personal computer
• Transducers
• Signal conditioning
• DAQ Hardware
• DAQ Software
Typical PC based DAQ System

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• Personal computer - Computer used for your data acquisition
system can drastically affect the maximum speeds at which you
are able to continuously acquire data. For remote data acquisition
applications that use RS-232 or RS-485 serial communication,
your data throughput will usually be limited by the serial
communication rates.
• Transducers - sense physical phenomena and provide electrical

signals that the DAQ system can measure. Eg: thermocouples,
RTDs, thermistors, and IC sensors convert temperature into an
analog signal that an ADC can measure.
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Why use signal conditioning ?
• Field configurable signal conditioners – reduce cost –

control inputs (4-20 mA) DC.
• Controls do not accept all sensor: T/C, RTD, POT, etc
• It may not be possible to add additional I/O cards.
• It is preferred to perform math functions in a signal
conditioner rather than controller.
– Add, Subtract, Multiply, Divide
– Square Root
– Comparator
• Converting a process signal to frequency allows
totalization, counting.
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• Signal conditioning - Electrical signals generated by the
transducers must be optimized for the input range of the DAQ
board.
• Signal conditioning accessories can amplify low-level signals, and

then isolate and filter them for more accurate measurements. In
addition, some transducers require voltage or current excitation to
generate a voltage output.
• Signal conditioning has the following applications:

– Amplification,
– Isolation,
– Filtering,
– Excitation and
– Linearization. 88
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• Amplification - Convert a low or weak signal to one that is robust
and capable of driving larger loads and/or transmitting over a long
distance.
• Low-level thermocouple signals, for example, should be amplified

to increase the resolution and reduce noise.
• Signal should be amplified so that the maximum voltage range of

the conditioned signal equals the maximum input range of the
analog-to-digital converter (ADC). Very high resolution reduces the
need for high amplification and provides wide dynamic range.
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Why Isolation?
• Eliminate ground loops and unwanted interference.
• Reduce potential for damage to sensitive equipment due to

transients or spikes.
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• Isolation - to isolate the transducer signals from the computer for safety
purposes.
• To make sure that the readings from the plug-in DAQ board are not
affected by differences in ground potentials or common-mode voltages.
• The system being monitored may contain high-voltage transients that

could damage the computer.
• It will eliminate the ground loop and ensure that the signals are accurately
acquired.
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• Filtering - purpose of a filter is to remove unwanted signals from the
signal that you are trying to measure.
• Noise filter - DC-class signals such as temperature to attenuate higher

frequency signals that can reduce the accuracy of your measurement.
• Antialiasing filter (low pass filter) - removes all frequencies of the signal
that are higher than the input bandwidth of the board.
• If the signals were not removed, they would erroneously appear as

signals within the input bandwidth of the board.
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• Excitation - generates excitation for transducers like Strain

gauges, thermistors, and RTDs, for example, require external
voltage or current excitation signals.
• RTD measurements are usually made with a current source that

converts the variation in resistance to a measurable voltage.
• Strain gauges, which are very low-resistance devices, typically are

used in a Wheatstone bridge configuration with a voltage excitation
source.
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• Linearization - Characteristic of a sensor is non-linear. Special

circuits were designed to linearize signals. Use computer software
for linearization.
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• Replication - Split, duplicate, replicate a sensor or process input to

2 or more outputs.
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• Attenuation - Reduce a high input signal to one that is compatible

with a control or monitoring device.
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• Communications - Monitor and/or control sensors or process

signals via Ethernet, Modbus, Profibus, CANopen, Etc.
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Functions of Signal conditioning
• Amplification
• Filtering
• Differentiation
• Integration
• Linearization
• Combining a measured signal with a reference signal
• Converting a resistance to a voltage signal
• Converting a current signal to a voltage
• Converting a voltage signal to a current signal
• Converting a frequency signal to a voltage signal
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Advantages of Signal conditioning
Signal conditioning may typically include
• Converting resistance changes to voltage changes,

