Agenda

Alarm & Trip System

DCS
PLC
Ashwani Kansal
Sr. Engineer Instrumentation
23/1/2006

Shut Down System Intervention - ESDS

Mechanical Intervention - PRVs
Human Intervention Alarm System
Control System Intervention (DCS)
Normal Operation (LOCAL CONTROL)

Layered Protection

 Control System: System compensates for minor

disturbances, adjusting the process as needed.
Alarm System: This alerts the operator to problems
beyond the capabilities of the control system to
enable human intervention.
Relief System: If changes are beyond human
intervention or too fast for intervention, relief
systems energy to prevent unsafe condition from
occurring.
Shut Down System: If the plant continues in to an
unsafe region, independent shut down system should
stop operation.

Basic Concepts of Control System

Evaluation History and benefits of
DCS
Basic Concepts of DCS

What is a Control?
Measurement of a Process Variable
Processing of measured data with
other information
Cause a control action

Process Variable

Pressure
Temperature
Flow
Level
Relative Humidity
Current
Voltage, ETC.

Types Of Control
Two Position Control
Floating Control
Analog Control
Proportional Control

PI Control

PID Control

Digital Control

Two-Position Control
In a two-position control sequence, the controller
compares an analog or variable input with instructions
and generates a digital (two-position) output. The
instructions involve definitions of upper or lower limits.
The output changes value as the input crosses the
limits.

Floating Control
A floating control response produces two digital
outputs based on changing variable input. One
output increases the signal to the controlled device
while the other output decreases the signal to the
controlled device. The control response also
involves an upper and lower limit with the output
changing as the variable input crosses these limits.

Proportional Control
A proportional control response produces an
analog or variable output change in proportion to
a varying input. A linear relationship exists
between input and output. A set point, throttling
range, and action normally define this
relationship.

PI Control
PI control measures offset or error over time. The
error is integrated, and a final adjustment is made
to the output signal from a proportional part of
this model. PI control response will work the
control loop to reduce the offset to zero.

PID Control
PID control adds a predictive element to the control
response. In addition to proportional and integral
calculation, the controller will compute the
derivative or slope of the control response. This
calculation dampens a control response that is
returning to set point so quickly that it would
overshoot the set point.

Digital Control
Based on pre defined control logics and status of
digital input signals, digital control signals are send
as output for control. These types of control are
normally used in on/off control , shutdown
systems, etc.

INPUT A
INPUT B
INPUT C

OUTPUT X
AND

Evaluation of Control Systems

1930s Machine type instrument, manual
control
1940s Large size pneumatic control
instrument
1950s Small size pneumatic control
instrument
1960s Small size analog instrument
1970s Distributed control system, CRT
operation
1990s Microprocessor based DCS, PLC, etc.
Now Compact systems, PC based systems,
Open connectivity, MIS, etc.

Control Techniques
Manual Operation
Pneumatic Controllers (Phase - I & Phase II)
Electronic Analog Controllers
Supervisory Control Computers
Distributed Control System (DCS)
Field Bus Technology

Advantage of Pneumatic
Controller over Manual Controller
Improved Reliability
Centralized System
Improved Operator Efficiency
Auto Operation
Reduced Manpower

Problems of Pneumatic Control

System
Failures due to moving parts
(Baffles & Nozzles assembly)
Signal Loss due to long travel
High Maintenance cost

Advantage/Disadvantage of
Electronic Control

Improved Reliability (No moving Parts)

No signal Loss
Better representation of Process
No data storage and retrieval ability

Distributed Control System - DCS

Introduced in late 1970s.
The concept behind the DCS was to use
microprocessor technology for implementing
control.
Control loops were distributed among many
smaller controllers each with its own Central
Processor Unit.
Controllers were linked together along with
Operator Console and Engineering Station
through a Communication Highway.
Provides Redundancy

