Process Control and Data

Acquisition Systems
CM4120
Chemical Plant Operations
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Distributed Control System (DCS)

Architecture

Used for continuous control of chemical processing

Control functions are distributed throughout redundant,
deterministic networked computer architecture

I/O interface and level 1 control functions

advanced control functions
human interface

DCS replaced mainframe computer controllers

Added a high level of robustness to control systems
Pre-configured functionality geared toward process
industries, but a relatively high cost

Programmable Logic Controller (PLC)

Architecture

Used for control where the devices are primarily discrete

(the controlled devices are energized/de-energized and the
inputs are open/closed circuit)

Provide very fast response (< .1 sec) to system changes

Typical applications are packaging, material conveyance,

and waste water treatment

Very little, if any pre-configured functionality, but PLCs

are relatively low cost

In chemical processing, often are used along side DCS

SCADA Supervisory Control and Data

Acquisition System

Scalable systems that provide some additional level of

control and data acquisition above the controller, DCS
and/or PLC level

Typically use non-redundant TCP/IP communications and

therefore are not considered appropriate for direct process
control

Built upon non-proprietary, off-the-shelf hardware

Very useful in large plant environments where data from

many sources must be collected

Rockwell Automation ProcessLogix DCS

and OSISoft PI in PSCC
PI is process data management system

WE Network

External historized and real-time data

requests are served thru PI Server
Operator Stations and other internal data
users communicate thru PLX Server
Control executes at PLX Controller
Plant Area valves, xmitters

PI Server
Control Room
Network Switch

ProcessLogix
Server

PLX Controller
and I/O Cards

Operator Stations

ProcessLogix How it works

Control Room network is
Windows 2000 domain PSCC
PDC is PI Server
Control system configuration is
done thru PLX Server creates
configuration database
PLX server stores configuration
database and stores/updates an
active, real-time database
Operator stations access process
thru PLX server

PI Server
Control Room
Network Switch

ProcessLogix
Server

Operator Stations

ProcessLogix How it works

Communications via ControlNet
Controller configuration is
downloaded to PLX Controller
PLX Controller continuously updates
copy of active database at PLX server
PLX Controller continuously
executes all control logic, alarming,
PID loops, indicators, etc.
Controller continues to function,
even after loss of communication w/
server

ProcessLogix
Server

PLX Controller
and I/O Cards

ProcessLogix How it works

Plant Area valves, xmitters

PLX Controller
and I/O Cards

I/O cards are specific to device requirements

4-20 mA input, 4-20 mA output
24 VDC input, 24 VDC output, etc.

A pair of wires runs from each device back to the I/O card
Typically 8 to 16 devices per I/O card
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PLX Controller Cabinet

PLX controller

I/O cards
Zener barriers
8 pr. cables from
field junction cabinet

2nd I/O chassis

Field Junction Cabinet

Single pairs from

field device

8 pr. Cables to
controller cabinet

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Field Devices Transmitters

Level transmitter

Wiring to field
junction cabinet
Thermocouple
head
Wiring from
transmitter to
measuring element
Temperature
transmitter

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Field Devices Transducer

Solenoids for 2-position
air-actuated ball
valves
Air lines to
ball valves
Current to pneumatic
transducers
Air lines to
control valves

Single pr. cable

from field
termination cabinet

Wire prs. to solenoids

Wire prs. to transducers

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Field Devices Regulatory Control Valve

Air line from transducer
Actuator w/ positioner
Control valve

Block valves
Bypass valve

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Field Devices Ball Valve w/ Actuator

Air line from
solenoid
Ball valve body
Actuator
Process line

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PI Plant Information System

PI is a process data historization/
data retrieval system

WE Network
- PIPC
- ProcessBook

PI server (Steam) is PDC for

control room network and is also
on WE network
PI data are available anywhere on
campus network

PI Server
- OPC Interface
Control Room
Network Switch

ProcessLogix
Server
- OPC Server

PIPC is Excel add-in

ProcessBook is graphical tool for
viewing process and process data

Operator Stations
- PIPC
- ProcessBook

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PI Plant Information System

Data Historian system is required part of process

management system
Long-term data storage/ retrieval system
Optimizes use of hard drive storage space and permits
quick recall of archived data
Includes data retrieval software tools
OSISoft, Inc. PI system

Import process data into supervisory control or process monitoring

applications
Link process control systems with business management systems
Provide data for production and compliance reporting

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PI How it works

A PI tag is configured for every piece of data you want to archive

Collected tags are scheduled to retrieve data periodically or upon
the occurrence of an event
Data are brought into the archive thru a filtering and compression
algorithm
Data are not archived unless they pass the filter and compression
tests
When data are retrieved from the archive and presented in a series,
the individual points are extrapolated between the stored data
Tags can also be manually entered lab data

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