Distributed Control System

&
Control Loops

Prepared by…
Mahroof Elahi
Applications of DCS

Distributed control systems are dedicated systems used

to control manufacturing processes that are continuous or
batch-oriented, such as oil refining, petrochemicals ,central
station power generation, fertilizers, pharmaceuticals, food
and beverage manufacturing etc.
 Distributed Control System

• A distributed control system (DCS) refers to a control system usually of a

manufacturing system, process or any kind of dynamic system, in which
the controller elements are not central in location (like the brain) but are
distributed throughout the system with each component sub-system
controlled by one or more controllers. The entire system of controllers are
connected by networks for communication and monitoring.

• A (DCS) is a control system for a process or plant, wherein control

elements are distributed throughout the system. It differs from the
centralized control system wherein a single controller at a central location
handles the control function, but in DCS each process element or
machine or group of machines is controlled by a dedicated controller.

• DCS consists of a large number of local controller in various sections of

plant control area and are connected via a high speed communication.
Honeywell DCS Architecture
EXPERION PKS System Details

Hardware

 Architecture
 C 300 Controller
 I/O Module
 I/O Link
 FTE Switch
 Fire wall
 Servers
 RMS
 Operator Workstation
 Printers
 ECC
 UPS
Controllers C-300

Controller C-300

Each Honeywell DCS at EPCL has 2 pairs

of redundant controller.

One of the controller is primary whereas

the other is at backup

In case primary controller fails secondary

Controllers
will automatically take over with alarm on
DCS and indication on controller.

Failed controller can be replaced online

without any shutdown requirement.
I/O Cards

• There are mainly 4 types of I/O

card:
– Analog Input
– Analog Output
– Digital Input
– Digital Output
• Certain critical signals are on
redundant I/O cards also. I/O Cards
• Cards can be replaced online if
required.
I/O Link

Non-Redundant C300 with One Series C I/O Link

Non-Redundant C300 with Two Series C I/O Link

Redundant C300 with One Series C I/O Link

Redundant C300 with Two Series C I/O Links
I/O Components

Analogue Input / Output

•For 4~20mA Input/output Signals
Digital Input / Output
•For 0-24V Digital Signal (ON/OFF)

IOTA – Input Output Termination Assembly

•Assembly at which IO modules are mounted. IOTA
provides power and communication to the IO
module.

LLMUX- Low Level Analog Multiplexer

•Used for RTD/Thermocouples or low voltage
signals
Redundant modules / IOTA
•Critical signals are configured on redundant
modules to increase reliability
FTE – Fault Tolerant Ethernet

Fault Tolerant Ethernet, FTE switch establish a

redundant communication network between all
nodes of DCS. FTE transfer all the data from
controller to servers and operator stations.

Two FTE switches are connected via a cross

over link cables which provide a dual redundant
network.

This provides multiple paths between an FTE

node and any other node, as well as allowing
every Ethernet node to communicate with every
other Ethernet node.
Network Switches
.

FTE Redundant
Network Switches
Control Firewall

• Control Firewall checks and routes Control

the traffic from switches to Firewall

Controllers.

• 02 Redundant control firewall are

installed in each DCS.

• 4 ports of each Firewall are in use to

communicate with controllers

• 1 port of each firewall communicates

with network FTE switch.
 Servers
• Server offers powerful configuration tools that allow the user
to perform engineering function such as creating new
projects, creating various inputs & outputs logics, modifying
sequential and continuous control logics, configuring various
distributed devices etc.
• DCS system is equipped with two Experion redundant
servers, which hold the following information.
• All the graphics are stored on the server hard drive.
Operator stations take the process variable information
from these servers.
• System logon security is configured in these servers. Data
archiving, Alarming, Trending and Event logging is
configured on servers.
• History collection is available in both average and
snapshot/ production formats.
• A large amount of history can be retained on line, with Server
automatic archiving.
Servers

The default history collection intervals include

• 1 second snapshot, 1 minute snapshot, 6 second average, 1 hour average,

• 1 hour snapshot, 8 hour average and snapshot, 24 hour average and

snapshots,

• Once collected historical data is available for use by trend facilities,

custom displays, reports, application programs and spreadsheets.

• Archives can be stored on the local hard drive etc.

 DCS Operator Station
• Operator Station also called as HMIs
provide interactive interface to Plant
operation.
• Boardman takes actions through them by
observing and responding to changing
plant parameters and maintains reliable
operation.

• These stations are normal PC based

systems, using Microsoft Windows 2003.

• Operator station also provides interface for

system maintenance and all the system
alarms are reported and displayed on it
based on which Engineering and Operator Station
maintenance activities are carried out.
 Marshaling Cabinet
• Signal from Junction boxes in Field is terminated in Marshaling cabinets.

• From marshaling cabinet, these cabinets go to I/O cards.

• Marshaling Cabinet provides isolation for maintenance jobs such as….. loop
verification.

• For analog I/Os there are knife type TBs in Marshaling Cabinets.

• For digital I/Os there are Fuse Type TBs.

