Introduction to DCS and DAS in Thermal

Power Station & Recent Trend of Technology

Industrial Communication System
 Presentation outline

 DAS and DCS

 DCS of ABB for Thermal Power Plant

 DCS of Yokogawa for Thermal Power Plant

 Recent Trend of Technology

 Protection and Interlocks of Boiler System and DCS

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 Part 1
DAS and DCS

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 Content

 Introduction to DCS & DAS

 History of Control Hardware

 Advantages of Digital System

 Computer Control Networks

 DCS Elements

 Advantages of DCS/Objective of DCS/Benefits of DCS

 Modes of Computer control

 Utilization of DCS

 DCS Vendors

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 Use of computer for measurement and control (in real
time) application were conceived as early as
1950
Measurement
Sequential
Control Monitoring (Alarms &
annunuciations

PLC&
DCS

Automatic DAS Recording/SOE

control Trending/History
Digital computer application in process
industry may be:

Passive or Active
• Passive application involves only acquisition
of process data (data acquisition / data
logging)

• Active application involves acquisition and

manipulation of data and uses it for (real
time) process control.
 History of Hardware

 Pneumatic Implementation:
 Transmission: the signals transmitted pneumatically are
slow responding and susceptible to interference
 Calculation: Mechanical computation devices must be
relatively simple and tend to wear out quickly.
 Electronics analog implementation:
 Transmission: analog signals are susceptible to noise,
and signal quality degrades over long transmission line.
 Calculation: the type of computations possible with
electronic analog devices is still limited.

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 History of Hardware

 Digital Implementation:

 Transmission: Digital signals are far less sensitive

to noise.

 Calculation: The computational devices are digital

computers.

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 Advantages of Digital System

 Digital computers are more flexible because they are

programmable and no limitation to the complexity of the
computations it can carry out.

 Digital systems are more precise.

 Digital system cost less to install and maintain

 Digital data in electronic files can be printed out, displayed on

color terminals, stored in highly compressed form.

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 Data Acquisition System- DAS

A data acquisition system consists of many components that

are integrated to:

 Sense physical variables (use of transducers)

 Condition the electrical signal to make it readable by an A/D
board

 Convert the signal into a digital format acceptable by a

computer

 Process, analyze, store, and display the acquired data with the
help of software

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 Data Acquisition System- DAS (Cont.)

Data Acquisition System Block Diagram

 Data Acquisition System- DAS (Cont.)

 Data acquisition hardware generally performs

one or more of the following functions:

 analog input,

 analog output,

 digital input,

 digital output and

 counter/timer functions

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 Computer Control Networks

PC Control: Display

 Good for small processes

such as laboratory prototype
or pilot plants, where the
Main
Computer
number of control loops is
relatively small
Final Data
control PROCESS acquisition
element

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 Computer Control Networks

Programmable Logic Controllers:

 specialized for non-continuous systems

such as batch processes.

 It can be used when interlocks are

required; e.g., a flow control loop cannot
be actuated unless a pump has been
turned on.

 During startup or shutdown of continuous

processes.
 Process Control Systems

 Process control systems are classified

into

 Analog Control Systems

 Digital Control Systems

 Basic Control Loop

Basic Loop

SV
Transmitter PV MV
4-20 mA Controller

I/P 4-20 mA
I/P
Convertor
Pneumatic Signal
(0.2 to 1 Kg/cm2 or 3 to 15 psi)

Final Control Element

 Analog Control System

Analog Control System

Operational Amplifier
Transmitter
1 to 5V DC
Signal
Conversion

4-20 mA DC
I/P

Set Point

Final Control Element

 Digital Control System

Digital Control System

Memory
Unit

1 to 5V DC Control
Unit Set
A/D Input Point
Digital Unit
4-20 mA DC Arithmetic
Output
D/A Unit Unit
I/P

Processor
 THE NINETIES BEYOND
THE SIXTIES THE SEVENTIES THE EIGHTIES
2000

* First control * First DDC * First mini * First distributed * First one-loop * Integrated systems * multimedia
computers computers DDC using DDC controllers
microprocessors * windows NT gaining prominence
* Use of factory
Ge.Tr Sl. Tr management * Internet
DTL SSI
Rapid growth of computers
TTL.SSI LSI uP
process Industries * Pentium Processor
Demand for V LSI 32bit UP
Energy crisis
conservation Appearance of * Multi produce batch
(Transition to
of resources OA, LA and FA applications * Revolution in info tech
steady growth)
(Improved man- * Integrated FA system
machine interface * CIM * Objectlinking

* ODBC

* RDBMS
 THE SIXTIES THE SEVENTIES THE NINETIES BEYOND
THE EIGHTIES
2000
Factory Management Computer System
YEWCOM HP9000

Computer Control System

CCS YODIC 100 YODIC 1000
Manufacturing Line Control System
YEWMAC
Centralized DDC System
YODIC 500 YODIC 600
Distributed Control System
CENTUM II CENTUM V CENTUM-XL

YEWPACK YEWPACK
Mark II uXL
YEWSERIES 80
CS
YS 100
CS1000
CS3000
Analog Control System
ECS EBS I SERIES
 Digital Control System

 Digital Control Systems are further

classified into

 Centralized Control Systems

 Distributed Control Systems

 Centralized Control System

Centralized Control , Centralized Monitoring

PV1 MV1
Centralized
Input PV2 MV2 Output
Processing
Signals PV3 MV3 Signals
from Unit to
PVn MVn
Field CPU Field

