DCS Seminar

بسم الله الرحمن University of Khartoumالرحيم

Dept. Electrical and Electronics Engineering5th Year

Seminar about: Distributed Control Systems (DCS)

Presented By:

Ahmed Hayder Mohamed ElZaki

054010

Ahmed Adel Mahjoub Farah 054011

Hassan Mohammed Hassan Hamza

054031

Seminar Contents

DCS Overview

HMI Concept

Procontrol P13

DCS Overview

Presented By:

Ahmed Adel Mahjoub Farah

• The concept of automatic control includes accomplishing two major operations:

Introduction

The calculation of control actions

The transmission of signals

• The evolution concerns the heart of any control system which is how information flow and decision making advanced.

Historical Review

Pneumatic Implementation

Electron analogue implementation:

Digital Implementation

• Information flow was accomplished by pneumatic transmission. • Computation was done by mechanical devices using bellows, spring etc.• There are two fundamental problems with pneumatic implementation.• The signals transmitted pneumatically (via air pressure) are slow.• Mechanical computation devices must be relatively simple and tend to wear out quickly.

Historical Review (Cont.)

Pneumatic Implementation

Historical Review (Cont.)

Electron Analog Implementation

• Electrons are used as the medium of transmission.• Electrical signals to pressure signals converter (E/P transducers) and vice verse (P/E transducers) are used.• The primary problems in this type are:• analog signals are susceptible to contamination from stray fields, and signal quality tends to degrade over long transmission line. • the type of computations possible with electronic analog devices is still limited.

• The transmission medium is still electron, but the signals are transmitted as binary numbers.

• The computational devices are digital computers.

Historical Review (Cont.)

Digital Implementation

• The DCS was introduced in 1975. Both Honeywell and Japanese electrical engineering firm Yokogawa introduced their own independently produced DCSs at roughly the same time, with the TDC 2000 and CENTUM systems, respectively.

Historical Review (Cont.)

• US-based Bristol also introduced their UCS 3000 universal controller.

• Bailey (now part of ABB) introduced the NETWORK 90 system

Historical Review (Cont.)

Control System Architecture

Local control

Centralized control

Control System ArchitectureCentralized control

• Distributed control system architecture offers the best features of both local control and centralized control.

• controllers are provided locally to systems or groups of equipment.

• networking is provided to one or more operator stations in a central location through a digital communication circuit.

Distributed control

• A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind of dynamic system

• in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers.

• The entire system of controllers are connected by a network for communication and monitoring.

Definition

• flexibility in system design.• ease of expansion.• reliability, and ease of maintenance.• complete loss of the data highway will not cause

complete loss of system capability.• Input and output wiring runs are short and less

vulnerable.• Each local controller can function on its own upon

loss of communication with the central controller.

The advantages of DCS systems

• Networks used for communication may become electronically compromised from outside the facility.

• Interconnection of controllers in different locations can produce ground loop and surge voltage problems.

The Disadvantages of DCS systems

Types of distributed control systems

Programmable logic controller (PLC) based systems

Remote terminal unit (RTU) based SCADA

Direct digital control (DDC)

Plant distributed control system (P-DCS)

• Local Control Unit(LCU).• Data Acquisition Unit. • Batch Sequencing Unit.• Local Display. • Bulk Memory Unit.• General Purpose Computer. • Central Operator Display. • Data Highway. • Local area Network (LAN).

DCS elements

• DCS is a very broad term used in a variety of industries, to monitor and control distributed equipment.

• Electrical power grids and electrical generation plants

• Traffic signals • Oil Refining plants • Pharmaceutical manufacturing

Uses and Applications

DCS in Electrical Power Grids

• Substations are considered to be the nodes in the electrical network.

• controlling and routeing of the power flow.

DCS in Electrical Power Grids (Cont.)

DCS in Electrical Power Grids (Cont.)

RTUs (remote terminal

units)

IEDs(intelligent electronic devices)

CTs and VTs….etc

DCS in Electrical Power Grids (Cont.)

Common used Controllers and terminals

HMI Concept

Presented By:

Hassan Mohammed Hassan Hamza

HMI overview

• For applications where operators interact with machines, there is a natural need for a mechanism through which the operator can configure and monitor the machine. A Human Machine Interface (HMI) typically fulfills this need.

• The devices and instruments operators use to control process equipment have changed dramatically since the beginning of the digital control system age.

• Digital Displays have replaced Bench Board Controls.

