DCS/PLC: DCS (Distributed Control System) / PLC (Programmable Logic Controller) in a automated

process/manufacturing plant is a window for plant operator to control, monitor the entire plant from a common place
i.e. central control room. It also performs the safety interlocks of the plant.

ESD – Emergency Shutdown System. The ESD system forms part of the facility’s safety systems. Its prime function
is to shutdown the facilities to a safe state in case of an emergency situation, thus protecting personnel, the
environment and the asset.

PSS – Process Safety System: The PSS forms part of the facility’s safety systems. Upon command, it shall
automatically carry out the safe shutdown of particular units or equipment as defined by the safety philosophies.

PCS – Process Control System: The PCS system forms part of facility’s control systems. It shall ensure a safe,
reliable and efficient control and monitoring of the process plant and utilities.

FGS – Fire and Gas System – The F&G detection and protection system forms part of the facility’s safety systems.
Its function is to mitigate against the effects of any fire and/or gas releases in order to protect personnel, the
environment and the asset. The F&G system will continuously monitor the facilities and initiate the protective actions
as defined in the safety philosophies.

HMI – Human Machine Interface : the HMI shall provide the facility for the operator to control and monitor the plant
via mimic displays, alarms, trend displays and operstor commands.

EWS – Engineering Work Station: Engineering Work Station allows its control system’s (DCS,PLC, etc)
maintenance, configuration and diagnostic.

ICSS – An Integrated Control and Safety System is a technology platform that combines elements of
process control and functional safety into a single architecture. Our systems may include elements from
multiple or single vendors and can incorporate existing systems or implement completely new architecture.

I/O – Input/Output

(SIS) Safety integrity level

Safety integrity level is defined as a relative levels of risk-reduction provided by a safety function, or to specify a target
level of risk reduction. In simple terms, SIL is a measurement of performance required for a safety instrumented function.

SOE – Sequence Of Events. SER – Sequence of Events Recorder : A facility provided by ICSS in order to identify
and record the time of all events in any part of the system (controllers) of all subsystems.

IPF - Instrumented Protective Function : A function comprising the Initiator function, Logic Solver function and
Final Element function for the purpose of preventing or mitigating Hazardous Situations.

IPS – Instrumented Protective System : The electromechanical, electronic and/or programmable electronic Logic
Solver component of the Instrumented Protective Function, complete with input and output equipment.

MTBF – Mean Time between Failures: MTBF ratings are measured in hours or years and indicate the reliability of
equipment. Calculated by dividing the total unit operating hours accrued in a period by the number of unit failures
that occurred during the same period.

Trip - An Instrumented Protective Function action to bring the Final Element(s) to a safe state.
RTU - Remote Terminal Units (RTUs), used to continually collect data from the sensors in the field, and process and
send the information to a centralised Master Station.

SCADA - Supervisory Control and Data Acquisition (SCADA) is used to monitor and control remote plant and
equipment.

Operator console - A group of equipment comprising VDU screens, keyboards, pointing devices and switches which
are allocated to a defined part of the plant (e.g. "console for hydrogen units").

TCP/IP - Transfer Control Protocol / Internet Protocol: The complete and (for internet use) necessary protocol
that allows computers to communicate irrespective of brand, type, speed or operating system.

MMS – Machine Monitoring System

MCC – Motor Control Centre

ELICS - Electronics, Informatics and Computer Science.

Split range control loop

In a split range control loop, output of the controller is split and sent to two or more control valves. The splitter defines how
each valve is sequenced as the controller output changes from 0 to 100%. In most split range applications, the controller adjusts
the opening of one of the valves when its output is in the range of 0 to 50% and the other valve when its output is in the range of
50% to 100%.

What is HAZOP?
HAZOP- an abbreviated term of “HAZards and OPerability”- is defined as: “The application of a formal systematic
critical examination of the process and engineering intentions of the new facilities, to assess the hazard potential of
mal-operation or malfunction of individual items of equipment and the consequent effects on the facility as a whole”.

It is a rigorous examination to the process and engineering facets of a process facility, based on “guide-words” to
help provoke thoughts about the way deviations from the intended operating conditions can lead to hazardous
situations or operability problems.

