Process Control Concept

Process Control Hierarchy

Corporate Level Controls (ERP)

Optimation (Advance Process Control)

Advance Regulatory Control (Ratio, Cascade, Feedforward, Override, Decoupling)

Basic Regulatory Control (Feedback)

PROCESS

Process Control Manual With Off line Computer Assistance

OPERATING INSTRUCTION

CONTROLLER
ANNUNCIATOR

RECORDERS

LOG

OFF LINE

DELAY

PROCESS

Process Control Manual With On line Computer Assistance

RECORDERS

CONTROLLER

ON LINE

LOG

PROCESS

Process Control Automatic with Feedback

RECORDERS

ON LINE

CONTROLLER

LOG

PROCESS

BASIC CONTROL LOOP

TWO BASIC LOOPING IN SYSTEM MEASUREMENT

OPEN LOOP

INDICATING, RECORDING , ALARM ANNUCIATING ONLY

CLOSE LOOP CONTROL TO FINAL ELEMENT PLUS CAPABILITY ON INDICATING, RECORDING, AND ALARM ANNUNCIATOR

OPEN LOOP

INDICATING

DATA LOGGER

RECORDING

ALARM
OPERATOR WILL ACTUATE THE VALVE BASE ON DEMAND SHOWN BY PANEL DISPLAY

PROCESS

CLOSE LOOP
SET POINT

CONTROLLER

CONTROL ELEMENT

DATA LOGGER FIELD ELEMENT

PRIMARY ELEMENT

PROCESS

FINAL ELEMENT

Control System
ON-OFF Control System Example : Motor Control, ESD Valve, Interlock System Variable (Regulatory) Control System Feedback Control Loop, Cascade Control, Ratio Control

Automatic Control
FIELD ELEMENT: Orifice, RTD, T/C, etc PRIMARY ELEMENT: Transmitter CONTROLLER: Manipulated device CONTROL SIGNAL: 3-15psig, 4-20 mA, HART/ Fieldbus CONTROL MODE: Proportional, Integral and Derivative SET POINT: value to be given to any controller FINAL ELEMENT: Control valves, switches etc.

Types of Automatic Control Loop

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

Control Diagram of a Typical Control Loop

A c tu a to r S y s te m F1 T
1

F2 T
2

S en so r S y stem C o n tr o lle r
TC TT

Components and Signals of a Typical Control Loop

F1 T
1

F2 T 3 -1 5 p s ig
2

T h e r m o w e ll T

A ir

I /P

4 -2 0 m a

D /A

T h e r m o c o u p le m illiv o lt s ig n a l 4 -2 0 m a

O p e ra to r C o n s o le

sp

DCS C o n tro l C o m p u te r

A /D

T r a n s m itte r

Feedback
A feedback control configuration measures the error after the process as correction factor to be transmitted to controller in order to give signal input to final control element

Feedback Controller

Manipulated Input

Process

Process Output

Cascade Control Loop

T T

T C R SP

sp

P ro cess S tr e a m

F C F T G as

Feedforward
A feedforward control configuration measures the disturbance directly and takes control action to eliminate its impact on the process output.
Disturbance

Feedforward Controller

Manipulated Input

Process

Process Output

Ratio Control Loop

FIELD CONTROLLER FIELD

OUT1
M LD-SW

OUT PID SPLIT OUT2

M LD-SW

MV 100 50 0 50 100 PV 100 50 0

MV

PV 50 100

Pneumatic Controller
Introduced in the 1920s Installed in the field next to the valve Use bellows, baffles, and nozzles with an air supply to implement PID action. Provided automatic control and replaced manual control for many loops Transmitter type pneumatic controllers began to replace field mounted controllers in the late 1930s. Controller located in control room with pneumatic transmission from sensors to control room and back to the valve. Allowed operators to address a number of controllers from a centralized control room.