• subtracting offset voltages,
• increasing signal voltages,
• removing unwanted frequency components.
• power amplification
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• DAQ hardware - includes the following functions.
• Analog input
• Sampling rate
• Multiplexing
• Resolution
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• Analog input - give you information on both the capabilities and the
accuracy of the DAQ product such as number of channels, sampling rate,
resolution, and input range.
• Number of analog channel inputs will be specified for both single-ended

and differential inputs on boards that have both types of inputs.
• Single- ended inputs are all referenced to a common ground point. These
inputs are typically used when the input signals are high level (greater
than 1 V),
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• Sampling rate - determines how often conversions can take place. A

faster sampling rate acquires more points in a given time and can
therefore often form a better representation of the original signal.
• Example - audio signals converted to electrical signals by a microphone

commonly have frequency components up to 20 kHz..
• Nyquist sampling theorem - sample at more than twice the rate of the
maximum frequency component. Sampling rate greater than 40 kS/s is
needed to properly acquire this signal.
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Effect of sampling rate
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• Multiplexing – is a technique for measuring several signals with a

single ADC.
• ADC samples one channel, switches to the next channel, samples it,
switches to the next channel, and so on.
• Because the same ADC is sampling many channels instead of one, the
effective rate of each individual channel is inversely proportional to the
number of channels sampled.
103

• Resolution – number of bits that the ADC uses to represent the

analog signal.
• Higher the resolution, the higher the number of divisions the range is
broken into, and therefore, the smaller the detectable voltage changes.
• A 3-bit converter (which is actually seldom used but a convenient

example) divides the analog range into 23, or 8 divisions. Each division is
represented by a binary code between 000 and 111
Digitized sine wave with 3-bit Resolution 104
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• DAQ software - transforms the PC and DAQ hardware into a

complete DAQ, analysis, and display system.
• Two types of software is used:
• Driver software
• Application software
105

• Driver software - is the layer of software that directly programs the
registers of the DAQ hardware, managing its operation and its integration
with the computer resources, such as processor interrupts, DMA, and
memory.
• Driver functions for controlling DAQ hardware can be grouped into analog
I/O, digital I/O, and timing I/O.
• Acquire data at specified sampling rates.

• Acquire data in the background while processing in the foreground.
• Use programmed I/O, interrupts, and DMA to transfer data.
• Stream data to and from disk.
• Perform several functions simultaneously.
• Integrate more than one DAQ board.
• Integrate seamlessly with signal conditioning equipment.
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• Application software - an additional way to program DAQ

hardware. use driver software to control the DAQ hardware.
• It add analysis and presentation capabilities to the driver software.
• Application software also integrates instrument control such as

GPIB (General Purpose Interface Bus), RS-232, PXI (Peripheral
component interact Extensions for Instrumentation), and VXI
(Virtual Extension for Instrumentation) with data acquisition.
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SYLLABUS
Unit-1

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SCADA
Introduction:
• Industrial control system (ICS) is a general term that has several
types of control systems, including
• Supervisory Control And Data Acquisition (SCADA) systems

• Distributed Control Systems (DCS)
• Other smaller control system configurations such as
Programmable Logic Controllers (PLC).
• Provides management information, including scheduled

maintenances procedures, logistic information, trending and
diagnostic data for sensor or machine.
Features of SCADA 109
SCADA
Why SCADA?
• Saves Time and Money

• Less traveling for workers
• Reduces man-power needs
• Increases production efficiency of a company
• Cost effective for power systems
• Saves energy
• Reliable
• Supervisory control over a particular system.
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SCADA
Technology Evolution
Supervisory control and data acquisition system (SCADA)

111
SCADA
Control operation - Plant 112
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SCADA
What is SCADA ?
• SCADA - Supervisory Control And Data Acquisition.
• Used for monitoring, analysing and controlling an industrial

process.
• Capable of real time monitoring and management of physical asset

dispersed over very large geographical area.
• used to monitor and control a plant or equipment in industries such as

telecommunications, water and waste control, energy, oil and gas refining
and transportation.
• It encompass the transfer of data between a SCADA central host

computer and a number of Remote Terminal Units (RTUs) and/or
Programmable Logic Controllers (PLCs), and the central host and the
113
operator terminals.
SCADA
Typical SCADA system SCADA system general

layout
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SCADA
SCADA System consists of
• One or more field data interface devices, usually RTUs, or PLCs, which
interface to field sensing devices and local control switchboxes and valve
actuators .
• A communications system used to transfer data between field data

interface devices and control units and the computers in the SCADA
central host. The system can be radio, telephone, cable, satellite, etc.,
• A central host computer server or servers (sometimes called a SCADA

