INTEGRATED

CONTROL
SYSTEM
Prepared by : Guided By :
Rajyaguru Maulik M. D.M. Patel
(General Manage,inst)
RELAYS
 CONTI..
 More recently relays has been used for control
and early electrical control was based on relays.

 These relays allow power to be switched on and

off without a mechanical switch.

 It is common to use relays to make simple logical

control decisions.
 PLC
 In the earlier days, the equipment was operated
by Electro-mechanical Relay mounted panel
 The PLC replaced Relay mounted panels
 Definition:
“PLC is a digitally operating electronic system
designed for use in an industrial environment
which uses a programmable memory for the
storage of instruction for implementing specific
functions to control various types of process”.

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 Advantages PLC
Advantages over the Relay Logic are:
 Less cabling

 Less space requirement

 High flexibility

 High reliability

 Fast response time

 PLC Controls Operation of the Compressors,

Heater, Filters, Analyzer Safe Guarding System

and Other package units

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 Processor Architecture
The main parts of
PLC are:
1) CPU
2) Memory
3) Inputs
4) Outputs
5) Programming
Terminal
6) Power Supply

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 PLC System Architecture
 Input to the PLC are mainly of two types :
- Digital Input: Proximity Switch, Pressure switch,
Temperature switch etc.
- Analog Input: 4 to 20 mA signals of Pressure, Level,
Temperature, Flow transmitters.

 Output form the PLC going to I/P converter of the Valve,

variable Speed Drives, Relay, Lamp indication, Hooter, etc.

 The Digital and Analog input signals comes to the Digital and
Analog input card respectively

 This cards are installed in Chassis called Remote I/O Chassis

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PLC System Architecture
 PLC System Architecture
 Remote I/O adaptor Card is Required for the
Communication with the Processor. It always
remains in the first slot of the Chassis
 The Power Supply card in the Chassis is required to
supply power to the complete chassis (110 Vac
Power Supply)
 The Panelview is used for monitoring the data of
the process as well as controlling the operation
 Programming Terminal for Viewing, Modifying and
Configuring the PLC Programming

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 Signal Flow In PLC
 The Field Signals are connected with I/O cards
in RIO chassis and stores in I/P image
tables/memory
Start
Output Input
cycle
scan Scan Start
Star
output program
scan scan

Control
program scan

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CONTI..
 The data is processed in Processor according to the
program written, the result is transferred to the
output cards in RIO Chassis & the Output will be in
the terms of 4-20mA or Contacts.
 The Processor updates the data on every scan.
 The scan of the processor means processor doing
input scan, program scan, then output scan, and
serving the communication.
 The time taken for completing this cycle is called
Scan time (Average 40 ms).
 System Redundancy
 Each PLC having redundant processor.
 It is Hot Standby redundancy
 The BEM cards are installed for increasing the no.
of communication channels available for
networking.
 Both the PLC executes Application program.
Primary processor controls the I/O, but
Secondary can monitor only
 The Switch over between processor is doing by
BEM card

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 PLC Software
 The program can written in Ladder Logic, Sequence
function charts and in FBD

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CONTI..
 The Software package can load From PC/Laptop

 Processor can communicate on COM port of

PC/Laptop Serially thru Ch0 with processor

 The PLC program is protected with different level

access passwords
 Man-Machine interface
The Operator interface monitor for PLC is called
Panelview, it can
 Display process graphics

 Display various digital indications, analog

signals from transmitters mounted in field
 It communicates with Start/Stop of Motors &
varying Set points of Controller
(Auto/manual mode change)
 Acknowledgement and Reset of Alarms and

also History of Alarms

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 Diagnosis
 There are status LEDs on the processor face
 The first LED is battery status indicator, if it
glows Red - the battery is low
 The second LED is Steady Green - processor is
healthy. If it is Flashing Red - the program
downloading is under progress & for Steady Red -
hardware fault
 If Communication LED Steady Green - the Channel
0 communication is working & channel is healthy, If
Flashing Green-bad communication, when it is Red-
adaptor fault