Pneumatic Controller

F1 T
1

F2 T 3 -1 5 p s ig
2

T h e r m o w e ll T A ir T h e r m o c o u p le m illiv o lt s ig n a l 3 -1 5 p s ig A ir T r a n s m itte r

sp

P n e u m a tic C o n tr o lle r

Electronic Analog Controller

Became available in the late 1950s. Replaced the pneumatic tubing with wires. Used resistors, capacitors, and transistors based amplifiers to implement PID action. Out sold pneumatic controllers by 1970. Allowed for advanced PID control: ratio, feedforward, etc.

Electronic Analog Controller

F1 T
1

F2 T 3 -1 5 p s ig
2

T h e r m o w e ll T

A ir

I /P

4 -2 0 m a

T h e r m o c o u p le m illiv o lt s ig n a l 4 -2 0 m a

sp

E le c tr o n ic A n a lo g C o n tr o lle r

T r a n sm itte r

Computer Control System

Based upon a mainframe digital computer. Offered the ability to use data storage and retrieval, alarm functions, and process optimization. First installed on a refinery in 1959. Had reliability limitations.

Computer Control System

V id e o D is p la y U n it

A la r m in g F u n c tio n s

P r in te r

S u p e r v is o r y C o n tr o l C o m p u te r

A n a lo g C o n tr o l S u b sy tem

In te r fa c in g H ardw are

D a ta S to r a g e A c q u is itio n S y stem

...

Evolution - Microprocessor Base Controller

PC

PLC

Multi Loop Continuous & Discrete Controller

Multi Loop Programmable Controller

Field Instrument

Field Instrument

Evolution - Direct Digital Control (DDC)

CPU

PC

RS 232

SEGREGATED I/O RACK

HARD WIRED

FIELD INDTRUMENTS

PLC
A PLC (i.e. Programmable Logic Controller) is a device that was invented to replace the necessary sequential relay circuits for machine control PLC for safety

Evolution Programmable Controller (PLC)

PC

BUS

SEGREGATED I/O RACK (See Detail)

HARD WIRED

FIELD INDTRUMENTS

PLC System - Rack/Card Configuration

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

PROGRAMABLE CARD

PROGRAMABLE CARD

PROCESSOR CARD

PROCESSOR CARD

COMMUNICATION

COMMUNICATION

POWER SUPPLY

POWER SUPPLY

I/O CARD

I/O CARD

I/O CARD

I/O CARD

I/O CARD

I/O CARD

I/O CARD

Note:: Normally a Rack can be filled in max. 16 Cards This Rack has redundancy in power supply , Communication and CPU/ Processor To Others Rack, or Others Devices

Field Instrument

I/O CARD

DCS
Introduced in the late 1970s. Based upon redundant microprocessors for performing control functions for a part of the plant. SUPERIOR RELIABILITY Less expensive per loop for large plants. Less expensive to expand. Facilitates the use of advanced control.

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

D a ta H ig h w a y (S h a r e d C o m m u n ic a tio n F a c ilitie s )

L ocal C o n s o le

L ocal C o n tro l U n it

..............

L ocal C o n tr o l U n it

L ocal C o n so le

P r o c e ss T r a n s m itte r s a n d A c tu a to r s

Evolution - Distributed Control System (DCS)

MMI

MMI

DATA BASE RACK DAT LOGGER

ETHERNET / BUS GATEAWAY SYSTEM INPU/ OUTPUT RACK PLC SYSTEM CONTROLLER RACK

FIELD INDTRUMENTS

DCS VERSUS PLC SYSTEM

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

SCADA
Basic concept: Definition, Automation or remote, SCADA Architecture Communication Field Device RTU MTU Data communication

SCADA
SCADA : A system for monitoring and controlling for geographically dispersed process from a central location. Acquires Data Supervisory Control