Center, master station, or Master Terminal Unit (MTU).
• HMI or MMI systems used to provide the SCADA central host and
operator terminal application, support the communications system, and
monitor and control remotely located field data interface devices.
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SCADA
Supervisory control and data acquisition system (SCADA)

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SCADA
SCADA System perform functions
• Data acquisition
• Networked data communication
• Data presentation
• Control
Components of SCADA System
• Telemetry system
• Data acquisition server
• Human-machine interface (HMI)
• Supervisory (computer) system
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SCADA
• Telemetry system - used to connect PLCs and RTUs with control centers
data ware houses, and the enterprise.
• Examples of wired telemetry media - telephone lines and WAN circuits.
• Examples of wireless telemetry media - cellular and microwave and other
communication medium.
• Data acquisition server - is a software service which uses industrial

protocols to connect software services via telemetry with field device such
as RTUs and PLCs.
• It allows clients to access data from these field devices using standard
protocols.
• Supervisory (computer) system - acquiring data on the process and

sending commands(control) to the SCADA system.
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SCADA
• Human machine interface (HMI) – which presents processed data to a
human operator, and through this, the human operator monitors and
interacts with the process.
• Also known as Operator Station/Work Station /Control Client.
• Present the process graphic displays with operator interaction process

values, monitor & analyze, control process, optimize performance.
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SCADA
• Human machine interface (HMI) – is a client that requests data from a
data acquisition on server.
• A "historian", is a software service within the HMI which accumulates

time-stamped data, events, and alarms in a database which can be
queried or used to populate graphic trends in the HMI.
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SCADA
SCADA Architecture
• First generation: Monolithic

• Second generation: Distributed
• Third generation: Networked
Monolithic
Networked 121
Distributed
SCADA
Monolithic SCADA System
• Minicomputers are used earlier for computing the SCADA systems.
• First generation - monolithic SCADA systems were developed wherein the

common network services were not available.
• These are independent systems without having any connectivity to other

systems.
• Wide Area Networks (WANs) that were implemented to communicate

with remote terminal units (RTUs) were designed with a single purpose
for communicating with RTUs in the field.
• Connectivity to the SCADA master station itself was very limited by the
system vendor.
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SCADA
123
First Generation SCADA Architecture - Monolithic
SCADA
Distributed SCADA System
• Improvement in system miniaturization and Local Area Networking

(LAN) technology to distribute the processing across multiple systems.
• Multiple stations, each with a specific function, were connected to a LAN

and shared information with each other in real-time.
• It serve as communications processors, primarily communicating with

field devices such as RTUs and operator interfaces, providing the human-
machine interface (HMI) for system operators.
• It functions across multiple systems provided more processing power for

the system than in a single processor.
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SCADA
Second Generation SCADA Architecture - Distributed 125
SCADA
Networked SCADA System
• Third generation SCADA systems comes from the use of WAN protocols
such as the Internet Protocol (IP) for communication between the master
station and communications equipment.
• Master station is responsible for communications with the field devices to

be separated from the master station “proper” across a WAN.
• Vendors are now producing RTUs that can communicate with the master
station using an Ethernet connection.
• Distribution of SCADA functionality over a WAN is that of disaster

survivability.
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SCADA
127
Third Generation SCADA Architecture - Networked
SCADA - Architecture
Master station area
• Scada Server, Network &
Operating System Software,
• Engineering Software
• Application development platform
• Performs calculations, logs and
archives historical data
• provides I/O server functionality and
switching
Field station area

• Field Devices
• Communication Infrastructure
• RTUs
• Programmable Logic Controllers SCADA system
(PLC) architecture
• Human Machine Interface (HMI) 128
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Master station area – Scada server
• Systems include at least one, if not two,

data server computers. The server
computer is at the physical Centre of the
Star topology.
• Server computer performs all of the

communications with the PLCs and RTUs
on the SCADA network.
• It maintains and collects data pertaining to

its process areas. This data is then
retrieved by the server computer to update
the current process and the historical
databases.
SCADA servers
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Field station area – Field devices
• Field Devices in a SCADA system include wireless sensors, multi-

variables transmitters, and flow computers.
• These devices transmit data to the RTUs, regarding parameters that are
monitored, such as flow, level or temperature.
• RTUs in turn transmit the data to the SCADA server for monitoring and
controlling purpose.
Field devices
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Communication Infrastructure
• It enables communication between the various components in a scada
system.
• It includes cables and wireless networks, Data radios, Modems and

satellites to connect all fundamental components via a Local Area Network
(LAN) or remote connectivity, using Ethernet or other high-speed
communication system.
• There are three basic topologies used for SCADA system :

