Ian Jade B.

Abrasado BSCPE - IV

Instrumentation and Control Engineering

Basic Process Control System (BPCS)

Basic Process Control System (BPCS) is a system which handles process control and
monitoring for the facility. It will take inputs from sensor and process instruments and provide
output based on control functions in accordance with approved design control strategy.

Typically, Basic Process Control System (BPCS) performs the following functions:
 Control the process within pre-set operating condition, optimize plant operation to produce a
good quality product and attempt to keep all process variables within its safety limit.
 Provide operator interface for monitoring and control via operator console (Human Machine
Interface)
 Provide alarm/event logging and trending facilities
 Generate production data reports

Distributed Control System DCS

In recent years, the use of smart devices and field buses makes distributed control system
(DCS) to be prominent in large and complex industrial processes as compared to the former
centralized control system. This distribution of control system architecture around the plant has
led to produce more efficient ways to improve reliability of control, process quality and plant
efficiency.

Nowadays, distributed control system has been found in many industrial fields such as chemical
plants, oil and gas industries, food processing units, nuclear power plants, water management
systems, automobile industries, etc.

A distributed control system (DCS) is a specially designed automated control system that consists of
geographically distributed control elements over the plant or control area.

It differs from the centralized control system wherein a single controller at central location handles the
control function, but in DCS each process element or machine or group of machines is controlled by a
dedicated controller. DCS consists of a large number of local controllers in various sections of plant
control area and are connected via a high speed communication network.

Programmable Logic Controller

A programmable logic controller (PLC) is an industrial solid-state computer that monitors inputs
and outputs, and makes logic-based decisions for automated processes or machines.

PLCs were introduced in the late 1960s by inventor Richard Morley to provide the same
functions as relay logic systems. Relay systems at the time tended to fail and create delays.
Technicians then had to troubleshoot an entire wall of relays to fix the problem.
PLCs are robust and can survive harsh conditions including severe heat, cold, dust, and
extreme moisture. Their programming language is easily understood, so they can be
programmed without much difficulty. PLCs are modular so they can be plugged into various
setups. Relays switching under load can cause undesired arcing between contacts. Arcing
generates high temperatures that weld contacts shut and cause degradation of the contacts in
the relays, resulting in device failure. Replacing relays with PLCs helps prevent overheating of
contacts.

Supervisory Control And Data Aquisition

is a system of software and hardware elements that allows industrial organizations to:

 Control industrial processes locally or at remote locations

 Monitor, gather, and process real-time data
 Directly interact with devices such as sensors, valves, pumps, motors, and more through
human-machine interface (HMI) software
 Record events into a log file

SCADA systems are crucial for industrial organizations since they help to maintain efficiency,
process data for smarter decisions, and communicate system issues to help mitigate downtime.

The basic SCADA architecture begins with programmable logic controllers (PLCs) or remote
terminal units (RTUs). PLCs and RTUs are microcomputers that communicate with an array of
objects such as factory machines, HMIs, sensors, and end devices, and then route the
information from those objects to computers with SCADA software. The SCADA software
processes, distributes, and displays the data, helping operators and other employees analyze
the data and make important decisions.

Safety Instrumented Systems

The Safety Instrumented Systems are used to monitor the condition of values and parameters
of a plant within the operational limits and, when risk conditions occur, they must trigger alarms
and place the plant in a safe condition or even at the shutdown condition.
The safety conditions should be always followed and adopted by plants and the best operating
and installation practices are a duty of employers and employees. It is important to remember
that the first concept regarding the safety law is to ensure that all systems are installed and
operated in a safe way and the second one is that instruments and alarms involved with safety
are operated with reliability and efficiency.
The Safety Instrumented Systems (SIS) are the systems responsible for the operating safety
and ensuring the emergency stop within the limits considered as safe, whenever the operation
exceeds such limits. The main objective is to avoid accidents inside and outside plants, such as
fires, explosions, equipment damages, protection of production and property and, more than
that, avoiding life risk or personal health damages and catastrophic impacts to community. It
should be clear that no system is completely immune to failures and, even in case of failure; it
should provide a safe condition.