PAGE-1

HISTORY OF THE CONTROL SYSTEM

About 60 years ago instrumentation was mostly mechanical, integral transmitters and controllers were mounted directly on the process line and sensed the process variable directly with no amplification. The operator made rounds in the plant, reading instruments, adjusting set points and logging readings. Clearly, increased process complexity and greater demand on plant efficiency and safety required a more centralized mode of operation. As a result pneumatic amplification and transmission line techniques were developed, allowing the control location of controllers, indicators and recorders in a control room. Advances were made in packaging, permitting greater instruments densities on the panel boards. Further miniaturization was made possible with the advent of the transistorized electronics in 1950s. Electronic computer were introduced in the 1950s, and were first applied to process control in the 1960s. Due to high cost of digital computers, it was necessary to put many of the plants control loop on the computer to justify its initial cost. All process signal were multiplexed, digitized and stored in memory. PID control function were performed by the computers using series approximation technique. The advent of the microprocessor in the early 1970s, did much to alleviate the remaining problems with computer control. Its most immediate impact was a dramatic reduction in the cost of computer power. Not only did microprocessor make large computer systems more economical, they also made it possible to use many small computers to control the process. By ruggedizing the hardware and utilizing digital transmission techniques, it is now possible to locate the controller in the process area. A data highway is then routed through the plant to link the microprocessor based controller together and provide communications with the control room. To provide the operator interface, a process computer or stand-alone CRT console is connected to the data highway. By using this Distributed Approach a process control, reliability has been increased, hardware and installation cost reduced and performance improved to the point where computer control is very competitive with analog instrumentation. This type of distributed approach control system is also mentioned as DCS ( distributed control system ).

PAGE-2

THE CONTROL SYSTEM

The control system is that means by which any quantity or process variable of interest in a machine, mechanism, process plants, or other equipment is maintained or altered in accordance with desired manner. But before going to study about the any type of control system, it is most important to measure and transmit that process variable up to the control unit to which we want to control. There are several types of process variables in any process plant, which are requi ed to control r at their optimum required value to get the performance or task more efficiently. The most general types of process variables in any process plant are listed bellow. 1. 2. 3. 4. 5. 6. 7. 8. 9. Pressure Flow Level Temperature Speed of turbine, generator or motors ( RPM ) Frequency Analytical process variable like Conductivity and pH. Vibrations in rotary machines Flame intensity

All these process variables are measured by means of transducers and transmitted to the control room ( control unit ) in the form of electrical signal ( normally in the form of mA, mV, voltage, frequency, pulse etc. ) are known as input signal of the controller. REQUIREMENT OF CONTROLLER: Generally a controller is required to process the error signal such that overall system satisfies certain criteria specification. Some of these criteria are given below. 1. Reduction in effect of disturbance signal. 2. Reduction in steady state error ( permanent off set ). 3. To improve the transient and frequency response of the system ( process ). 4. Sensitivity to the parameter changes within the system. There are mainly two types control system. 1. Open loop control system 2. Close loop control system 1 . OPEN LOOP CONTROL SYSTEM: This type of control system does not have any type of feed back system from the output of the system as shown in PLANT OR following INPUT CONTROLLER OUTPUT PROCESS figure. This FIGURE: OPEN LOOP CONTROL SYSTEM system does not have automatically correction capability for variation in output is called open loop control system. In this system the output remain constant for a constant input signal provided the external condition remain

PAGE-3 unaltered. The output may be changed due to change in internal parameter of the system. The open loop control system is, therefore satisfactory only if such fluctuation can be tolerated or system components are designed and constructed so as to limit parameter variations and environment condiions are well controlled. t The gain of the forward path in open loop control system is unity. 2. CLOSE LOOP CONTROL SYSTEM: In the close loop control system the information about the instantaneous state of the output is feed back to the input and is used to modify it in such a manner as to achieve the desired output. The block diagram of a general close loop control system is given below.

