Topic 7:

Practical Distributed Control Systems (DCS)

You Will Learn How to:

Understand the architecture and operation of Distributed Control Systems (DCSs) Design the overall DCS and process control system Specify planned DCSs Improve process performance for your plant Understand the key ergonomic issues in design of operator displays Apply advanced control strategies to your plant control system Use your existing DCS process control capabilities more effectively Design and create a consistent and effective alarm philosophy for your installation Recognise and deal with human problems in interfacing to alarm systems

THE PROGRAM
Module 7.1 INTRODUCTION SUMMARY OF TYPICAL DISTRIBUTED CONTROL SYSTEMS DCS VERSUS SCADA VERSUS PLCS Comparison The Smart Instrument as a key component in a DCS system DCS SYSTEM ELEMENTS Main differences between a Distributed Control System and PLC/SCADA systems. Requirements of the operator interface within the DCS Layout of a DCS system with data highway communications paths Redundancy in the DCS DATA COMMUNICATIONS IN A DCS Overview of DCS and SCADA communications (field/operator/long distance) Network topologies Digital field communications Industrial Ethernet Industrial network security Links to MES and ERP ASSIGNMENT - When to use what type of controller and communications protocol Module 7.2 THE BASIC CONTROLLER Function of the Central Processing Unit (CPU) Discrete and logic control Sequential and batch control BASIC DCS CONTROLLER CONFIGURATION Control algorithms The use of diagnostics PROGRAMMING OF DCS SYSTEMS Block Configuration IEC 61131-3 "open" programming languages (structured text, function block, ladder, sequential) THE OPERATOR INTERFACE The operators process 'window' The various operator display configurations The requirement for keyboard entry of data Ergonomic requirements in the operator environment ASSIGNMENT -Simulation of a typical DCS will be used 14

Module 7.3 ALARM SYSTEM MANAGEMENT FOR DCSS Philosophies of alarm management Human and ergonomic factors Structure of good alarm system Safety Integrity Level (SIL) Design of alarm system Measurement of performance

DISTRIBUTED CONTROL SYSTEM REPORTING Alarm reporting, types of alarms generated and acceptance of alarms The different types of logs and reports which can be configured on a DCS system Data history use in logs, reports and trend displays ASSIGNMENT - Alarm Management for a simple Unit Operation Module 7.4 DISTRIBUTED CONTROL SYSTEM CONFIGURATION The organisation of system data files The need for different security levels attached to various operating parameters ADVANCED CONTROL STRATEGIES MAINTENANCE CONSIDERATIONS Maintenance requirements of system and system elements The requirements for in-built diagnostics and for maintenance diagnostic routines The requirements for installation of UPS system Recovery of a DCS following a power outage PRACTICAL SESSIONS Configuration of a typical DCS Control Loop using a typical plant problem

Overview
This section will cover the practical application advantages of the modern distributed control system (DCS) and how to maximise your return on this significant investment in both hardware and software. This includes the monitoring of the effectiveness and return on the on-line process and control system performance including due diligence on system alarm management. A variety of causes and cures for how these situations occur and can be corrected will be addressed as part of the course curriculum. Most of the process control functionality that should be in a DCS can be configured in terms of well tried and virtually standard combinations of function blocks. All DCSs have a comprehensive library of these function blocks but few operations outside the hydrocarbon industries implement the control schemes required for reasonably comprehensive process stabilisation ("straight lines on screens") and constraint compliance ("operating hard up against the limits") capabilities on which control systems are justified. This course will provide you with the tools to realise how to effectively use an integrated distributed control system and consequently optimise your process and profitability.