Marshaling cabinet Marshaling cabinet Marshaling cabinet

 DCS-Signals
• Similarly in DCS there are 2 types of
signals
– Analog
• Input
• Output
– Digital
• Input
• Output

• Analog Signals:
– Pressure/Flow/Level Transmitter reading
– Control Valve Opening Signal
• Digital Signals:
– Pressure/Level Switch
– ON/OFF Valve SOV signal
 DCS Control loop

Controller

Junction Box
Field Transmitter
Marshaling Cabinet I/O Card

Marshaling Cabinet I/O Card

Final Control element

Junction Box
 Types of Process Control Loops
• Open Loop Control
• A Loop which has no feedback -
no information about process
parameters value.
• Example: Boiling of Water for Tea
• Example: Opening of an HV by a
DCS operator.

• Closed Loop Control

• A loop which controls i.e. take
decisions based upon a feedback.
• Example: Thermostat control of Air
conditioner.
• Example: Pressure control loop with
pressure transmitter and control
valve.
 Open loop

• Open-loop control system, an operator makes

a manual adjustment to a device.

• (valve) which controls the flow of a

manipulated variable (steam) to attempt to
achieve some SP (desired temperature) value
of a controlled variable (hot water).

• However, this adjustment is only valid for the

conditions under which the operator made
the adjustment.

• Any disturbance such as a change in inlet

water temperature, steam temperature, heat
loss to the surroundings, or throughput will
cause the outlet temperature to change.
Close Control Loop
• If appropriate measuring and
controlling elements are added to the
system, the loop is closed by the
inclusion of an automatic feedback
controller.

• The controller detects any difference

between the set-point and
measurement signals (error signal)
and produces an output signal to
drive the valve in the proper direction
to adjust the heat input to cause the
measurement to reach the set-point
value.
Cascade Control Loop

• In single-loop control , The SP is set

by an operator and its OP drives a
final control element.

• In cascade control arrangement ,

There are two (or more) controllers
of which one controller’s OP derives
the SP of another controller.
 Ratio Control Loop

• A ratio controller is a special type

of feed-forward controller Where
disturbances are measured and
there ratio is held at a desired SP
by controlling one of the streams.
Examples are

• Maintaining the stoichiometric

ratio of reactants in a reactor.
 Feedback and Feed Forward Control Loop
• Feedback controller responds only after it
detects a deviation in the value of the
controlled OP from its desired SP.
• An AC ( room temperature controller ) is
the example of a feedback controller and
stream drum level control.

• Feed Forward controller detects the

disturbance directly and take an
appropriate control action in order to
eliminate its effect on the process output.
• A ratio controller is an example of feed
forward controller.
 Three Element Control Loop
• The “three element control” in Boilers commonly use for The stream drum
level control.
• Its takes three process variables as inputs.
1) Flow rate of steam leaving the boiler
2) Flow rate of boiler feed water
3) Liquid level inside stream drum

• In boiler level control (at optimum range) is highest priority to ensure all the
tubes filled with water.
• During level control level, there will be any offset, level fluctuate very quickly
and to protect this fluctuation, advance control scheme is needed and three
element control is applied in such a system.
• At DCS all three PV signals become inputs of PID controller (Complex
calculation done) and OP signal manipulate BFW flow to get the desired BFW
flow in stream drum.
 Split Range Control Loop
• In split range control loop, OP of
the controller is split and sent to two
or more control valves.
• The splitter defines how each valve
is sequenced as the controller OP
changes from 0 to 100%.
• Split range example , Pressure
Control valve A(0~50%) and
B(%50~100%).
 CEE- Control Execution Environment
• The CEE is the foundation of the controller
and provides a configured control execution
environment.

• A single builder tool, Control Builder, allows

integrated application configuration.

• The Control Execution Environment offers

dedicated function blocks to cover all control
requirements for continuous processes,
batch processes, discrete operations, and
machine control applications.

What we will see:

• Configuration Studio
• Control Builder
• HMI Web Display Builder
 About This Guide

• EXPERION Knowledge Builder is a pulp &

paper / a user guide .
• It about start menu and external
Applications.
• It is a trouble shooting guide.
• DCS Gives an Operator a Station Help.
• System Configuration
• This Guide describes how to use Station
to monitor and control your Experon
system.
• The use of screen and keyboard.
• How to responding to Alarms, events,
massages, Alerts, System states etc.
DCS Features
DCS Gives an Operator:

• Real Time Process Over-View

• Alarms & Events
• Trends
DCS Schematics- Display Overview
• An overview of All schematics display is available.
• It is consists of all schematic build for to understand the process .
• A quick view Display Incinerators BMS Sequence For light up and control.
• It consists of all BMS Sequence display
 Emergency Response Schematics

• A quick View and Display for

emergency handling .

