GET 2014

I & C TRAINING PROGRAM

INTRODUCTION OF I & C ENGINEERING

&
BASIC CONTROL SYSTEM

PRESENTED BY-
Mr. ASISH SAHA
DATE: 27-01-2014

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 Introduction
 Control and computing are essential features of any modern
instrumentation and control systems. Growing requirement of control and
computing to enhance the quality of product & process with high degree of
automation resulting optimized cost and minimal human interaction has
created a large space for research in instrumentation.

 The demand for use state of the art technological software is also
increasing. Hence emphasis on measurement, testing and control using
software to improve commercial, industrial, and service productivity
through automation is envisaged.

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 Purview of Instrumentation & Control System
A. Measurement
Physical parameter to be measured & consideration of the process medium.
 Direct measurement.
 Indirect measurement.
 Requirement of Accuracy & Response
 Installation for sustained operator

B. Transmission to secondary Device

Though cable
 Conventional hardwired 4-20 mA signal.
Conventional hardwired SMART transmission.
Field Bus.

C. Data communication
 Serial communication by RS-232C/422/485
Field Bus.
 Ethernet TCP/IP
Wireless communication

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D. Processing
 Monitoring (Indication , Recording, Computing & MIS functions).
 Control (Conventional DCS based & advanced control)
 Performance Monitoring & Optimization.
 Diagnostic & Asset management
 Operator intervention & system configuration

E. Field Actuator / Final Control Element

 Electro pneumatic / hydraulic Actuator
Control signal to Motorized Actuator.
SMART positioner .

F. Plant Diagnostic & Asset management

G. Web based ERP implementation

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 Open Loop & Close Loop System:

Input Actuator/
Output
Controller
FCE
Process

Open loop System

Controller

r e
+ - Actuator/
Controller
Set Point FCE Process
Output
c

Sensor
Close loop System

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Example:

Open Loop System Close Loop System

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 Feedback Control:
Block Diagram
Advantages:
• Corrective action occurs regardless of the
source and type of disturbances.
• Requires little knowledge about the
process, a process model is not necessary.
• Versatile and robust.

Disadvantages:
Control action is taken after disturbances
have been felt.
FB control is incapable of correcting a
deviation from set point at the time of its
detection.
Theoretically not capable of achieving
“perfect control.”
For frequent and severe disturbances,
process may not settle out.

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 Feed-forward Control:
Block Diagram
Advantages:

Takes corrective action before the

process
is upset.
Theoretically capable of "perfect
control“.
Does not affect system stability.
Disadvantages:
 Cannot cope with unmeasured
disturbances
 Requires more knowledge of the process
to
be controlled (process model)
Ideal controllers that result in "perfect
control”: may be physically unrealizable.
Use practical controllers such as lead-lag
units

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 Feedback-feed-forward control:

Block Diagram
D

Controller Process
Ysp U Y

FF Control
 Attempts to eliminate the effects of
measurable disturbances.

FB Control
 Corrects for unmeasured disturbances,
modeling errors, etc.

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 Example: Heat Exchanger:

FB Controller

FF Controller

Heat Exchanger

FB Controller
Feedback Control

FF Controller

Heat Exchanger

Heat Exchanger
Feedback-feedforword Control
Feedforward Control
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Cont…Deaerator Level Control

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Cont…Deaerator Level Control

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 Ratio Control:

X2
- Controller Process X1/X2 C
Set Point + X1

KX2
X2
+ K
- Controller Process
Set Point + C
X1

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Cont…

Method 1 Method 2

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 Split Range Control:
In a split range control loop, output of the controller is split and sent to two or more
control valves. The splitter defines how each valve is sequenced as the controller
output changes from 0 to 100%. In most split range applications, the controller
adjusts the opening of one of the valves when its output is in the range of 0 to 50%
and the other valve when its output is in the range of 50% to 100%.

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Cont…Hotwell Level Control

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 Block Diagram of Cascade Control:

Primary Loop
Secondary Loop

d1 d2

Set Point +
Primary Secondary +
+ + Process II + Process I +
- Controller - Controller
Controlled
O/P

Measuring
Device

Measuring
Device

Philosophy:
One controller output is the set point of other controller to integrate
information.
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Example: Level Controller on a Tank
With and Without
Cascade Control

Without cascade control With cascade control

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 Advantage & Disadvantage Of
Cascade Controller

Advantage:
• Controller responds quickly to high frequency changes.
• Controller integrates multiple sensor readings together
• Secondary loop reduces the phase lag.
• Process gain variations in the secondary part are taken care of in this loop
itself.