FORWARD PATH ELEMENT CONTROLLER ERROR OR ACTUATING SIGNAL CONTROLLED OUTPUT

REFERENCE INPUT

CONTROL ELEMENT

PLANT OR PROCESS

FEED BACK PATH FEED BACK ELEMENT FIGURE: CLOSE LOOP CONTROL SYSTEM

In above figure an error detector compares a signal operated trough feed back elements, which is function of output response, with the reference input. Any difference between these two signals constitutes an error or actuating signal, which actuates the control element. The control elements in turn alter the conditions in the plant or process ( controlled member ) in such a manner as to reduce the original error. SIGNIFICANCE OF CLOSE LOOP CONTROL SYSTEM: 1. The controlled variable accurately follows the desired value. The close loop control system has automatic control capability. 2. Effect on the controlled variable of external isturbances other than these associated with feed back sensor are greatly reduced. 3. Feed back in control system greatly improve the speed of its response (improve sensitivity of the system) . 4. Effect of variation in controller and process parameters on system performance is reduced. 5. Only disadvantage of the close loop control system is, its over all gain reduced (less than unity )

PAGE-4 DIGITAL CONTROL SYSTEM: Before the digital control system came into practice, in the controlled system used so far, the signal at every point in the system is a continuous function of the time (analog signal). In particular the controller elements are such that the controller produces continuous time control signals from continuous time input signal. Such controller is referred to as an analog controller. As the complexity of the control system increases, several demands of flexibility and adaptability and even demands to account for economic control function complexity. the use of a digital computer as a compensator ( controller )device has grown during 1970s as the price and reliability of digital computer have improve dramatically. A simple digital control loop system is shown in figure.

Powerful but expensive computers, called micro computers, which uses 16 bit word or 32 bit word, have become readily available. These computer can be equipped with sufficiently large memory to handle a large amount of data in a complex control process. The speed of these computer is also increasing and already system with a speed as high as 300 MHz. As shown in above figure an analog to digital converter is needed at the computer input. The A/D converter converts the error or actuating signal into a digital signal and then expressed in numerical

FORWARD PATH ELEMENT CONTROLLER DIGITAL A/D REFERENCE INPUT ERROR SIGNAL CONTROL ELEMENT D/A PLANT OR PROCESS CONTROLLED OUTPUT

FEED BACK PATH FEED BACK ELEMENT FIGURE: DIGITAL CLOSE LOOP CONTROL SYSTEM

code such as binary code. Numerically coded output data of digital computer decoded into continuous time signal by digital to analog converter. This time signal then controls the plant or process. SAMPLI NG TECHNIQUE I N DIGI TAL CONTROL SYSTEM: Sampled data technique is most appropriate for control system requiring long distance data transmission. Pulse amplitude modulated (PAM) data is easily transmitted by means of a carrier over a transmission channel and the data reconstructed at the receiving end. It is well known that may be transmitted with a little loss of accuracy. Using sampled data technique, more than one channel of information may be sequentially sampled, transmitted and processed through a single processing system or unit. By using the sampling technique a general purpose computer lends it self to time shared use for other control function, in the plant or process. The block diagram of a sample data control system is shown below.

PAGE-5

The sampler and analog and analog to digital converter is needed at the computer input. The sampler converts the continuous time error signal into sequence of pulses. The over all system is hybrid in which the signals in a sampled form in the digital controller and in the continuous form in the rest of the system. A system of this kind is referred to as a sampled data control system. The circumstances that lends to use of sampled data control system are summarized below. 1. For using digital computer ( or microprocessor ) as part of the control system. 2. For time sharing of control components. 3. When ever a transmission channels forms part of the control loop. 4. When ever the output of a control component is essentially in discrete form.

FORWARD PATH ELEMENT CONTROLLER DIGITAL

s+
REFERENCE INPUT ERROR SIGNAL A/D

CONTROL ELEMENT

CONTROLLED OUTPUT PLANT OR D/A +HOLD CKT PROCESS

FEED BACK PATH FEED BACK ELEMENT FIGURE: SAMPLED DIGITAL CLOSE LOOP CONTROL SYSTEM

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PAGE-7

PAGE-8 SINGLE LOOP DIGITAL CONTROLLER: The single loop, single input digital controller having mainly three elements, which are given below. 1. Input-output unit 2. Controller or controlling processor 3. Display & operator interface unit In this type of controller all three parts of controller are kept in single box. The block diagram of such type of digital controller is shown below. Input & output units are used to condition the input signal from the field & output signal to the field. The display unit is used to show (display) all the measured variable and output of the controller. By the means of key pad an operator can change the set value set value (required value) or output to the final control element in the process.