– Bus topology
– Star topology
– Token ring topology
Communication
devices
131
Communication interface – Bus topology
• All traffic or communications in the system is accomplished via this single

bus-type network.
• For increased traffic, the network can become overloaded, and the result is
a slowing down of the transfer of data from one node to another.
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Bus Topology
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Communication interface – Star topology
• This master node would typically consist of one or two master SCADA
workstation functioning as masters of the system. All data collection from
the various RTU/PLC nodes is done through individual connections in a
star configuration.
• It does require that the information be passed first from the source node,
then through the host node, and then out to the destination node.
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Star Topology
Communication interface – Token ring topology
• Works like a ring in which all nodes are interconnected by two network connections.
All nodes in the topology are of equal value, and data is passed via this ring from
one node to the next.
• It is predictive in that the speed is constant and the time to transfer data is always
at a fixed rate.
• As the number of nodes in the network increases, the overall data transfer rate
drops since there are more nodes through which data must pass to travel from the
source node to the destination node.
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Token Ring Topology
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Remote terminal unit - RTU
• To connect to field devices like sensors, flow meter.
• Microprocessor based controlled device, extreme temp environment,
rugged, remote location.
• Converts field level signal in to data and transfer data to supervisory
system.
• Added advantages is in environment tolerances, backup power options,
and autonomy.
• Visual Basic, C+, Ladder logic, IEC and DNP3 protocol compatible.
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RTU
PLC
• A solid state device that controls output devices based on input status and
a user developed program.
• Microprocessor based controlled device , receives information from input
devices, processes the data, and triggers outputs based on pre-
programmed parameters.
• Unlike an RTU, a PLC is configurable, economical and flexible
• Human body is the biggest example of PLC.
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PLC
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SCADA
Advantages of SCADA :
• Obtain information leading to better process traceability - Frequency

inverter configuration, Motor Speed, Pressure Settings, Fan Status
Cycles.
• Storage of performance data in order to correct quality problems- Having

a historical record of readings will allow for the timely correction of faults
that adversely affect production quality – Fluctuation in instruments
Production issues, Shut downs, Operator efficiency.
• Creating a smart maintenance regime and decreasing downtime.
• Making operatives jobs easier by having graphical statistics presented in

real time.
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SCADA
Applications of SCADA System
• Electric power generation, transmission and distribution

• Water treatment plant
• Oil and Gas Trans & Distributions
• Food processing industry
• Traffic signals.
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SCADA
• Load management
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SCADA
• Water distribution
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SCADA
• Water treatment plant
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SCADA
• Metro elevated station
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SCADA
• Refining and petrochemical
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SYLLABUS
Unit-1

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Hybrid System
Introduction:
• Hybrid system - denotes in general a system composed of two unlike

components.
• A hybrid control system is a control system with both analog and digital
parts.
• Such a system generates a mixture of continuous and discrete signals,

which take values in a continuum (such as the real numbers R) and a finite
set (such as {a; b; c}) respectively.
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Hybrid System
What is Hybrid system?
• Form a richer class of systems than ordinary control systems.
• The continuous flow is in general influenced not only by the continuous

control, but also by the discrete mode.
• Discrete dynamics are affected by both discrete control actions and,

indirectly, by the continuous flow.
• In addition to control inputs, there might be both continuous and discrete

disturbances acting on the system.
• Hybrid control system can be a rather complicated object.
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Hybrid System
Hybrid system:
• Use of a combination of discrete control hardware and computer hardware

in a central location to implement the required control functions.
• First level or local control of the plant unit operations is implemented by

using discrete analog and sequential logic controllers.
• Panel board instrumentation connected to these controllers is used for

operator interfacing and is located in the central control room area.
• A supervisory computer and associated data acquisition system are used

to implement the plant management functions, including operating point
optimization, alarming, data logging and historical data storage and
retrieval.
• Computer also used to drive its own operator interface, usually consisting
147
of one or more video display units (VDUs).
Hybrid System
148
Lukcas, 1986 Hybrid System Architecture
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Hybrid System
Hybrid system:
• It exploit the merits of both analog (compactness, potential speed and