SCADA SYSTEM CONFIGURATION

MASTER Station Half-Duplex Transmission Mode Sub Master Station #.1

Point to Multipoint Topology

Sub Master Station #.2

REMOTE Station #.1

REMOTE Station #.2

REMOTE Station #.3

Field Devices

SCADA SYSTEM COMPONENT

Master Station

Master Station

VAX-BASE COMPUTER MASTER STATION DCE

Point-to Multipoint, Half Duplex, PSTN, TCP/IP Protocol, Telemetry Network

DCE ANALOG DIAL UP MODEM

ANALOG DIAL UP MODEM

DCE

Pipeline Remote Shutdown Valve

MASTER STATION Personal Computer

Master Station
RS 232 LINK
DCE DCE

DCE

DCE

DTE REMOTE STATION #.1 REMOTE STATION #. 2

DTE

MASTER STATION VAX- or UNIX or Windows - Base Computer

VAX OR UNIX-BASE SERVER

Work Station

Work Station

ETHERNET NETWORK

CONTROLLER AND I/O MODULE RS 232 LINK DTE

DCE

DCE

DCE DCE

DTE DTE REMOTE STATION #. 1 REMOTE STATION #. 2

SUB MASTER STATION PLC BASE

COMMUNICATION WITH MASTER STATION
DCE

ETHERNET PROGRAMMABLE CONTROLLER BASE

DCE

DCE

DCE

DCE

DTE REMOTE STATION #. 1 REMOTE STATION #. 2

DTE

REMOTE STATION PLC BASE

PUMP STATION MMI

DCE

MASTER STATION ETHERNET

DCE DCE DCE DCE

DCE

DCE DCE

WASTE WATER TREATMENT PLANT

PUMP STATION GAS METERING STATION

DCS VERSUS SCADA SYSTEM

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

FieldBus Technology
The open, nonproprietary all-digital, serial two-way, multi-drop communication link among intelligent field devices and automation systems. Based upon smart valves, smart sensors and controllers installed in the field. Uses data highway to replace wires from sensor to DCS and to the control valves. Less expensive installations and better reliability. Can mix different sources (vendors) of sensors, transmitters, and control valves. Now commercially available and should begin to replace DCSs.

Field Bus Configuration

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

L ocal A rea N e tw o rk

.................
Sm art S en so rs

L ocal A rea N e tw o r k

Sm art S en so rs

S m a r t C o n tr o l V a lv e s a n d C o n tr o lle r s

S m a r t C o n tr o l V a lv e s a n d C o n tr o lle r s

F ie ld b u s N e tw o r k a

F ie ld b u s N e tw o r k

Fieldbus Vs Conventional
Field wiring Information flow Quantity of information Information type Control functionality Maintenance location Maintenance type

Conventional 4 to Point-to-point 20 mA

Unidirectional

Single data value

Measurement numerical value

Centered on a control system

Mainly in the field Corrective maintenance

Fieldbus

Multi-drop

Bidirectional

Multiple data values

Various data types Optimally From a remote allotted to controllocation system and/or field devices

Predictive maintenance

Fieldbus Control

PID
Controllers and Fieldbus Modules

Fieldbus

Fieldbus

AI

AO

AI

PID

AO
Integrated Fieldbus/Host Control Fieldbus Control on the Wire

Foundation Fieldbus
Foundation H1 Foundation Ethernet

Fondation H1
Intended primarily for process control, field-level interface and device integration. Running at 31.25 kbit/s, The technology interconnects devices such as transmitters and actuators on a field network. Twisted pair instrument cabling with power and signal on the same wire. Fiber optic media is optional. It also supports Intrinsic Safety (IS) applications.

Foundation HSE
Ideally suited for use as a control backbone. Running at 100 Mbit/s, Designed for device, subsystem and enterprise integration. Fieldbus capabilities: including standard function blocks and Device Descriptions (DDs), Flexible Function Blocks (FFBs) for advanced process and discrete/hybrid/batch applications Supports complex logic functions, such as those performed by Programmable Logic Controllers (PLCs), or data-intensive process devices, such as analyzers and gateways to other networks. HSE enhances access to H1 fieldbus technology via linking devices, while providing expanded capabilities for high-speed automation devices and hybrid/batch applications

Typical Fieldbus Network