Disadvantage:
• Cascade controller can be employed only when a suitable intermediate
variable can be measured.
• Cascade controller is effective only when the secondary time constant is
smaller than the primary time constant.

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 Conclusion

Each of these techniques offers advantages with respect to

disturbance rejection:

• Cascade reduces the effect of specific types of disturbances.

• Ratio reduces the effect of feed flow rates changes
• Feed-forward control is a general methodology for
compensating for measured disturbances.
• Feedback corrects for unmeasured disturbances, modeling
errors, etc.

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 I & C SYSTEM - THE CONTROL CENTRE FOR THE PLANT
 DCS
 PLC
 Local panel
 Local Gauges
controllers ..,  Primary sensors
 Transmitters, Analyzers
  Control valves
CONTROL SYSTEMS  Erection hardware ..,

 FIELD INSTRUMENTS , FIELD INTERFACE ,

CABLES..,
Control system and Field
instruments for –
 Offsite plants like
Handling systems , Water
intake system ,
Desalination plant ..,.

 PACKAGE UNIT INSTRUMENTATION

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TYPICAL CONTROL HIERARCHY

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 PLC

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 PLC
• A solid state (electronic) device that controls output devices based on
input signals and a user developed program.
• Originally developed to directly replace relays used for discrete control.

Inputs Output
Devices

PLC
(Programmable
Logic Controller)

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 WHAT IS PLC ???

PROGRAMMABLE CONTROLLER, PC

A digitally operating electronic system, designed for use in an industrial

environment, which uses a programmable memory for the internal
storage of user-oriented instructions for implementing specific functions
such as logic, sequencing, timing, counting and arithmetic, to control,
through digital or analog inputs and outputs, various types of machines
or processes. Both the PC and its associated peripherals are designed so
that they can be easily integrated into an industrial control system and
easily used in all their intended functions.

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 PLC = Programmable Logic Controller
Function : •Measure , •Siemens
HMI •ABB
•Control , •Schneider
•Protect •GE-Fanuc,
•Event Logging •Honeywell,
•Alarm •Invensys (Foxboro)
•Communication •Rockwell, (Allen-Bradley,…)
•Emerson (Fisher Control,
•Human Machine
Rosemount, Westinghouse)
interface (HMI) •Hitachi, Toshiba, Fujitsu, Yokogawa
PLC Rack
Features :
• Large number of peripherals, high density of wiring, easy assembly
• Binary and analog Input / Output with standard levels
• Located near the plant (field level), with robust construction, protection against dirt,
water and mechanical threats,
• Protection against electro-magnetic noise, vibration, extreme temperature range
(-30C..85C)
• Programming: either with hand-help terminals on the target machine itself, or with a
lap-top able to down-load programs
• Network connection allowing programming on workstations and connection to other
Control systems
• Field bus connection for remote I/Os
• Man-Machine interface, either through LCD-display or connection of a laptop / work
stations over serial lines
• Economical - the value is in the application software !!!

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Major Components of a Typical PLC

POWER
SUPPLY

I M O M
N O
P D U O
U U PROCESSOR T D
T L P U
From E U L
To
SENSORS T E
OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE

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 PLC cabinet
CPU1 CPU2

serial connections
redundant field
bus connection
inputs/outputs

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 PLC: Location in the control architecture

Enterprise Network
Engineer Operator Supervisor
station station gateway
Station

Control Bus
(e.g. Ethernet)

PLC
Large Control Station

COM1

COM 2
PLC
COM1
COM1

COM 2

CPU
with Field Bus
CPU

CPU

I/O
PLCs gateway
I/O
I/O
I/O
I/O
I/O

I/O
I/O
I/O
I/O
direct I/O
Field Bus Field Bus

COM

COM

COM
COM

COM
CPU

CPU

CPU
directly connected
I/O
I/O
I/O
I/O

I/O
I/O
I/O
I/O
Field Stations FB
gateway Field Devices
small PLC
Data concentrators,
(not programmable,
but configurable)
Sensor Bus (e.g. ASI)