• A birds Eye view of Different

emergencies nacreous a perfect SOPs
and guidelines .
Bypass switches at EDC Board
• A Display of EDC and VCM Board DCS based Bypass switches .
• All PLC based logic are given.
• And all ESD indications are given on ESD panel.
System Cabinets Power Status
• “Power Supplies’ Status Indication on DCS”, the health indication and alarm
configuration of all 4 DSP Panel Power Supplies .
• The power to the field instruments that require 24VDC to operate like the
SOVs of On/ Off valves and other self-powered instruments.
• These power supplies are critical for the safe and reliable plant process as
their malfunction can lead to safety/ process incident.
• Display of power supplies status indications of System cabinets /
Marshaling cabinets. Alarms are also configured at DCS .
 Typical Alarm Summary Display
• A typical Alarm Summery Display shows various area alarms.
• And printing a page from DCS A page set up display .
 Alarms Management
Experion PKS includes several predefined filters, including:
• Unacknowledged alarms, which shows only unacknowledged alarms
• Urgent alarms, which only shows urgent alarms
• Urgent and high alarms, which only shows urgent and high alarms
You can also create your own filters, based on various criteria such as priority and
date/time etc.
Filters
Filters enable operators to filter out inappropriate alarms and events —
alarms that belong to assets for which they are not responsible.
Process Alarms (Associated with monitoring process),System Alarms (Associated
with system components),Alarm and events recording can be at least one month
and can be removed after archiving this data to any record media.
Operator response
Operators can: View events and alarms in Stations. The Status Line (below the
display), always shows the most recent (or oldest) and highest priority alarm that
has not been acknowledged.• Print a summary of alarms and events to an
alarm/event printer.
 Power System of DCS
To power the DCS system there are two kinds of power supplied in the DCS rack
room .one is AC power that is 220 AC and second is 24 V DC. These two power
supplies are provided to the system through the distribution cabinets.

DC Power is converted from AC and it is being done at four location as

mentioned below.
• Controller group1,system Cabinet 1, Redundant power supply.
• Controller group2,system Cabinet 2, Redundant power supply.
• Relay DO power, Marshaling Cabinet, Redundant power supply.
• Field power ,DC Distribution panel , Redundant power supply.

AC Power is supplied to following location from AC distribution panel.

• Server A and B, Redundant
• Network switch , Redundant
• Operating consoles and printers
UPS Distribution Network

UPS in installed in CCR for Power Plant, CA & EDC-VCM marshaling

Socomec Sicon UPS DELPHYS – 60kVA

Socomec Delphys - 60kVA

Supplies to:
Power Plant, CA & EDC-VCM marshalling
 UPS Distribution Network

MCCB
MCCB 160A
Power supply of loads in each panel has
125A independent supply from each UPS unit

PP CA EDC-VCM LMS
Main UPS Consumers

UPS consumers

AC (DCS )

DC (24V to field
instruments)
UPS Distribution Network

• Operator workstation
• Marshalling cabinet
• Emergency panel
Power • Server
• Color and B/W
to DCS printers
• Local control box
• Instrument dc power
DB
Power to UPS

PVC-II
PVC-II S/S
Mastery IP 16KW
General
substation
UT-II
Delphys MP Elite
48KW

CCR
Usage of UPS

DEG powers the emergency loads of the plant & UPS in case of power
failure.UPS powers control system during DEG starting so that there is no
interruption during power failure.

Incase of DEG failure, UPS is used to bring the plant process to safe shut
down.

It mainly turns off the critical valves.

PID Controller

• A proportional-integral-derivative controller (PID controller) is a control

loop feed back mechanism wildly used in industrial control systems.

• As a feedback controller , it delivers the control OP at desired levels.

• PID Controller continuously calculates an error value as a difference

between a desired SP and a measured PV and applies a correction
based on proportional, integral, and derivative terms (denoted P,I,D
respectively) which gives the controller its name.

• PID concept in applications is an accurate and optimized automatic

control.
PID Detail & PIDA Block
• PID point detail in main page indicate an
execution state (active/inactive ).
• An execution control running state or
control confirmation.
• Safety interlock and Red tag status.
• Alarm state Enable or Disable status .
• And assign controller name.

• PIDA – A regularity control block that

operates as a Proportional- Integral-
Derivative (PID) Controller.
• It supports the Ideal form of calculating the
PID terms.
• The Ideal form is often called the digital-
computer version of the PID controller.
 PID Loop Tune & Flow Compensator
• PID Loop Tune gives the general information
about loop tune of a PID controller.
• Its control equation and its control action (
Direct/Reverse).
• Its Proportional or Gain-option limits and
factor.
• Its Integral and Derivative time and Filter
time too .

• Flow compensation block computes a flow

compensation factor based on variations in
parameters like temperature, pressure,
specific gravity and molecular weight.
• The block derives as compensated flow as
its output.
 PID - PV & OP & Alarms Display
• PID controller gives all PV
characteristic.
• PV source (Auto/Man) and Fail Safe
option at manual mode.
• PV clamping option and Filtering
Time.
• OP limits and Bad control option
(Shed Safe, No Shed, Shed Hi & low).

• All types of Alarm configuration

limits option (High, low, Ext. high &
low).
• Dead Band and Dead Band times.
A simple PLC Application at DCS

• At 2000 Kg/hr flow of ethylene

will shut off the flow of steam
to the heat exchanger.

• A simple PLC logic design at DCS

as shown in blocks.
Thank You