IPB1A/1B IPB2A/2B
1.01

1.02
2.02

1.04

2.01

AS160OS DAS/MMI

Diagnostic Station

2.04

SOE

1.10
HRSG 1

1.11
Aux. Boiler 1

1.12
GT 1

1.13
BoP-HP

1.14
Nitrogen

2.15

HRSG 2

2.16

Aux. Boiler 2

2.17

CW / IAPA

2.18

BoP-MP

2.19

AB 1/AB 2 Inputs

Procontrol P13/42 DCS System O&U

Basic Layout of DCS

Control Room

Programmable Controller

Bus Controller

Input / Output

MMI

BUS
Input

Output
DCS

Analog / Digital Signals

Field / MCC

Example of Analog Signal Flow From Field To DCS

PV
4-20 mA

INPUT
1-5 VDC

1- 5 VDC

A/D

PV

SET POINT

DIGITAL SIGNAL

INPUT SIGNAL CONDITIONER

PID

MMI

Sensor
Bus

I/P

MV
ISOLATOR

D/A

DIGITAL SIGNAL

Signal
Processing

I/O Card
Field

Signal Conversion
& Isolation

DCS

Control Room

Example of Digital Signal Flow From Field To DCS

TERMINAL
BOARD

DIGITAL
INPUT
CARD

Sensor

SEQUENCE
CONTROL
RELAY
BOARD

BUS

DIGITAL
OUTPUT
CARD

I/O NEST

Field

Marshalling

MMI

PROCESSOR

DCS

C/R

Outline Of Control System

Input module
Output Module
Processing Module
Communication Module
Bus Controller Module
Bus System

Function Of Input Module

Supplies power to Transmitters or
transducers
Signal Verification
Digitization, Parallel/Serial Conversion
Storage of Measured value
Address allocation
Module can be Analog or Digital

Function Of Output Module

Conversion of digital values in to
Analog/Binary signals
Storage of signal for Output
Address allocation
Power supply for the driven end
Module can be Analog or Digital

Function Of Processing Module

Accept Input data from the Bus
Executes Control/Logical/Arithmetic
functions as per written program
Data Simulation
Diagnostic Functions
Checks the Redundancy

Function of Bus Controller & Bus

System
Provides Hardware path for travel of
information
Clock Generation
Address generation
Data Transmission
Data Reliability Checking

Advantages of DCS

Superior reliability due to Redundancy

Improved Effectiveness
Improved Operation Efficiency
Better Diagnosis of Problem
Facilitates the use of advanced control
Alarm generation capabilities
Modular System
Less expensive per loop
Less expensive to expand

 Data storage and retrieval features

Easier modification
Minimum Down time
Ease of Maintenance (less
Complexity)
Reduction in cost
DCS can be placed away from Control
Room (Reduces Cable Cost)

ABB Procontrol P13 DCS

DCS Systems in CFCL

Ammonia / Urea I: Yokogawa Centum XL
Ammonia / Urea II: Yokogawa Centum CS
Offsite & Utilities: ABB Procontrol P13/42

Ammonia / Urea I: Yokogawa Centum XL

System hardware Configuration

Terminology

EOPS : OPERATOR STATION

EOPC : OPERATOR CONSOLE
ENGS : ENGINEERING STATION
EFCD : DUPLEX FIELD CONTROL STATION
EFMS : FIELD MONITORING STATION
EFGW : FIELD GATEWAY UNIT
EPRT : PRINTERS
HF BUS : BUS FOR INTER CONNECTING CONTROL
STATIONS AND OPERATOR STATIONS
ECHU : COLOUR HARD COPY UNIT

Salient Features Of Control Station

Processor : Dual redundant
Communication : Dual redundant
Control cards : Dual redundant
Battery backup : 72 hours
Bus Transmission : 1 Mbit / sec
Transmission distance : Upto 1 km
No of stations : Upto 63
Self diagnostics

PHASE I AMMONIA PLANT

MAN MACHINE INTERFACE
CENTUM CS3000
YOKOGAWA

SALIENT FEATURES OF OPERATOR STATION

CPU : MC68030 (25 MHz, 32 bit)
Memory : 8 MB
Hard Disk : 80 MB
Touch screen operation
Self Diagnostics
Application Capacity
No. of tags : Upto 16000
Trend points : Max 2300
Graphics pages : 300
Alarm Messages : Max 7680

Functions of MMI System

Display of Process Data

Trending
Recording
Control Function
External System Connectivity
Sequence of event recording

DCS Configuration Ammonia II

Terminology
FCS
ICS
EWS
ACG
ABC
V-NET
E-NET
APS
ACS
RIO BUS
NIU

: Field control station

: Information & command station
: Engineering work station
: Advance Gateway unit
: Bus converters
: Bus for connecting FCS & ICS real time
control network
: Communication network EWS to ICS and
Gateway to secondary system.
: Application Station
: Advance Control Station
: Remote I/O Bus
: Node interface Unit

HARDWARE SPECIFICATIONS & MODEL CODES

Processor

Memory size : 8 Mb (Enhanced type - 16 Mb)

Battery backup time

Recharging time

: 48hrs or longer

Communication

: V-NET Duplex or Single

: RIO bus Duplex or Single

Power Supply: 100 to 120 AC

: 50 0R 60HZ +/- 3HZ

: RB3000 (25 MHz)

: 72hrs max.