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 PLC Specification
• Controller Module
• Discrete Input Module
• Discrete Output Module
• Output Relay Module
• Analog Input Module
• Analog Output Module
• I / O Interface Module
• Ethernet Communication Module
• Operator’s Station / Engineering Station (PC Based)
• Ethernet Switch

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 Where could we use a PLC
• Conveyor control
• SCADA(Supervisory Control And Data Acquisition)
– Remote pump/lift station (water/wastewater)
– Flow monitoring for leak detection (Oil & Gas)
• Palletizers
• Compressor control
• Amusement park rides and attractions
• Hard-wired relay panels or Single Board Computers
• Many, many more

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 DCS

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 WHAT IS DCS?????

“DCS is a control system which collects the data

from the field and decides what to do with them. Data
from the field can either be stored for future reference,
used for simple process control, use in conjunction with
data from another part of the plant for advanced
control strategies”

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 DISTRIBUTED CONTROL SYSTEM (DCS)
 BHEL
 Honeywell Automation
India Limited
DCS  ABB,
Yokogawa,
 INVENSYS (Foxboro )
 Emerson
 GE etc.

• Microprocessor based, Geographically and Functionally distributed system

• - Nerve centre of the plant
• Operation of plant, Control and Monitoring of Process/equipment parameters &
equipment status
• Window to the plant through HMI – Data at Fingertips !!!
• Includes Marshalling cabinets, System Cabinets, Network cabinets, Human
Machine interface (HMI)
• Marshalling cabinets, System Cabinets, Network cabinets are generally located in
a separate room called “ The Electronic cubicle / Electronic equipment room”
• Human Machine interface equipment like CRTs, LVS , are located in Control room
• Configuration and maintenance of the DCS is done by Maintenance Engineer’s
station located separately ..,

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 Basics of DCS …..,

Basic Parameters Control / Operation

Philosophy
• Open System Architecture
• Controller Features • Functionally distributed v/s
• HMI flexibility Geographically distributed
• I/O Capability control hardware
• Communication • Remote v/s local control
• Third party interface options • Only DCS v/s
DCS + Backup panel control

Features
DCS Architecture
•Redundancy RequirementsMapping
DCS Capability
•Interface Requirements • Client Server based Architecture
•Engineering capability • Server less Architecture
•Sequence of Events Recording
•Historization
•Graphics capability
•Alarm & Event monitoring
•Time synchronization
•Hardware features
•Software features

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 Control Philosophy

 Geographically Distributed
 Functionally Distributed

GEOGRAPHICALLY DISTRIBUTED CONTROL

 Location of controllers and I/O interface modules are geographically
distributed.
 Each control station with its controllers and I/O will cater to the
requirements of a specific area / unit of the plant.
 All such controlled stations are interfaced with HMI in main control
room via FO network.
 Geographically distribution may include functional distribution.

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 FUNCTIONALLY DISTRIBUTED CONTROL

 All the controllers are located in the Central Control Room.

 I/O can be remotely located or located in the control room.

 Functionally distribution is with respect to Close Loop Control system,

Open Loop Control system, SOE and MS.

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 ARCHITECTURE

 CLIENT SERVER ARCHITECTURE

 SERVERLESS ARCHITECTURE

CLIENT SERVER ARCHITECTURE

 All the DCS control processors are connected to a redundant high speed
control Network(Plant Bus).
 The Operator Station and ES are connected to another redundant high
speed network(Terminal Bus).
 The two network through a redundant server.
 In this configuration the operator station are not Work station but are
known as ‘Thin clients’.

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CLIENT SERVER ARCHITECTURE

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 SERVER LESS ARCHITECTURE

 All the system nodes represented by Operator Station, Engineering

Station & DCS processing station are connected to the same redundant
high speed control network.

 In this configuration , the OS are WS with access to Global Data Base and
have peer-to-peer communication with the controllers.

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SERVER LESS ARCHITECTURE

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 CONTROL SYSTEM – REDUNDANCY ..,
REDUNDANCY :
• Redundancy is built into the Instrumentation and Control System at
various levels for reliability and safety of the system and the plant. The
level of redundancy can be Dual or Triple depending on the criticality of
the process / protection.

• Field level redundancy is built in by having two or three instruments for

the same measurement.