Objectives of HAZOP

The objective of HAZOP is to assess the hazard potential of mal-operation or malfunction of equipment and the
consequent effects on the facility. It attempts to identify how a process may deviate from the design intent.

Typical documents needed for HAZOP Study

- Process Flow Diagram (PFS or PFD)
- Description of the process
- Piping and Instrumentation Diagram (P&ID)
- Process Calculations
- Process Datasheets
- Instrument Datasheets
- Interlock Schedules (Cause and Effect Chart)
- Layout Requirements
- Hazardous Area Classification
- Incident Records (for existing plant HAZOP)
- Modification Records (for existing plant HAZOP)
SIMOPS - Simultaneous operations, also known as SIMOPs,
refer to two or more work activities carried out within the same location at the same time. The term is used
within the process manufacturing industries

1. Proportional controllers.
2. Integral controllers.
3. Derivative controllers.

Proportional Controllers
All controllers have a specific use case to which they are best suited. We cannot just insert any
type of controller at any system and expect a good result – there are certain conditions that
must be fulfilled. For a proportional controller, there are two conditions and these are written
below:
1. The deviation should not be large; i.e. there should not be a large deviation between the
input and output.
2. The deviation should not be sudden.
Integral Controllers
As the name suggests in integral controllers the output (also called the actuating signal) is
directly proportional to the integral of the error signal. Now let us analyze integral controller
mathematically. As we know in an integral controller output is directly proportional to the
integration of the error signal, writing this mathematically we have,
Derivative Controllers
We never use derivative controllers alone. It should be used in combinations with other
modes of controllers because of its few disadvantages which are written below:
1. It never improves the steady-state error.
2. It produces saturation effects and also amplifies the noise signals produced in the
system.
Proportional and Integral Controller
As the name suggests it is a combination of proportional and an integral controller the output
(also called the actuating signal) is equal to the summation of proportional and integral of the
error signal. Now let us analyze proportional and integral controller mathematically. As we
know in a proportional and integral controller output is directly proportional to the
summation of proportional of error and integration of the error signal, writing this
mathematically we have,

Proportional and Derivative Controller

As the name suggests it is a combination of proportional and a derivative controller the output
(also called the actuating signal) is equals to the summation of proportional and derivative of
the error signal. Now let us analyze proportional and derivative controller mathematically. As
we know in a proportional and derivative controller output is directly proportional to the
summation of proportional of error and differentiation of the error signal, writing this
mathematically we have,

Proportional plus Integral plus Derivative Controller (PID Controller)

A PID controller is generally used in industrial control applications to regulate temperature,

flow, pressure, speed, and other process variables.

Feed-Forward Control

is an Advanced Strategy for Proactively Dealing with Upstream Disturbances. ... By initiating the response
in synch with the disturbance's arrival, then Feed-Forward effectively neutralizes the upset and avoids any
negative impact to control loop performance.

Feedback Control

loops take the system output into consideration, which enables the system to adjust its performance to meet a
desired output response. there are just two main types of feedback control namely: Negative Feedback and
Positive Feedback.

Ratio control

architecture is used to maintain the flow rate of one stream in a process at a defined or specified proportion relative
to that of another. A common application for ratio control is to combine or blend two feed streams to produce a
mixed flow with a desired composition or physical property.

Cascade Control

is to improve process performance by reducing – or even eliminating – the effects of a known disturbance
through control of an early warning variable.

Split-range control

is used when a single controller is employed to control two final-control elements (two valves for example). In
such a system, the controller struggle to keep one controlled variable at the set point using two manipulated
variables.

Override control

is used to regulate a process input to maintain one process output at target without violating a constraint on another
output. → Two controllers and a control selector (Low or High) are required for override control.

HART = Highway Addressable Remote Transducer-. is a communication protocol.

HART standard helps instruments to digitally communicate with one another over the same two
wires used to convey a 4-20 ma analog instrument signal.
SMART = Single Modular Auto-ranging Remote Transducer.
SMART instruments can be HART,FF or Profibus.

