Process Control Concept
Process Control Hierarchy
Corporate Level Controls
(ERP)
Optimation
(Advance Process Control)
Advance Regulatory Control
(Ratio, Cascade, Feedforward, Override, Decoupling)
Basic Regulatory Control
(Feedback)
PROCESS
Process Control
Manual With Off line Computer Assistance
OPERATING
INSTRUCTION
CONTROLLER
ANNUNCIATOR
RECORDERS
LOG
OFF LINE DELAY
PROCESS
Process Control
Manual With On line Computer Assistance
RECORDERS
CONTROLLER
ON LINE
LOG
PROCESS
Process Control
Automatic with Feedback
RECORDERS
ON LINE CONTROLLER
LOG
PROCESS
BASIC CONTROL LOOP
TWO BASIC LOOPING IN SYSTEM MEASUREMENT
• OPEN LOOP – INDICATING, RECORDING ,
ALARM ANNUCIATING ONLY
• CLOSE LOOP – CONTROL TO FINAL ELEMENT
PLUS CAPABILITY ON
INDICATING, RECORDING, AND ALARM
ANNUNCIATOR
OPEN LOOP
INDICATING
DATA
LOGGER
RECORDING
ALARM
OPERATOR WILL ACTUATE
THE VALVE BASE ON DEMAND
SHOWN BY PANEL DISPLAY
PROCESS
CLOSE LOOP
SET
POINT
CONTROLLER
CONTROL
ELEMENT
DATA LOGGER
FIELD
ELEMENT
PRIMARY
ELEMENT
FINAL
PROCESS ELEMENT
Control System
• ON-OFF Control System
Example : Motor Control, ESD Valve, Interlock System
• Variable (Regulatory) Control System
Feedback Control Loop, Cascade Control, Ratio Control
Automatic Control
• FIELD ELEMENT: Orifice, RTD, T/C, etc
• PRIMARY ELEMENT: Transmitter
• CONTROLLER: Manipulated device
• CONTROL SIGNAL: 3-15psig, 4-20 mA, HART/ Fieldbus
• CONTROL MODE: Proportional, Integral and Derivative
• SET POINT: value to be given to any controller
• FINAL ELEMENT: Control valves, switches etc.
Types of Automatic Control Loop
• OPEN LOOP is used to indicate or record a process fluid
without any control output
• CLOSED LOOP or Feedback Control uses the output of
controller to manipulate the final control element (e.g.
control valves)
• SPLIT RANGE CONTROL is used to split two outlet flow
within a range of controller output
• RATIO CONTROL: is used to ensure two or more flow
(mixed flow) are kept at the same ratio even if the flow
are changing
• CASCADE CONTROL: uses the output of primary
controller to manipulate the set point of the secondary
controller as if it were the final control element
• OVERRIDE CONTROL :is used to take control of an
output from one loop to allow a more important loop to
manipulated the output
Control Diagram of a Typical Control Loop
A c tu a to r
S y s te m
F1 F2
T 1
T 2
S en so r
S y stem
C o n tr o lle r TC
T
TT
Components and Signals of a Typical Control Loop
F1 F2
T 1
T 2
T h e r m o w e ll
3 -1 5 p s ig
T
A ir 4 -2 0 m a
I /P D /A T h e r m o c o u p le
m illiv o lt s ig n a l
T DCS 4 -2 0 m a
O p e ra to r sp
C o n tro l A /D T r a n s m itte r
C o n s o le
C o m p u te r
Feedback
• A feedback control configuration measures the error after the process
as correction factor to be transmitted to controller in order to give
signal input to final control element
Feedback
Process
Controller Manipulated Process
Input Output
Cascade Control Loop
T T T C T sp
R SP
P ro cess
S tr e a m F C
F T
G as
Feedforward
• A feedforward control configuration measures the disturbance directly
and takes control action to eliminate its impact on the process output.
Disturbance
Feedforward
Process
Controller Manipulated Process
Input Output
Ratio Control Loop
FIELD CONTROLLER FIELD
OUT1
MLD-SW
A
OUT
PID SPLIT
OUT2
MLD-SW
MV MV
100 100
50 50
0 PV 0 PV
50 100 50 100
Pneumatic Controller
• Introduced in the 1920’s
• Installed in the field next to the valve
• Use bellows, baffles, and nozzles with an air supply to implement PID
action.
• Provided automatic control and replaced manual control for many
loops
• Transmitter type pneumatic controllers began to replace field mounted
controllers in the late 1930’s.
• Controller located in control room with pneumatic transmission from
sensors to control room and back to the valve.
• Allowed operators to address a number of controllers from a
centralized control room.
Pneumatic Controller
F1 F2
T 1
T 2
T h e r m o w e ll
3 -1 5 p s ig
T
A ir T h e r m o c o u p le
m illiv o lt s ig n a l
T A ir
sp P n e u m a tic 3 -1 5 p s ig
T r a n s m itte r
C o n tr o lle r
Electronic Analog Controller
• Became available in the late 1950’s.