CONNECTION TERMINALS BACK OF CONTROLLER POWER SUPPLY TERMINAL FIELD CONTROLLER DIGITAL CONTROLLER CONTROL UNIT MAIN PROCESSOR IO UNIT INPUT CARD OUTPUT TERMINAL INPUT TERMINAL

OUTPUT CARD

DISPLAY AND OPERATOR INTERFACE UNIT

160

TIC GC DE

ALARM TERM.

FUNCTIONAL BOLCK DIAGRAM

DIGITAL CONTROLLER

% 74

FIGURE: SINGLE LOOP SINGLE INPUT CONTROLLER

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PAGE-10

PAGE-11

PAGE-12

DISTRIBUTED CONTROL SYSTEM ( DCS )

Now, I think you have enough idea about requirements of the control system, type of control system, requirement of the controllers, sampling technique in digital control system & working of digital controller. As shown in block diagram of digital controller, all three main units ( input-output unit, control unit and display operator interface unit) are kept in a single box & all the functions are controlled by a single processor. In this type of controller or control system, any fault in any unit causes failure of whole unit (controller) & we have to replace the whole controller. To overcome this problem and other advantages, Distributed Control System is employed. The Distributed Control System (DCS) is a control system in which all the control unit (input-output, control unit and operator interface) are physically, geographically, functionally & area wise distributed (all units are located at different places), for the operation / monitoring / controlling the process parameter of the plant. The basic architecture of DCS is shown bellow.

OPERATOR INTERFACE

ENGINEERING STATION

GATEWAY UNIT
C C

ETHERNET

V-NET

P S

O O M M M M

C P U 1

C CC P U 2
OO MM MM

P S

V-NET CONTROL UNIT

RIO BUS RIO BUS

P S
I/O PROCESSOR ANALOG I/O UNIT

P S
I/O PROCESSOR

DIGITAL I/O UNIT INPUT-OUTPUT UNIT

PAGE-13

PAGE-14

PAGE-15

PAGE-16 DCS is computerized control system consolidating many function of the controllers, indicators & recorders for a centralized control for improved reliability. As shown in above figure, all units of the control system function independently and have its own processor. They are connected with communication bus like V-NET, RIO bus and ETHERNET to transfer the data from one unit to the other as per requirement. The main parts of the DCS are Operator Interface Station Control Unit Station Engineering Work Station Communication Network IO Unit (Input / Output Cards) Communication Gateway Unit

OPERATOR INTERFACE UNIT: Operator Interface Unit works as a computer interface between human (operator) and machine (control unit). It has visual display unit or CRT to display the data of the process or plant to the operator and issue a control data to the control unit as per requirement of the process or control action taken by the operator. CONTROL UNIT STATION: The Control Unit Station has the microprocessor based controllers. It is the unit where all the control calculation are done and responsible to control the process or plant. ENGINEERING WORK STATION: Engineering Work Station is a auxiliary unit which is used to modify or generate a new control loop, modifying range and other engineering work in Control Unit or Opera Interface unit. tor COMMUNICATION NETWORK: Communication network uses different types of communication network buses connected among the different parts of the system (like V -net, RIO bus and ETHERNET). INPUT-OUTPUT UNIT: IO unit have the input and output card. It has its own processor to communicate the data to or from Control Unit. There are different types of input card, like mA input, mV input, frequency input, resistance input and others. Output card is used to provide the output signal to final control element in the field. COMMUNICATION GATEWAY UNIT: Communication Gateway Unit is used to transfer the data from one type of bus to any other type of bus ( here its transfer the data from ETHERNET to V-NET and vice versa. The detailed theory of the all above things will be discussed later.

PAGE-17

PAGE-18

PAGE-19 IFFCO PHULPUR UNIT having the following DCS. Make : M/s Yokogawa Model : Centum- CS The CS in the Centum-CS stands for Concentral Solution & also Customer Satisfaction. The system concepts are, * Monitoring * Operation * Control * Engineering * Maintenance The major system components are 1. 2. 3. 4. 5. 6. Information & Command Station (ICS) Field Control Station ( FCS ) Engineering Work Station ( EWS ) Auxiliary Communication Gateway Unit ( ACG ) Nodes with Input /Output Cards Communication Network

Following are the main significance of the distributed control system. Functional Integration: Real time production management system fully integrating the powerful DCS functions with information systems. Advance Control: Provide power tools for complex applications. Efficient Engineering: Minimize cost of engineering by increasing effectiveness & reducing time. Easy expansion & scaling. High Reliability: Redundant cards & communication bus. User friendly Human Machine Interface ( HMI )- allows process engineers to concentrate on the process by minimizing effort required to set up control and operations. ARCHITECTURE OF DCS (YOKOGAWA): The following figure shows the architecture or configuration of the YOKOGAWA DCS.

