G. H.
Raisoni College of Engineering , Nagpur
( An Autonomous Institutions under UGC affiliated to RTM, Nagpur University , Nagpur
Department of Electronics and Telecommunication Engineering
Unit-I: COMPUTER BASED CONTROL
Elective-VI-INDUSTRIAL AUTOMATION
(BECL351)
Year/ Semester : 4th / VIIth
Name of Faculty:
Dr. Umesh Sahu
Department of Electronics & Telecommunication Engineering
Vision of the Department
To achieve excellent standards of quality education by keeping pace with
rapidly changing technologies and to create technical manpower of global
standards in electronics & telecommunication engineering with capabilities of
accepting new challenges.
Mission of the Department
• To create competent professionals who are trained in the design &
implementation of Engineering & Telecommunication systems.
• To contribute towards the advancement of engineering, science and
technology
• To impart quality and value based education to raise satisfaction of all stake
holders
• To promote research & development activities in the field of electronics &
telecommunication engineering and allied areas
Syllabus
CO-I: (7 Hours)
COMPUTER BASED CONTROL
Implementing control system using computer or microprocessor; computer
based controller: hardware configuration and software requirements.
DISTRIBUTED CONTROL SYSTEM- Meaning and necessity of
distributed control; hardware components of DCS; DCS software.
Contents
• Implementing control system using computer or
microprocessor
• Computer based controller
• hardware configuration and
• Software requirements
• DISTRIBUTED CONTROL SYSTEM
• Meaning and necessity of distributed control
• hardware components of DCS
• DCS software.
• Numerical
Implementing control system using computer or
microprocessor
Figure: The objective is to regulate the level of liquid in the tank, h, to the
value H.
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-1)
Implementing control system using computer or
microprocessor
Figure: A human can regulate the level using a sight tube, S, to compare
the level, h, to the objective, H, and adjust a valve to change the level.
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-1)
Implementing control system using computer or
microprocessor
Figure: An automatic level-control system replaces the human with a
controller and uses a sensor to measure the level.
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-1)
Implementing control system using computer or
microprocessor
Figure: The proposed use of computer in measurement and control
Hand Book: Introduction to computer based Control System
(Section-1.1 to 1.4 )
Implementing control system using computer or
microprocessor
Figure: The picture of Ramo-Wooldridge (RW-300) computer used in
process control and data logging
Hand Book: Introduction to computer based Control System
(Section-1.1 to 1.4 )
Implementing control system using computer or
microprocessor
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)
whereas active application involves
acquisition and manipulation of data
and uses it for (real
time) process control.
Figure: Digital computer use limited to passive application; used only for
data acquisition / data logging
Hand Book: Introduction to computer based Control System
(Section-1.1 to 1.4 )
COMPUTER BASED
CONTROL
• Introduction
• hardware configuration and
• Software requirements
• Fieldbus
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
Comparison of control system bus types
DISTRIBUTED CONTROL
SYSTEM
DEFINATION
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
DCS (Distributed Control System) is a computerized
control system used to control the production line in the
industry controlled by one or more controllers.
DCS is a very broad term used in a variety of industries, to
monitor and control distributed equipment.
APPLICATION AREA
• Electrical power grids and electrical generation plants
• Environmental control systems
• Traffic signals
• Radio signals
• Water management systems
• Oil refining plants
• Metallurgical process plants
• Chemical plants
• Pharmaceutical manufacturing
Sensor networks
Dry cargo and bulk oil carrier ships
HISTORY
The DCS was introduced in 1975. Both Honeywell and Japanese
electrical engineering firm Yokogawa introduced their own
independently produced DCSs at roughly the same time, with the
TDC 2000 and CENTUM[3] systems, respectively. US-based
Bristol also introduced their UCS 3000 universal controller in
1975. In 1978 Metso(known as Valmet in 1978) introduced their
own DCS system called Damatic (latest generation named Metso
DNA[4]). In 1980, Bailey (now part of ABB[5]) introduced the
NETWORK 90 system. Also in 1980, Fischer & Porter Company
(now also part of ABB[6]) introduced DCI-4000 (DCI stands for
Distributed Control Instrumentation).
Distributed Control Systems
• Collection of hardware and instrumentation
necessary for implementing control systems
• Provide the infrastructure (platform) for
implementing advanced control algorithms
History of Control Hardware
• Pneumatic Implementation:
– Transmission: the signals transmitted
pneumatically are slow responding and
susceptible to interference.
– Calculation: Mechanical computation devices
must be relatively simple and tend to wear out
quickly.
History (cont.)
• Electron analog implementation:
– Transmission: analog signals are susceptible to
noise, and signal quality degrades over long
transmission line.
– Calculation: the type of computations possible
with electronic analog devices is still limited.
History (cont.)
• Digital Implementation:
– Transmission: Digital signals are far less sensitive
to noise.
– Calculation: The computational devices are digital
computers.
Advantages of Digital System
• Digital computers are more flexible because they are
programmable and no limitation to the complexity of the
computations it can carry out.
• Digital systems are more precise.
• Digital system cost less to install and maintain
• Digital data in electronic files can be printed out,
displayed on color terminals, stored in highly compressed
form.