absence of quantisation effect) and digital (robustness, ease of weight
storage and programmability) methods.
• Pulse mode signalling technique has been used in hybrid systems.
• Example – Neuro Fuzzy system
• Both the techniques can handle extreme non-linear behaviour of the

system and allow interpolative reasoning.
• The main idea in integrating the neuro and fuzzy control techniques is to
use the strength of each, resulting in neuro-fuzzy Control Systems.
149
Hybrid System
Neuro Fuzzy system:
• Fuzzy knowledge representation can help the neural network with

explanation facility. The neural network on the other hand can continue to
learn and facilitate fuzzy controller in improving its performance.
• The integration of neuro and fuzzy controller will thus enable the automatic
design and fine-tuning of membership function used in fuzzy control
through learning of neural networks.
• Architecture has main elements, namely, Action-state Evaluation Network

(AEN) and Action Selection Network (ASN).
• Both these elements are modelled by multi-layer neural networks. The

Action Selection Network includes a fuzzy controller and acts as main
controller.
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Hybrid System
Architecture of neuro-fuzzy control system 151
Hybrid System
Neuro Fuzzy system:
• AEN evaluates the performance of system and learns by updating the

prediction of failure.
• It then advises the ASN on fine-tuning the fuzzy controller.
• Both AEN and ASN neural networks employ reinforcement learning with
hidden layer, using modified error backpropagation scheme.
• Combination of neuro controller and fuzzy controller has been successfully

used to control the flatness of cold rolling process in Sendzimir Rolling Mill,
Japan.
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Hybrid System
Example of Hybrid system:
• Problem of maintaining the temperature T of a room at some desired level

(about 19 degrees Celsius, say). If the radiator is off, the temperature
dynamics is given by
• Temperature dynamics is given by
153
Hybrid control system
Hybrid System
• When the thermostat turns on the radiator, the hybrid system jumps from
the off to the on state through the discrete transition turn on.
• It jumps back again when the thermostat turns off the radiator.
• The temperature T, which is a continuous-time variable, is governed by one

of the two differential equations depending on the current discrete state.
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Hybrid System
• Temperature is equal to T = 15 and the radiator is in the mode q = on. The

thermostat control mechanism switches the radiator off and on as T
enables discrete jumps at T = 18 and 20, respectively.
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Evolution of Hybrid control system
Hybrid System
Control Design:
• There is a wide range of control design problems for hybrid systems.
• Supervisory control and

• Optimal control of hybrid systems.
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Hybrid System
Supervisory Control:
• It represents a certain class of hybrid control systems. A supervisor S

decides which of the controllers C1,..,Cm that should be active at each time
instant.
• The switching signal σ: [0;∞]->{1,..,m} is determined by the supervisor

based on the control signal u and the measurement y.
157
Supervisory control
Hybrid System
Supervisory Control:
• The purpose of the supervisor can be to stabilize the plant despite large
uncertainties or disturbances.
• A supervisory control scheme can also be interpreted as so called gain

scheduling, which is a common approach to handle large variations in
operating conditions.
• Controllers are designed for a few operating conditions and then during
operation, the supervisor chooses the controller closest to the current
condition as defined by the state of the system.
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Hybrid System
Optimal Control:
• Example of a control problem utilizing both continuous and discrete control
is provided by a car with a gear box having four gears.
• The longitudinal position of the car along the road is denoted by x1 and its
velocity by x2 (lateral dynamics are ignored).
• The model has the control u = (gear, v), where gear ε [1,...,4] denotes the
gear position and v ε [vmin,vmax] the throttle position. Gear shift is necessary
because little power can be generated by the engine at very low or very
high engine speed.
159
Hybrid system modeling a car with four gears
Hybrid System
Applications of Hybrid system:
• Hybrid system applications studied with some depth in the literature include
• Air traffic management