• Replaced the pneumatic tubing with wires.
• Used resistors, capacitors, and transistors based amplifiers to
implement PID action.
• Out sold pneumatic controllers by 1970.
• Allowed for advanced PID control: ratio, feedforward, etc.
Electronic Analog Controller
F1 F2
T 1
T 2
T h e r m o w e ll
3 -1 5 p s ig
T
A ir 4 -2 0 m a
I /P T h e r m o c o u p le
m illiv o lt s ig n a l
T E le c tr o n ic 4 -2 0 m a
sp
A n a lo g T r a n sm itte r
C o n tr o lle r
Computer Control System
• Based upon a mainframe digital computer.
• Offered the ability to use data storage and retrieval, alarm functions,
and process optimization.
• First installed on a refinery in 1959.
• Had reliability limitations.
Computer Control System
V id e o D is p la y A la r m in g
P r in te r
U n it F u n c tio n s
S u p e r v is o r y C o n tr o l C o m p u te r
A n a lo g D a ta S to r a g e
In te r fa c in g
C o n tr o l A c q u is itio n
H ardw are
S u b sy tem S y stem
...
Evolution - Microprocessor Base Controller
PC PLC
Multi Loop Continuous Multi Loop
& Discrete Controller Programmable Controller
Field Instrument Field Instrument
Evolution - Direct Digital Control (DDC)
CPU PC
RS 232
SEGREGATED
I/O RACK
HARD WIRED
FIELD INDTRUMENTS
PLC
• A PLC (i.e. Programmable Logic Controller) is a device that was
invented to replace the necessary sequential relay circuits for machine
control
• PLC for safety
Evolution – Programmable Controller (PLC)
PC
BUS
SEGREGATED
I/O RACK (See Detail)
HARD WIRED
FIELD INDTRUMENTS
PLC System - Rack/Card Configuration
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PROGRAMABLE CARD
PROGRAMABLE CARD
PROCESSOR CARD
PROCESSOR CARD
COMMUNICATION
COMMUNICATION
POWER SUPPLY
POWER SUPPLY
I/O CARD
I/O CARD
I/O CARD
I/O CARD
I/O CARD
I/O CARD
I/O CARD
I/O CARD
Note::
Normally a Rack can be filled in max. 16 Cards
This Rack has redundancy in power supply ,
Communication and CPU/ Processor
To Others Rack, or
Others Devices
Field Instrument
DCS
• Introduced in the late 1970’s.
• Based upon redundant microprocessors for performing control
functions for a part of the plant. SUPERIOR RELIABILITY
• Less expensive per loop for large plants.
• Less expensive to expand.
• Facilitates the use of advanced control.
DCS
D a ta
S y stem H ost
S to r a g e PLC
C o n so les C o m p u ter
U n it
D a ta H ig h w a y
(S h a r e d C o m m u n ic a tio n F a c ilitie s )
L ocal
C o n s o le
L ocal
C o n tro l .............. L ocal
C o n tr o l
L ocal
C o n so le
U n it U n it
P r o c e ss T r a n s m itte r s a n d A c tu a to r s
Evolution - Distributed Control System (DCS)
DATA BASE
RACK
MMI MMI
DAT LOGGER
ETHERNET / BUS
GATEAWAY INPU/ OUTPUT CONTROLLER
SYSTEM RACK PLC SYSTEM RACK
FIELD INDTRUMENTS
DCS VERSUS PLC SYSTEM
DCS PLC
• Small “controlled area” • Small “limited I/O”
• Distributed, no master • Originally Programmable
• High capacity only
• Low capacity
• Microprocessor - base
• Microprocessor - base
• Continues & discrete
control • Batch and Discrete
• Dynamic system Control
• Dynamic System
• Medium speed, 100
mSec • High speed, less 10 mSec
• Bus, Ring and Star • Star Topology
topology • Mostly programmable
• Mostly configurable • Connectable to other
• Connectable to other system
system • Peer to peer
• Peer to peer communication
communication • SIL – 3 (IEC 60518)
• SIL – 2 (IEC 60518) • AK5 & AK6 (TUV Class)
SCADA
• Basic concept: Definition, Automation or remote, SCADA
Architecture
• Communication
• Field Device
• RTU
• MTU
• Data communication
SCADA
• SCADA : A system for monitoring and controlling for geographically
dispersed process from a central location.