SMART transmitters compared to analog transmitters have microprocessor as their integral part ,
which helps for self diagnostic abilities , non-linear compensations , re-ranging without performing
calibrations ,and ability to communicate digitally over the network.

What is a 4 - 20mA current loop?

Electrical analog current signals are used to transmit measurement values in control logic, so that to avoid noise in transmission
line. Because analog current signals are not effected by noise.
4 - 20 mA is the common range of signals used in instrumentation.

The signal is the current in the loop. This kind of signal can be transmitted for long distances over wire without regard to voltage
drops in the wire. If we transmit the signals as voltage, the voltage drops caused by supply currents in the wires usually appear
as an error in the signal measurement.

A 4 mA represents the 0% working & 20mA means 100% working. For example 4mA for a valve means it is fully closed, and
20% means fully opened.

A current loop works under simple ohm’s law. V = I * R.

Bently Nevada 3500 Vibration Monitoring System

-Reduces non-critical vibration system diagnostic indications trips, noise-driven and transient vibration shutdowns/trips and
nuisance vibration alarms/trips during start-up period.
- Virtually every aspect of the BN3500’s operation is software configurable, resulting in the most flexible system.
- Easier spare parts management – a single module type can be configured for a variety of functions rather than just a single
function.
- Communication between the vibration system and the control system is Ethernet enabled.
- Reduces number of spare parts and support for units with the BN7200, a discontinued product.
- It can easily fit twice as many channels into the same rack space as previous monitoring systems, resulting in lower.

Anti Surge Controller- by (Compressor Controls Corporation) (CCC)

The anti-surge controller protects the compressor from surge by continuously calculating the distance between
the compressor's operating point and its surge limit line. ... Sometimes, derivative control is used to increase
the Surge Control Margin when the compressor is exposed to large surges.

American Petroleum Institute -598 (API)

ANSI/FCI 70-2 - Seat leakage test.

 Industrial Automation Communication Protocols

There are many types of buses and networks that might come across. Each one has its own applications,
advantages, and disadvantages.

The following are the different types of communication protocols, its uses and its makers in the
field of process automation:
CIP (Common Industrial Protocol)
Encompasses a comprehensive suite of messages and services for the collection of
manufacturing automation applications – control, safety, synchronization, motion, configuration
and information. Can be treated as application layer common to DeviceNet, CompoNet,
ControlNet and EtherNet/IP – ODVA, Inc.

Controller Area Network or CAN bus

a vehicle bus standard designed to allow microcontrollers and devices to communicate

with each other in applications without a host computer. Utilised in many network
implementations, including CANopen and DeviceNet – Bosch

EtherCAT
an Ethernet-based fieldbus system, invented by The protocol is standardized in IEC 61158
and is suitable for both hard and soft real-time requirements in automation technology. –
Beckhoff Automation

Ethernet Global Data (EGD)

a protocol that enables producer (server) to share a portion of its memory to all the consumers
(clients) at a scheduled periodic rate. – GE Fanuc PLCs

EtherNet/IP

IP stands for “Internet Protocol”. An implementation of CIP, originally. – Rockwell Automation

Ethernet Powerlink

a deterministic real-time protocol for standard Ethernet.- Ethernet POWERLINK

Standardization Group (EPSG).
FOUNDATION fieldbus

an all-digital, serial, two-way communications system that serves as the base-level network in
a plant or factory automation environment. It is an open architecture. – Fieldbus Foundation.

HART Protocol

(Highway Addressable Remote Transducer) – an early implementation of Fieldbus, a digital

industrial automation protocol. Its most notable advantage is that it can communicate over
legacy 4-20 mA analog instrumentation wiring, sharing the pair of wires used by the older
system. – Rosemount Inc

Honeywell SDS

Smart Distributed System, an open event-driven protocol used over Controller area
network based industrial networks. – Honeywell.