• Digital Displays installed in a control room in a way that lacks detailed planning to support the operator’s entire job.

• Images of control stations • Push buttons.• Chart recorders.• Controller faceplate.....

HMI overview (Cont.)

• The digital display human–machine interface (HMI) has allowed a single operator to monitor and control thousands of process control loops from a single station.

• The advances in HMI technology using inexpensive hardware, thin-clients, handheld computers, and cell phone technology have freed the operator from confinement to a particular location for control and information systems.

HMI overview (Cont.)

• There is a distinct difference between User Interface versus Operator Interface or Human Machine Interface (HMI).

• The term user interface is often used in the context of (personal) computer systems and electronic devices.

• HMI is typically local to one machine or piece of equipment, and is the interface method between the human and the equipment/machine.

HMI Terminology

• Operator interface is the interface method by which multiple equipment that are linked by a host control system is accessed or controlled.

• The user interface of a mechanical system, a vehicle or an industrial installation is sometimes referred to as the human-machine interface (HMI).

• HMI is a modification of the original term MMI (man-machine interface).

HMI Terminology (Cont.)

Term DefinitionHMI Human–Machine Interface: Computer hardware and

software that allows operators to interface with the control system

CRT HMI Cathode Ray Tube HMI: The term is specifically used where there is a transition from hand stations to the HMI

DCS HMI Proprietary HMI from DCS vendors that is optimized for process control

GUI Graphical User Interface: General computer term for software that allows graphical interaction with the computer

Open HMI HMI built on PC hardware and Windows operating system for general use; not specific to any hardware or industry

Open HMI Open HMI that incorporates information systems and controls

PLC HMI Proprietary HMI from PLC vendors that is optimized for discrete control; often connected as a remote PLC rack

HMI Terminology (Cont.)

- Hardware and software were inseparable.

- Control keyboards.

- DCS vendors have different ideas and standards for their individual HMIs.

1975-1985

Proprietary HMI background

- Increased integration with other components in the system.

- The difficulties in communication between different HMI generations.

- Redundancy .

1986-1995

Proprietary HMI background

- latest generation of HMI from most DCS vendors is based on Microsoft windows.

- Use as much standard hardware are possible to reduce costs.

- Organization of information and standards .

1996-2001

Proprietary HMI background

• Many people were very worried about operating potentially dangerous processes through a computer when the DCS first arrived on the scene.

• DCS vendors worked hard on the technical issues of redundancy and on selling the concept of the HMI to industries that liked the hand stations.

Redundancy

Redundancy (Cont.)

• WinCC (Windows Control Center) is a PC-based process visualization system of the company Siemens.

• The software was marketed broadly for the first time 1996 in the version 1.1 in the German-speaking countries.

Examples of HMI ProgramsWinCC

• InduSoft Web Studio™ is a powerful collection of automation tools that provide all the automation building blocks to develop HMIs, SCADA systems and embedded instrumentation solutions.

Examples of HMI ProgramsInduSoft Web Studio™

Examples of HMI ProgramsInTouch®

• A program produced by Wonderware company.

• Open and scalable software architecture that enables user to connect to virtually any automation system, remote terminal unit (RTU), intelligent electronic device (IED), programmable logic controller (PLC)…

Procontrol P13

Presented By:

Ahmed Hayder Mohamed ElZaki

• Procontrol P13 is a complete DCS software and hardware collection

• Produced by ABB• Can be installed in fossil power plants, gas

turbine and combined cycle power plants, hydro power plants, nuclear power plants, waste to energy plants, industrial plants and AC & DC high voltage distribution.

Procontrol P13

Procontrol P13 System Architecture

Procontrol key functions

Plant Management

Operations

Control and I/O

Engineering

• The power generation business must be able to adapt quickly to change.

• Reduced time to decision and action is critical for improving availability and productivity.

Procontrol key functions (Cont.)

Plant Management

Information Management

Plant Performance

Procontrol key functions (Cont.)

Plant Management

• Information management functions are inherent to the system 800xA.

• Historical process and business data is collected from disparate sources and stored securely.

Information Management

Plant Management

• Intuitive Presentation

• Flexible report generation and distribution

• Secure historical data storage and access

Information Management

Plant Management (Cont.)

Information Management

Plant Performance

Plant Management (Cont.)

• ABB’s OPTIMAX range of products provides solutions covering:

Plant Performance

• Plant level optimization• Reporting • Analysis tools• Enterprise level optimization

Plant Management (Cont.)