• Acquires Data
• Supervisory Control
SCADA SYSTEM – CONFIGURATION
MASTER Point to Multipoint
Station Topology
Half-Duplex
Transmission Mode
Sub Master Sub Master
Station #.1 Station #.2
REMOTE REMOTE REMOTE
Station #.1 Station #.2 Station #.3
Field Devices
SCADA SYSTEM – COMPONENT
Master Master
Station Station
VAX-BASE COMPUTER
MASTER STATION
DCE
Point-to Multipoint, Half
Duplex, PSTN, TCP/IP
Protocol, Telemetry
Network
ANALOG DIAL UP
DCE MODEM
ANALOG DIAL UP
MODEM
Pipeline Remote
DCE Shutdown Valve
C
MASTER STATION – Personal Computer
Master
Station
RS – 232 LINK
DCE DCE
DCE
DCE
DTE
DTE
REMOTE REMOTE
STATION #.1 STATION #. 2
MASTER STATION – VAX- or UNIX or Windows - Base Computer
VAX OR UNIX-BASE
Work Work SERVER
Station Station
ETHERNET
NETWORK
CONTROLLER AND
I/O MODULE
RS – 232 LINK
DTE
DCE DCE
DCE
DCE
DTE
DTE
REMOTE
REMOTE
STATION #. 1
STATION #. 2
SUB MASTER STATION – PLC BASE
COMMUNICATION
WITH
MASTER STATION
DCE
ETHERNET
PROGRAMMABLE
CONTROLLER BASE
DCE DCE
DCE DCE
DTE DTE
REMOTE REMOTE
STATION #. 1 STATION #. 2
REMOTE STATION – PLC BASE
PUMP STATION
MMI
MASTER DCE
STATION
DCE
ETHERNET
DCE DCE DCE DCE
WASTE WATER
TREATMENT PLANT
DCE
DCE
PUMP STATION
GAS METERING
STATION
DCS VERSUS SCADA SYSTEM
DCS SCADA
• Small “controlled area” • Big & wide “controlled
• Distributed, no master area”
• Centralized, master -
• High capacity
slave
• Microprocessor - base
• Low capacity
• Continues & discrete
• Microprocessor - base
control
• Remote, supervisory
• Dynamic system
control
• Medium speed, 100
• Static, shutdown
mSec
purposes
• Bus, Ring and Star
• High speed, less 10 mSec
topology
• Point to point/multipoint
• Mostly configurable
• Mostly programmable
• Connectable to other
system • Limited capability
• Peer to peer • Peer to peer
communication communication
• SIL – 2 (IEC 60518) • SIL – 3 (IEC 60518)
FieldBus Technology
• The open, nonproprietary all-digital, serial two-way, multi-drop
communication link among intelligent field devices and automation
systems.
• Based upon smart valves, smart sensors and controllers installed in the
field.
• Uses data highway to replace wires from sensor to DCS and to the
control valves.
• Less expensive installations and better reliability.
• Can mix different sources (vendors) of sensors, transmitters, and
control valves.
• Now commercially available and should begin to replace DCSs.
Field Bus Configuration
P la n t-W id e N e tw o r k
.................
L ocal L ocal
A rea A rea
N e tw o rk N e tw o r k
Sm art S m a r t C o n tr o l Sm art S m a r t C o n tr o l
S en so rs V a lv e s a n d S en so rs V a lv e s a n d
C o n tr o lle r s C o n tr o lle r s
F ie ld b u s N e tw o r k F ie ld b u s N e tw o r k
a
Fieldbus Vs Conventional
Field wiring Information flow Quantity of Information type Control Maintenance Maintenance type
information functionality location
Conventional 4 to Point-to-point Unidirectional Single data value Measurement Centered on a Mainly in the field Corrective
20 mA numerical value control system maintenance
Fieldbus Multi-drop Bidirectional Multiple data Various data types Optimally From a remote Predictive
values allotted to controllocation maintenance
system and/or
field devices
Fieldbus Control
PID
Controllers
and
Fieldbus
Modules
Fieldbus Fieldbus
AI AO AI PID
AO
Integrated Fieldbus/Host Control Fieldbus “Control on the Wire”
Foundation Fieldbus
• Foundation H1
• Foundation Ethernet
Fondation H1
• Intended primarily for process control, field-level interface and device
integration.
• Running at 31.25 kbit/s,
• The technology interconnects devices such as transmitters and
actuators on a field network.
• Twisted pair instrument cabling with power and signal on the same
wire. Fiber optic media is optional. It also supports Intrinsic Safety
(IS) applications.
Foundation HSE
• Ideally suited for use as a control backbone.
• Running at 100 Mbit/s,
• Designed for device, subsystem and enterprise integration.
• Fieldbus capabilities: including standard function blocks and Device
Descriptions (DDs), Flexible Function Blocks (FFBs) for advanced
process and discrete/hybrid/batch applications
• Supports complex logic functions, such as those performed by
Programmable Logic Controllers (PLCs), or data-intensive process
devices, such as analyzers and gateways to other networks. HSE
enhances access to H1 fieldbus technology via linking devices, while
providing expanded capabilities for high-speed automation devices
and hybrid/batch applications
Typical Fieldbus Network