SV1 SV2 SV3 SVn

Set Points
 Centralized Control System

 Drawbacks Of CCS:
 If the CPU fails the entire plant
gets affected.
 Redundancy concept is not
available.
Redundancy is having two controllers. One
would be active and the other would be
standby. If the active controller fails, standby
controller takes over.
 Distributed Control System

Distributed Control System

Distributed Control Centralized Monitoring
PV1 MV1

FCS Output OPS

PV8 MV8
Input SV1 SV8
Signals
Signals PV9 MV9 to Field
from
FCS OPS
Field PV16 MV16
SV9 SV16

PV17 MV17
Communication
FCS Bus
PVn MVn
SV17 SVn
Set Points
 Distributed Control System

As is apparent from the abbreviation, the word

‘Distributed’ supports following functionality’s

Physical Distribution - Nodes or Subsystems can be Distributed I.e

located physically apart

Functional Distribution - Specific Functionality is imparted for a

Node basing on the combination of hardware and software used. For
e.g Application work-processor with Historian, Application work-
processor with control configuration software

Structural Distribution - Different Structural hardware platforms

(Application Workstation processor, Workstation processor, Control
processor etc.) are used to achieve the required functionality.
 Distributed Control System- DCS

 Most comprehensive
Supervisory (host)
Computer

Operator Main Operator Archival

Control Control Control Data
Panel Computer Panel Storage

Data highway
To other Processes To other Processes

Local data acquisition and Local Local Local

control computers Computer Computer Computer
Local Display Local Display

PROCESS

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 DCS Elements-1

 Data Acquisition and Field Control Unit: Digital (discrete) and

analog I/O can be handle.
– Controller module

– Input module ( Analog :4-20mA, RTD, TC…; Digital:)

– Output module

• Analog output

• Digital output

– Power supply

– Communication module

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 DCS Elements-2

 Batch Sequencing Unit: This unit controls

a timing counters, arbitrary function
generators, and internal logic.

 Local Display: This device provides

analog display stations, and video display
for readout.

 Bulk Memory Unit: This unit is used to

store and recall process data.

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 DCS Elements-3

 General Purpose Computer : This unit is programmed by a

customer or third party to perform optimization, advance control,
expert system, etc

 Central Operator Display: This unit typically contain several

consoles for operator communication with the system, and multiple
video color graphics display units

 Data Highway : A serial digital data transmission link connecting all

other components in the system. It allow for redundant data highway
to reduce the risk of data loss

 Local area Network (LAN)

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 What is a DCS & PLC

In a control system there are three

elements:
 measurement,
 control algorithm;
 final control element.

• A PLC: Programmable Logic Controller was historically for machine control.

This means that it is primarily on/off control. Fast control loops, in the order
of milliseconds.

• A DCS: Distributed Control System was historically for control of a process,

where there are many analogue variables: pressure, temperature, flow:
constantly changing.
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 What are the important features of a DCS?

Distributed means:
 Distributed Risk: Reliability is important as many components
are linked together. Redundancy is a method of distributing
the risk.

 Distributed components: Controllers, Inputs and Outputs

(measuring and control signals)

 Robust communication system to connect the components:

I/O, controllers, operator interface.

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 DCS is the Centre of Information

Management

Load Dispatch Operator

DCS PLC
Controller

Auxilliary:
Coal Plant, Water Treatment
Field Signals
Boiler/Turbine

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 Power Station Control

 Complex Process: many relationships between many variables,

 Plant efficiency is related to how well the control is tuned,

 The Control System must not be the limiting factor to achieve
efficiency,

 Control must be robust to overcome plant problems, without a trip or

plant shutdown,

 Availability of DCS must be almost 100% to achieve plant efficiency:

 Redundancy to give reliability

 Ease of use of DCS to look at data

 Many Auxilliary Plants: often with PLC’s

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 Advantages of DCS

 Access a large amount of current information from the data highway.

 Monitoring trends of past process conditions.

 Readily install new on-line measurements together with local computers.

 Alternate quickly among standard control strategies and readjust
controller parameters in software.

 A sight full engineer can use the flexibility of the framework to implement
his latest controller design ideas on the host computer.

 Digital DCS systems are more flexible. Control algorithms can be

changed and control configuration can be modified without having
rewiring the system.

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 Objective of DCS

 Safe operation of plant

 Lowesr cost of generation

 Longest equipment life

 Minimum efficiency

 Energy conversation

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 Benefits of DCS

 High reliability

 Improved response time

 Improve operator interface to plant

 Improve accessibility of plant data to engineering &

managenment personals

 Historical storage and retrieval system

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 Modes of Computer control

signals from digital

1. Manual computer

Local PID
FC
2. Automatic controller

• PID with local set point

3. Supervisory Supervisory Control mode

• PID with remote set point Flow measurement

(supervisory) to computer
valve setting
from computer
4. Advanced

Direct digital Control mode

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 Utilization of DCS

 Implementation of advanced control:

 Developed software for control algorithms, DMC,
Aspen, etc.

 Control-oriented programming language supplied by

the DCS vendors.

 Self-developed programs using high-level

programming languages (Fortran, C++)

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DCS MANUFACTURERS
 HONEYWELL
 YOKOGOWA
 ALLEN BRADLEY
 GE FANUC
 EMERSON
 ASEA BROWN BOWERI – ABB
 FOXBORO – INVENSYS
 SIEMENS