HostLink Protocol

A communication protocol for use with or between PLC’s made by Omron. It is an ASCII-based
protocol generally used for communication over RS232 or RS422. – Omron

Interbus

a serial bus system which transmits data between control systems (e.g., PCs, PLCs, VMEbus
computers, robot controllers etc.) and spatially distributed I/O modules that are connected to
sensors and actuators (e.g., temperature sensors, position switches). – Phoenix Contact

MelsecNet

It has two variantsMELSECNET/H and its predecessor MELSECNET/10 use high speed and
redundant functionality to give deterministic delivery of large data volumes. Both variants can
use eithercoaxial bus type or optical loop type for transmission. – Mitsubishi Electric

Modbus PEMEX

a serial communications protocol for use with its Modicons programmable logic controllers
(PLCs). Simple and robust, it has since become a de facto standard communication protocol,
and it is now a commonly available means of connecting industrial electronic devices – –
Modicon/Schneider Electric
Profibus

A standard for fieldbus communication in automation technology used by Siemens. –

PROFIBUS International.

PROFINET IO

The basic idea of CBA is that an entire automation system can be divided into autonomously
operating subsystems.
RAPIEnet

Real time Automation Protocols for Industrial Ethernet , An Ethernet-based industrial

networking protocol. – LSIS

SERCOS interface

a globally standardized open digital interface for the communication between industrial
controls, motion devices (drives) and input output devices (I/O). – Sercos International

DeviceNet

a network system used in the automation industry to interconnect control devices for data
exchange.- Allen-Bradley

DirectNet

used by DirectLOGIC PLCs and is used in APS vacuum controls since 1999. It is a
master/slave protocol making use of RS-232 or RS-422 physical layers with a baud rate from
300 to 38,400. It is designed to drive a maximum of 90 PLCs on a serial line. – Automation
Direct

AS-i

an industrial networking solution(physical layer, data access method and protocol) used in
PLC, DCS and PC-based automation systems. – AS-International.

BSAP – Bristol Standard Asynchronous Protocol

A master-slave protocol suited to both synchronous high speed local networks and
asynchronous low speed wide area networks – Bristol Babcock
CC-Link Industrial Networks

An open industrial network that enables devices from numerous manufacturers to

communicate. It is predominantly used in machine, cell or process control applications in
manufacturing and production industries, but can also be used in facilities management,
process control and building automation. – CLPA Europe

ControlNet

an open industrial network protocol for industrial automation applications, also known as a
fieldbus – Allen-Bradley

DF-1 protocol

an asynchronous byte-oriented protocol that is used to communicate with most Allen Bradley
RS232 interface modules. DF1 protocol consists of link layer and application layer formats. –
Allen Bradley

FINS

provides a consistent way for PLCs and computers on various networks to communicate.
Compatible network types include Ethernet, Host Link, Controller Link, SYSMAC LINK,
SYSMAC WAY, and Toolbus. – OMRON

MACRO Fieldbus

Motion and Control Ring Optical” , – Delta Tau Data Systems.

MECHATROLINK

an open protocol used for industrial automation, originally developed by Yaskawa and
presently maintained by Mechatrolink Members Association (MMA) – Yaskawa

OSGP

The Open Smart Grid Protocol, a widely use protocol for smart grid devices built on ISO/IEC
14908.1 – ETSI

Optomux

Serial (RS-422/485) network protocol. The protocol was openly documented and over time
used for industrial automation applications. – Opto 22
PieP

Process Image Exchange Protocol, a very simple Fieldbus protocol used for process
automation. It is an application layer protocol developed over TCP/IP

SERCOS III

Ethernet-based version of SERCOS real-time interface standard

SSCNET

Servo System Controller Network for control of motion and I/O – Mitsubishi Electric

GE SRTP

for transfer of data from PLCs. – GE Fanuc PLCs

Sinec H1

an Ethernet-based protocol that provides the transport layer function– Siemens

SynqNet

an industrial automation network l for meeting the performance and safety requirements of
machine control applications. – Danaher

TTEthernet

TTTech, Time-Triggered Ethernet or TTE, a computer network technology for safety-related

applications primarily in transportation industries and industrial automation – TTTech
Computertechnik AG

MPI

Multi Point Interface, used for connecting the stations programming (PC or personal
computer), operator consoles, and other devices in the SIMATIC family. This technology has
inspired the development of protocol Profibus. – Siemens.