• Chemical process control
• Communication networks
• Embedded control
• Engine control
• Robotics
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Hybrid System
• Air traffic management – A finite set of manoeuvres, such as speed

change, short cut, and detour, is used by the air traffic controller to obtain a
conflict-free flight environment in which the aircrafts meet their dynamic
and other constraints.
• Chemical process control – To produce a substance, an instruction

sequence is designed, in which each instruction could involve one or more
continuous control elements.
• Communication networks – Large data flows are conveniently modeled

as continuous variables (in order to reduce the model complexity), while
traffic control mechanisms such as routing induce discrete controls.
161
Hybrid System
• Embedded control – Micro-computer embedded in a physical device has

an inherently discrete behavior (e.g., due to finite-precision computations
and quantization of signals), but it interacts with a continuous environment
through actuators and sensors.
• Engine control – Four-stroke gasoline engine is naturally modeled using

four discrete modes corresponding to the position of the pistons, while
combustion and power train dynamics are continuous.
• Robotics – Manipulator is accurately governed by continuous dynamics,

but impacts and load shifting cause discrete and asynchronous changes.
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SYLLABUS
Unit-1

Direct Digital Control (DDC) System

Introduction:
• Computer was not directly connected to the process but was used for
supervision of analog controllers.
• Analog controllers were interfaced to the process directly as well as

through specialized control for dedicated functions.
• Analog controllers and specialized controllers were called level 2 and level
1 control respectively.
• The emergence of economical and fast microprocessor has made analog

controllers completely out-dated, as the same functions can be performed
by digital computers in more efficient and cost effective way.
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165
Krishna Kant, 2011 Supervisory Computer Control

DDC Structure:
• It directly interfaces to the process for data acquisition and control purpose.
• It has necessary hardware for directly interfacing (opto-isolator, signal

conditioner, ADC) and reading the data from process.
• It should also have memory and arithmetic capability to execute required P,

P + I or P + I + D control strategy. At the same time, the interface to control
valve should also be part of DDC.
• Multiplexer acts like a switch under microprocessor control. It switches and

presents at its output the analog signal from a sensor/transmitter.
• Analog to digital converter converts the analog signal to digital value.
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Direct Digital Control 167

DDC Structure:
• Microprocessor performs the following tasks:
• It reads the various process variables from different transmitters through

multiplexer and ADC.
• It determines the error for each control loop and executes control strategy
for each loop.
• It outputs correction value to control valve through DAC.
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DDC Software:
• DDC software is program for control loops.
• There are two algorithms for programming a three-mode PID control loop:
– Position algorithm
– Velocity algorithm
169

Position Algorithm:
• Three-mode controller can be represented by,
• Where,
Yn - valve position at time n
Yo - median valve position
KP - proportional constant = l00 / PB (where, PB - proportional band in per cent),

KI - integral constant = 1/TI (where TI - integral time constant)
KD - derivative constant =TD (where TD - derivative constant)
en - error at instant tn = (S - Vn)
Vn - value of controlled variable at instant tn
S - set-point
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Position Algorithm:
• PID control can be realized with a microprocessor based system, if only the
above equation is implemented in the software.
• Apparently, it is very difficult to write the software for implementing the

above equation for a microprocessor based system.
• Integral term: Integral term at any given instant tn is equal to the algebraic
sum of all the control forces generated by the integral control action from
the beginning to that instant.
• Thus integral term can be represented as
171

Position Algorithm:
• Differential term: at any instant tn is proportional to the rate of

change of the error.
• Differential term, can be represented as
• Where,
– en is the current error
– and en-1 is the previous error calculated at instant tn-1.
• Thus, with this modification the three mode controller will become
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Position Algorithm:
• Integral and the differential control forces are dependent upon the interval
between the two consecutive errors.
• This interval is the inverse of the rate at which the value of the controlled
variable is measured i.e. the sampling rate.
• Provision for defining the sampling rate should be made available in the
software.
• ‘Sampling interval counter’, the set-point, the proportional constant KP, the
integral constant KI and the derivative constant KD are defined by the user.
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Krishna Kant, 2011

Flow chart of PID control 174
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Position Algorithm:
• Recalculates the full valve of the valve setting at each sampling interval.
Advantages
• It has distinct property that it maintains its own reference in yo.
Disadvantages
• Lack of bumples transfer from manual to auto switching.

• Reset wind-up due to integral saturation in test mode.
175

Velocity Algorithm:
• Integral and the differential control forces are dependent upon the interval
between the two consecutive errors.
• Computer calculates the required change in valve position. The output is

digital pulse train which can be directly used in case valve is stepper motor
driven.
• In case of other valves, stepper motor combined with slide wire

arrangement. The same function can be performed by an integrating
amplifier.
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Slide wire arrangement 177

Velocity Algorithm:
• Position algorithm derived earlier is
• Where Yn is valve position at tn.