• Control level redundancy is usually dual redundant at I/O card, Processor

card, communication card and power supply module levels.

• Triple Redundant control systems which are used for very critical controls.

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 OPERATION PHILOSOPHY

Human Machine
Interface – HMI

• Operator Stations / Large Unit Control Panel

video screens
• Maintenance Engineers (UCP)
Stations • Console Inserts
• Printers • Pushbuttons /
Illuminated
Pushbuttons
• Receiver Indicators
• Recorders
• Annunciation
Systems
• Auto / Manual
Stations
• Mimic with
Synchronizing
Hardware
• Display units

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 HMI
 Operator station
 SER and historian station
 Large Video Screen Displays
 Engineering Station

Operator
station
Access / authorization (Multiple levels)
Plant control display and plant schematics
Alarm notification and action
Alarm display function and alarm summaries
Individual point data
Trend plot features, X-Y Plots
Logs/ Reports
Performance calculations

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 DCS Specification & Architecture

• Specification of DCS –

• Architecture of DCS -

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TYPICAL CONTROL ROOM

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TYPICAL SYSTEM CABINET …..,

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PROTECTION INTERLOCK AND SEQUENTIAL CONTROL SYSTEM

• The protection interlock system keeps a constant watch over the

various parameters related to an equipment and prevents the
equipment from starting when all the conditions for their safe and
satisfactory operation are not fulfilled.

• The protection system trips the equipment under abnormal conditions

which are detrimental to the equipment or process

• The sequential control system simplifies the starting operation by

enabling the operators to treat a group of related equipment under one
interlocked sequence which automatically takes care of the various steps
involved in bringing up the sub-equipments of a group .

Example :
ID fan interlocks
FD fan interlocks
 Boiler feed Pump Interlocks

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UNIFIED CONTROL ROOM WITH LARGE VIDEO SCREEN

UNIT CONTROL PANEL Contd..

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Factory Acceptance Test (FAT) : Turbine control (in the test lab)

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 Communication

 Deterministic (IEEE 802.4 or IEEE 802.5)

 Speed (5 MBPS to 1 GBPS)
 Token passing
 Exception reporting

Communication
Deterministic (IEEE 802.4 or IEEE 802.5)
[ Control Net, Device Net, V-net, Master Bus]

Non-Deterministic (IEEE 802.3)

[TCP/IP on Ethernet]

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 Communication

 Between I/O Bus and Controller- Deterministic

 Across controller – Deterministic
 Between controller and HMI server- Deterministic
 Between HMI and MIS- Non-Deterministic
 Between server and HMI- Non-Deterministic
 Between DCS and third party systems- Non-Deterministic
 Between engineering station and DCS controller- Non-Deterministic
 Between HMI and LVS- Non-Deterministic

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 Interface Options

 MODBUS RTU and other serial interfaces

 OPC

 Wireless

 Ethernet on TCP/IP

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 Engineering Capabilities
 Online programme modification (Logics, Graphics & controller Tuning
etc.)
 Online Download to Controllers(Commissioning Tool)
 Access to Controller through control network.
 Facility to set in “Engineer” or “Operator “ Mode.

Sequence of Event Recording (SER)

 Integral to DCS or Stand alone SER ( Micro Processor based with
redundant Processor & Power Supply).
 Operator/ Change of Status initiated Reporting/Log facility.
 Time tagging of each input (digital) status change with 1mSec. Resolution.
 Time synchronization with external clock.
 Buffer memory for Historical Data.
 Battery backup for Sequence & Buffer Memory and Clock.

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 Historical- Archiving
 Historical data storage & retrieval
 Alarm & Event List.
 Periodic Plant Data.
 Selected Logs & Reports.
 Separate Memory Device for Long term storage & retrieval.
 ‘Quality tagging’ of the data as good, bad, substitute, etc.

Graphic Capability
 Plant Schematics : Plant level, Area level, group level and equipment level.
 Plant operation through soft face plates.
 Multiple window capability.

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 Alarm & Event Monitoring
 Alarm and event list.
 Operator action list.
 I&C fault list.
 Fast update time.

Time Synchronization
 Uniform timing in all systems throughout the plant.
 Master clock system synchronized to GPS satellite.
 Slave clock at strategic locations.

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THANK YOU

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