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DCS
CENTUM 3000 DCS
DCS
 What is DCS ?
DCS is abbreviation for “Distributed Control
System”
 As is apparent from the abbreviation, the word
‘Distributed’ supports following functionality’s
 Physical Distribution
 Functional Distribution
 Structural Distribution
DCS
 Physical Distribution - Nodes or Subsystems
can be Distributed, i.e. located physically apart
 Functional Distribution - Specific Functionality is
imparted on the combination of hardware and
software used. For e.g. Application of work-
processor with control configuration software
 Structural Distribution - Different Structural
hardware platforms (Application Workstation
processor, Control processor etc.) are used to
achieve the required functionality.
 Basic Building Blocks
The Constitution of the DCS can be divided into following
parts :
 MMI ( Man Machine Interface )

 GUI ( Graphical User Interface / Operator Graphics )

 Control Algorithms and Logic

- Add, Subtract, PID, ON-OFF, AND, OR, NAND

 Communication

- Star
- Ring
- Linear Bus
- Star Wired Ring

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MULTI WINDOW HIS
WHY DCS ?
 For Total Plant Automation
 For Higher Productivity
 For Optimal Process Control
 For Advance Process Control
 For Management Information System
 In Tune With Global Requirement
Basic Control Algorithms
 Analog & Digital Input / Output Block
 PID Block / Auto tune PID block
 Calculation Block / Advance Calculation Block
 Comparison blocks - Less than, More than, Equal to.
 Data blocks / Memory blocks
 Sequence blocks
 Mathematical block
 Programmable Logic Block
 Motor Operator Valve, Pneumatic Valve control block
 Communication
Network
Topologie
s

Physical Logical

Linear Tree Ethernet

Star FDDI
Bus

Star
Token
Ring Wired ATM
Ring
Ring

FDDI :- Fiber Distributed Data Interface

ATM :- Asynchronous Transfer Mode
 Information Flow Diagram
From TX
JB TB B/R EB Ip Card

FIELD CONTROL ROOM OS

JB TB B/R EB Op Card
To O/P

JB = JUNCTION BOX EB = ELCO BOARDO

TB = TERMINATION BOX I/O CARD = INPUT/OUTPUT CARD
B/R = BYPASS RELAY OS = OPERATOR STATION
 Ex. - Signal Loop Dia in Plant

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 DCS Design Basis
 Real-time data exchange among all the systems using
Modbus device integrators.
 Minimum communication load on LAN.
 Each plant can be started and shutdown independently.
 Expandability of the System at every level .
 Ease of Software up-gradation at node level without
disturbing complex wide operation.
 Emergency Shutdown Systems are integrated with DCS
and Human Interface from DCS, and also Redundancy at
all level
 What is Emergency Shutdown?
It is a Safety Instrumented System (SIS) called
emergency shut down system which will take care of the
abnormal process conditions and save :
 Human losses

 Property losses

 Environmental losses and

 Reduce the risks

Because modern industrial processes tend to be

technically complex, involve substantial energies, and
have the potential to inflict serious harm to persons or
property during a mishap

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Control Languages & Software

Basic Language used for DCS

 Pascal
 C, C++
 Fortran 77
Software used for DCS
 AdvaCommand
 AdvaInform
 AdvaBuild
 DCS integration with PLC
 The advantages of tying PLC to DCS are numerous
 It also reduces the initial capital investment and
simplifies the PLC programming by integrating DCS
with the PLCs.
 The best feature of each device can be used, the PLC
can be used for sequential logic and to provide
inexpensive and robust I/O. The DCS can be used to
provide a better MMI, the ability to handle analog
I/O, PID control, and midterm storage.
 The resulting productivity improvements through
reduced downtime can be enormous.

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 THANK YOU

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