• At tn-1 i.e at previous instant, the valve position was
• Change is valve position ΔYn at tn
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Effect of set-point band in velocity algorithm
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Krishna Kant, 2011
Krishna Kant, 2011

Flow chart for velocity algorithm 180
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SYLLABUS
Unit-1

Distributed Control System (DCS)

Key Milestones in Control System Evolution :
• 1934 – Direct-connected pneumatic controls dominate market.

• 1958 – First computer monitoring in electric utility.
• 1959 – First supervisory computer in refinery.
• 1960 – First solid-state electronic controllers on market.
• 1963 – First Direct Digital Control (DDC) system installed.
• 1970 – First programmable logic controllers (PLC) on market.
• 1975 – First distributed digital control system on market.
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Evolution of Industrial Control Technology 183

Types of Control System:
• Open loop system
• Closed loop system
• Analog control system
• Digital control system Open loop system
Closed loop system 184
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Analog control system

185
Analog control system

186
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Digital control system 187
Digital control system 188
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Types of Digital Control System:
• Centralized control system

• Distributed control system
Computer control system 189

Centralised control system:
• All system functions are implemented in high-performance computer

hardware in a central location.
• Operator interfacing for plant management functions is provided using

computer driven VDUs.
• Operator interfacing for first-level continuous and sequential closed-loop

control also may be implemented using VDUs.
• Computers can be interfaced to standard panel board instrumentation so

that the operator in charge of first-level control can use a more familiar set
of control and display hardware.
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Central Computer System 191
Centralised Computer System 192

Krishna Kant, 2011
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Central Computer System 193
Examples of Centralized Control System 194
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Drawbacks of DCS:
• Centralized Control System is a simple control system but has a few

disadvantages.
• If the CPU fails the entire plant gets affected.
• Redundancy concept is not available.
195

Introduction:
• Centralized computer control architecture - central processing unit (CPU)

represents a single point process if it is lost.
• Software required to implement all of the functions is extremely complex,
• It requires a priesthood of computer experts to develop the system.
• Hybrid system architecture - It is composed of many different subsystems.

Starting them up and making them work as an integrated whole is no less
difficult task.
• Its functionality limited compared to the central computer based system.
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Architecture:
• Limitation of centralized computer system and hybrid system introduced

distributed control system.
• The devices in this (DCS) architecture are grouped into three categories
that interface directly to the process to be controlled or monitored.
• It perform high-level human interfacing and computing functions, and those

that provide the means of communication between the other devices
197
Generalized Distributed Control System 198
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Devices:
• Local Control Unit (LCU)

• Low Level Human Interface (LLHI)
• Data Input / Output Unit (DI/OU)
• High Level Human Interfaces (HLHI)
• High Level Computing Device (HLCD)
• Computer Interface Device (CID)
• Shared Communication Facilities
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Basic components of DCS 201

Architecture:
• Local Control Unit (LCU) : smallest collection of hardware in the system

that can do closed loop control. LCU interfaces directly to process.
• Low Level Human Interface (LLHI) : It allows the operator or instrument

engineer to interact with LCU (eg: to change set points, control modes,
control configurations, or tuning parameters) using a direct connection.
• It also interface directly to the process. Operator-oriented hardware at this

level is called Low Level Operator Interface (LLOI); instrument engineer–
oriented hardware is called a Low Level Engineering Interface (LLEI).
• Data Input / Output Unit (DI/OU) : interfaces to the process alone for the
purpose of acquiring or outputting data. It performs no control functions.
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Architecture:
• High Level Human Interfaces (HLHI): A collection of hardware that

performs functions similar to the LLHI but with increased capability and
user friendliness.
• It interfaces to other devices only over the shared communication facilities.