Computer Control Networks
Display
1. PC Control:
• Good for small
processes such as Main
laboratory prototype or Computer
pilot plants, where the
number of control
Final
loops is relatively control PROCESS
Data
acquisition
element
small
Computer Control Networks
2. Programmable Logic Controllers:
• specialized for non-continuous systems such as batch
processes.
• It can be used when interlocks are required; e.g., a flow control
loop cannot be actuated unless a pump has been turned on.
• During startup or shutdown of continuous processes.
Computer Control Networks
3. DCS
Most comprehensive Supervisory (host)
Computer
Operator Main Operator Archival
Control Control Control Data
Panel Computer Panel Storage
Data highway
To other Processes To other Processes
Local data acquisition and Local Local Local
control computers Computer Computer Computer
Local Display Local Display
PROCESS
DCS Elements-1
• Local Control Unit: This unit can handle 8 to 16
individual PID loops.
• Data Acquisition Unit: Digital (discrete) and analog I/O
can be handle.
• Batch Sequencing Unit: This unit controls a timing
counters, arbitrary function generators, and internal logic.
• Local Display: This device provides analog display
stations, and video display for readout.
• Bulk Memory Unit: This unit is used to store and recall
process data.
DCS Elements-2
• General Purpose Computer : This unit is programmed
by a customer or third party to perform optimization,
advance control, expert system, etc
• Central Operator Display: This unit typically contain
several consoles for operator communication with the
system, and multiple video color graphics display units
• Data Highway : A serial digital data transmission link
connecting all other components in the system. It allow
for redundant data highway to reduce the risk of data loss
• Local area Network (LAN)
Advantages of DCS
• Access a large amount of current information from the data
highway.
• Monitoring trends of past process conditions.
• Readily install new on-line measurements together with local
computers.
• Alternate quickly among standard control strategies and
readjust controller parameters in software.
• A sight full engineer can use the flexibility of the framework
to implement his latest controller design ideas on the host
computer.
Modes of Computer control
• Manual signals from digital
computer
• Automatic Local PID
controller
– PID with local set
point
• Supervisory Supervisory Control mode
– PID with remote set Flow measurement
to computer
point (supervisory) valve setting
from computer
• Advanced
Direct digital Control mode
Additional Advantage
• Digital DCS systems are more flexible. Control
algorithms can be changed and control configuration can
be modified without having rewiring the system.
Categories of process information
Type Example
1. Digital Relay, Switch
Solenoid valve
Motor drive
2. Generalized digital Alphanumerical displays
3. Pulse Turbine flow meter
Stepping motor
4. Analog Thermocouple or strain gauge (mill volt)
Process instrumentation (4-20 am)
Other sensors (0-5 Volt)
Interface between digital computer
and analog instruments
• (A/D) Transducers convert analog signals
to digital signals. (Sensor Computer)
• (D/A) Transducers convert digital signals to
analog signals. (Computer Valve)
Data resolution due to digitization
• Accuracy depends on resolution.
• Resolution depends on number of bits:
Resolution = signal range × 1/(2m -1)
m = number of bits used by the digitizer (A/D)
to represent the analog data
Data Resolution
• Signal = 0 - 1 Volt, 3 bit digitizer:
Binary Digital Analog Analog range
representation Equivalent equivalent covered
000 0 0 0 to 1/14
001 1 1/7 1/14 to 3/14
010 2 2/7 3/14 to 5/14
011 3 3/7 5/14 to 7/14
100 4 4/7 7/14 to 9/14
101 5 5/7 9/14 to 11/14
110 6 6/7 11/14 to 13/14
111 7 1 13/14 to
14/14
Data Resolution
Digital data 6
4
3
2
1
0
0 1/7 2/7 3/7 4/7 5/7 6/7 1
Analog data
Utilization of DCS
• DCS vendor job:
– installation
• Control Engineer Job:
– Configuration
• Built-in PID control:
– How to Tune the PID control?
Utilization of DCS
• Implementation of advanced control:
– Developed software for control algorithms, DMC,
Aspen, etc.
– Control-oriented programming language supplied
by the DCS vendors.
– Self-developed programs using high-level
programming languages (Fortran, C++)
Advanced control topology
DCS Vendors
• Honeywell
• Fisher-Rosemont
• Baily
• Foxboro
• Yokogawa
• Siemens
• GE Fanuc Intelligent Platform
• Schneider Electrics
• ABB
COMPUTER BASED
CONTROL
• Numerical
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
Numerical
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
Numerical
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
Numerical
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
Numerical
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
COMPUTER CONTROLLER EXAMPLES
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
COMPUTER CONTROLLER EXAMPLES
Cont….
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
COMPUTER CONTROLLER EXAMPLES
Johnson CD, Process Control Instrumentation Technology, Prentice
Hall. (Chapter-11, Page: 553)
Summary
We have looked at:
• Implementing control system using computer or
microprocessor
• Computer based controller
• hardware configuration and
• Software requirements
• DISTRIBUTED CONTROL SYSTEM
• Meaning and necessity of distributed control
• hardware components of DCS
• DCS software.
• Numerical
Thank You