Connectivity to LAN - Overview

V-Net Bus

V-Net Bus
ACG10S
Ammonia
Ammonia DCS Gateway

Ethernet Switch

ACG10S
Ammonia
Gateway

TCP/IP

Citect
Server

Urea DCS

LAN Switch

Citect
Client

Citect
Client

Citect
Client

Citect
Client

Citect
Client

User-1

User-2

User-3

User-4

User-5

Salient Features Of Centum - CS

DUAL REDUNDANT V-NET SUPPORTS
MAX. NO. OF STATIONS
MAX. NO. OF DOMAINS
STATION NO. ICS
STATION NO. FCS
MAX. NO. OF ICS/DOMAIN
MAX. NO OF NIU/FCS
MAX. NO. OF I/O UNIT/FCS
MAX. NO. OF NEST/IOU
MAX. LENGTH OF V - NET
(WITH OPTICAL FIBER)
MAX. LENGTH OF RIO BUS
(WITH OPTICAL FIBER)

: 256/SYSTEM
: 16/SYSTEM
:1 TO 64
: 1 TO 64
: 16
:8
: 40
:5
: 20KM
: 20KM

O&U Plant
Procontrol P13/42 DCS
ABB

IPB2A/2B
1.01
1.04
2.04

AS160OS DAS/MMI

1.02
2.02

Diagnostic Station

2.01
SOE

1.10
HRSG 1

1.11
Aux. Boiler 1

1.12
GT 1

1.13
BoP-HP

1.14
Nitrogen

2.15

HRSG 2

2.16

Aux. Boiler 2

2.17

CW / IAPA

2.18

BoP-MP

2.19

AB 1/AB 2 Inputs

ABB Procontrol P-13/42 DCS System O&U

Salient Features of DCS System

Modular System
Multi Processor System
Expandable System
Processor : Dual Redundant
Bus Traffic Director: Dual Redundant
Intra Plant Bus : Dual redundant
Cycle Time: 5, 10, 20, 40 mSec (User Selectable).
Programming Language: Procontrol P10
Bus Transmission (Local Bus): 0.2 Mbits/Sec.
Bus Transmission (IPB): 0.27 Mbits/Sec.
Transmission distance : Upto 1 km (2 Km with amplifier card)
No of stations : Upto 64
Max. No. of addresses on Local Bus: 256 word address (FF)
Total No. of addresses: 16384

O&U Plant
Man Machine Interface
Advant AS160OS DAS
ABB

Configuration Diagram
Control Room
Printer # 2

Printer # 1
19

19

19

Printer # 3
19

19

Engineering
Station

AS 160OS Operator Station

Hub

Information Network
(TCP/IP)

AS 160OS
Server

IPB 1A/1B
IPB 2A/2B

Features Of ABB ADVANT AS160OS

MMI System
Direct integration with Procontrol P13 DCS
System structure modular, flexible, open
Easy operation point and click
Object oriented
Safe operation
Efficient navigation
User authorization and security levels
Easy to engineer

Task Performed by Server

Data acquisition and processing
Data management, archiving and retrieval
Interface to P13 DCS bus
Interface to LAN
Time synchronisation
System diagnostics

Overview of DAS Functions

Database
Analog inputs 1200
Binary inputs 3000
Analog drives 50
Binary drives 100
Reports
Daily reports 24 nos
Monthly reports 7 nos

Overview Of DAS Functions Used

Mimic displays 85 pages
Real time trend displays 42 pages
Historical trend displays 42 pages
Group displays 62 pages
UFF criteria displays 19 pages
Characteristic curves display 12 pages
Profile displays 12 pages
Alarms process, system, operator actions
System configuration display