Operated-oriented hardware at this level is called a High Level Operator
Interface (HLOI); instrument engineer-oriented hardware is called a High
Level Engineering Interface (HLEI).
• High Level Computing Device (HLCD): A collection of microprocessor

based hardware that performs plant management functions traditionally
performed by a plant computer.
• It interfaces to other devices only over the shared communication facilities.
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Distributed digital control system 205

Krishna Kant, 2011

Devices:
• Computer Interface Device (CID): A collection of hardware that allows an

external general purpose computer to interact with devices in DCS using
shared communication facilities.
• Shared Communication Facilities: One or more levels of

communication hardware and associated software that allow the sharing
of data among all devices in DCS.
• It do not include dedicated communication channels between hardware

elements within the device.
206
103
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Advantages of DCS:
• Control function is distributed among multiple CPUs (Field Control

Stations). Hence failure of one FCS does not affect the entire plant.
• Redundancy is available at various levels.
• Instruments and interlocks are created by software.
• Generation and modifications of the interlocks are very flexible and simple.
• Information regarding the process is presented to the user in various
formats.
• Cost effective in the long run.
207
SYLLABUS
Unit-1

104
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Comparison of Architectures
FEATURES HYBRID CENTRAL COMPUTER DISTRIBUTED
1. Scalability and Good - due to Poor – very limited range Good - due to modularity.
expandability modularity. of
system size.
2. Control capability Limited – analog and Full - digital control Full - digital control
sequential control capability. capability.
hardware.
3.Operator Limited by panel Digital hardware provides Digital hardware provides
interfacing capability board instrumentation. significant improvement for improvement for full range of
large systems. system sizes.
4. Integration of Poor - due to variety All functions performed by Functions integrated in a

system functions of products. central computer. family of products.
5. Significance of Low - due to High. Low - due to modularity.

single point failure modularity.
6. Installation costs High – discrete Medium- saves control Low – savings in both
wiring, large volume of and wiring costs and equipment
equipment. equipment room space, but space.
use discrete wiring.
7. Maintainability Poor –many module Medium- requires highly Excellent - automatic
types; few diagnostics. trained computer diagnostics and module
maintenance personnel. replacement.
209
Typical plant layout
210
105
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Field Instruments –Transmitters, Flowmeters
211
Field Controls –Pumps, Motors, Valves
212
106
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Control Room Instrumentation – Panel Instruments
213
Control Room Automation
214
107

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ICPC29 LOGIC AND DISTRIBUTED

1. To introduce the importance of process automation techniques.

ICPC29 Logic and Distributed Control Systems 2

Programmable logic controller (PLC) basics: Definition, overview of PLC systems,

PLC Data manipulation instruction - Arithmetic and comparison instruction- Skip,

Distributed Control system: Local Control Unit (LCU) architecture - Comparison of

LCU communication Facilities - Communication system requirements – Architectural

On the completion of this course, the students will be familiar with,

1. familiar with process automation technologies.

1. John W. Webb and Ronald A Reis, Programmable Logic Controllers -

2. Lukcas M.P Distributed Control Systems, Van Nostrand Reinhold Co.,

3. Frank D. Petruzella, Programmable Logic Controllers, McGraw Hill, New

1. Deshpande P.B and Ash R.H, Elements of Process Control

2. Curtis D. Johnson, Process Control Instrumentation

3. Krishna Kant, Computer-based Industrial Control, Prentice

Review of PC based control design for process automation:

ICPC29 Logic and Distributed Control Systems 8

PC based control design for process automation

Krishna Kant, 2011

PC based control design for process automation

Krishna Kant, 2011

PC based control design for process automation

PC based control design for process automation

• To increase labor productivity

PC based control design for process automation

PC based control design for process automation

PC based control design for process automation

• PC-Based Automation combines the features of PLC-Control

PC based control design for process automation

PC based control design for process automation

• Example : measurement and quality control systems, benefit

• Plants often operate continuously and in a harsh industrial

PC based control design for process automation

• Ease of implementation because of easily available

PC based control design for process automation

• Integration of non-PLC functionality with traditional PLC

• Large data storage capacities on-board or connected -

PC based control design for process automation

• open-loop and closed-loop control in mechanical

PC based control design for process automation

PC based control design for process automation

PC based control design for process automation

PC based control design for process automation

PC based control design for process automation

PC based control design for process automation

PC based control design for process automation

Review of PC based control design for process automation:

ICPC29 Logic and Distributed Control Systems 28

Computer control of process

Use of Computer in measurement and control 29

Computer control of process

• Passive application involves only acquisition of process data

• Active application involves acquisition and manipulation of

Computer control of process

Computer control of process

• Each dedicated control (PLC) is totally independent and

• It involves two or more computers communicating with each