• OPTIMAX is integrated with the PROCONTROL P13 system.

• This permits fast and simple extension of the proven PROCONTROL P13 functionality

Plant PerformanceOPTIMAX

Plant Management (Cont.)

• Calculate performance data online and alert the user when deviations between the actual and expected performance values arise.

• Simulate “what-if” scenarios.• Predict plant performance.

Plant PerformanceOPTIMAX Products

OPTIMAX performanceOPTIMAX Data Validation

•Early detection of calibration problems.•Avoid unnecessary trips and improve their predictive maintenance.

OPTIMAX ProductsPlant Performance

Plant Management (Cont.)

• Calculates the amount of emissions that will be generated.

• Informs the operator about emission violations ahead of time

Plant PerformanceOPTIMAX Products

OPTIMAX GT Emission PredictorOPTIMAX GT Gas Path Diagnosis

•Quantitatively analyzing the fouling and erosion effects in a gas turbine.

•Differentiates between compressor fouling and turbine degradation

• It serves as decision-support tool for diagnosis and predictive maintenance.

Plant Management (Cont.)

• calculates the optimal washing schedule.• estimation of compressor degradation and

recovery after a compressor online wash.• used by operators and maintenance

managers to reduce costs.

Plant PerformanceOPTIMAX Products

OPTIMAX GT Compressor Wash OptimizerRemote Diagnosis (Real-Time DB)

• continuously assess the plant condition.

• Quickly detects degradation or faults and identify corresponding corrective actions

• Stores the raw data and transfers these data via Internet, in a compressed encrypted format to a remote server.

Plant Management (Cont.)

• Used by traders and plant managers to determine the optimal load distribution of their generating units (Unit Commitment).

• addresses the influence of operating modes on the full cost of running a power plant.

• optimize the profits achieved by selling energy, fuel or emission credits (CO2, NOx) and manage the lifecycle of plant assets.

Plant PerformanceOPTIMAX Products

OPTIMAX Lifecycle Optimizer

Plant Management (Cont.)

Procontrol key functions

Plant Management

Operations

Control and I/O

Engineering

800xA Process Portal system interface extends beyond the realm of process control to provide rapid and consistent access to field devices, asset optimization tools, information management systems, safety systems, and applications.

Operations

Industrial IT 800xA Process Portal System Interface

• Process Portal provides accurate and timely information that is critical for making the right decisions.

• Presenting relevant information• Well Understood and Versatile Interaction• Quick Response to Plant Conditions• Access to Distributed Information• Addressing Mainstream Operator Needs

Operations (cont.)

Procontrol key functions

Plant Management

Operations

Control and I/O

Engineering

• The Procontrol P13 Control and I/O Devices have been designed for maximal robustness allowing very high plant operation availability and quality of the control tasks.

• Scalable system.• Multiprocessor control modules.• All modules are equipped with self-

supervision features for health diagnostic.

Control and I/O

Power Supply Modules

Input Modules

Local Bus Modules

Intra-Plant Modules

Test & Simulation Modules

Processing Modules

Output Modules

Control and I/O(cont.)

• All Procontrol P13 devices are supplied with 24 VDC.

• The Voltage tolerance is 19.5…30 VDC, allowing simple battery power supply.

• Additional voltage levels required by the devices like stabilized supply etc. are directly generated on the devices themselves, based on the 24 VDC device supply.

Control and I/O(cont.)

Power Supply

Procontrol key functions

Plant Management

Operations

Control and I/O

Engineering

• Procontrol P13 Engineering tools are engineering, documentation and service systems for the Procontrol P13 power plant control system.

• the engineering tools have access to all the modules of the inner control system throughout the plant.

Engineering

• Data entry for the input and maintenance of measurement and drive data.

• Generating and editing function charts for I&C functions.

• Allocation of hardware (assignment of functions) and downloading of programs.

• Debugging of function programs.• Printing of function charts as necessary.

Engineering (Cont.)

Engineering-tools main tasks

Procontrol main features

Data Transfer

Procontrol main features

Process Operator Station (POS)

OMSOperations and Monitoring Services

RCRRecording & Calculating & Reporting

Services

XTCData Transfer

Procontrol main features

Engineering, Documentation and Service (EDS)

Procontrol main features

Control Diagnostic System (CDS)

Procontrol Software Architecture

Procontrol Remote Access