PAGE-20

PAGE-21

PAGE-22

EVENT PRINTER E-NET

HARD COPY

PC ICS's

ETHERNET
.... .... .... ........

ACG

EWS

V-NET

ABC FCS
p s c p u p s c p u p s

FCS
c p u p s c p u p s c p u

CONTROL UNIT
p s c p u

RIO BUS

P S
I/O PROCESSOR

P S
I/O PROCESSOR

OTHER CONTROL SYSTEM OR PLC

ANALOG I/O UNIT

DIGITAL I/O UNIT INPUT-OUTPUT UNIT

ANALOG I/O DIGITAL I/O UNIT UNIT

PAGE-23

PAGE-24 FIGURE: DCS (YOKOGAWA) CONFIGURATION

PAGE-25

PAGE-26 The following are the components are used in above CENTUM cs configuration. Equipment list: EWS: Engineering Work Station ICS : Information and Command Station FCS : Field Control Station ACG: Auxiliary Communication Gateway unit ABC: Auxiliary Bus Converter RIO BUS: Remote Input-Output Bus V-NET : Communication Bus ETHER NET: Communication Bus E NET: Communic ation Bus IO UNIT: Input- Output Unit (Nest Unit) FDDI : Fiber Distributed Data Interface CENTUM CS SYSTEM SPECIFICATIONS: A CENTUM CS can be configured flexibly for applications ranging from small scale unit operation to full scale plant operations. Following lists shows the CENTUM CS specifications. ITEM Max. Number of Monitoring Tags Network SPECIFICATIONS 100,000 TAGS V net ETHER Net FDDI 64 stations maximum, combined number of ICSs, FCSs abd ABCs, there can be no more than 16 ICSs.

Maximum Number of Station

SYSTEM NETWORKS: As shown in above figure YOKOGAWA DCS uses following network buses. 1. 2. 3. 4. V-NET ETHERNET E-NET RIO BUS

V-NET AND ITS COMMUNICATION TECHNIQUE: V-NET is a real time control network for connecting a FCS to other station such as an ICS, ABC and ACG . V-NET is capable of performing dual redundant communication at speed as fast as 10Mbps ( 10 Mega Bit Per Second ). This network employ a link transmission system as well as much appreciated read/write communication system and message communication system.

PAGE-27

PAGE-28

PAGE-29

LOGICAL RING

DIRECTION OF ROTATION

0 2 4 6

STN 5
0 2 4 6

N ST

ST 4 N6

V-NET
ST N
4 2

3
0

N ST

1
2

STN 2
6 4 2 0

FIGURE: DATA COMMUNICATION SYSTEM IN V-NET

The V-net is also called a token bus. Physically, the token bus is a linear or tree shaped cable on to which various station are connected. Logically, the station are organized into a ring with each station knowing the address of the other station. When ring is initialized, stations are inserted into it i order of station address from highest to n lowest and highest numbered station may sent the first data frame. After it is done it passes the permission to its next lower numbered address station by sending the special control frame called token. The token passing is done from high to low addresses. Each time a station acquires the token, it can transmit frame for a certain amount of time; then it just pass the token on. If frame is short enough, several consecutive frames may be sent. If the station has no data, it passes the token immediately upon receiving it. The token bus define four priority classes; 0,2,4 and 6 for traffic, with 0 the lowest and 6 the highest. It is easiest to think of each station internally being divi ed into four sub station, one at each priority d label. When the token comes into the station over the cable, it is passed internally to the priority 6 substation, which may begin transmitting the data frame, if it has any. When it is done (or when its timer expires) the token is passed internally to the priority 4 substation, which may then transmit frames until its timer expires, and token passed to priority 2 substation and this process is carry on until either the priority 0 substation has sent all its frame or timer has expired and then the token is sent to the next station in the ring. V-NET SPECIFICATIONS: ITEM Transmission route Type Transmission Distance Communication Rate Redundancy

SPECIFICATION coaxial or fiber optic cable bus type or multi drop type 20 km max. 10Mbps dual-redundant

ETHER NET AND ITS COMMUNICATION TECHNIQUE:

PAGE-30

PAGE-31

PAGE-32 The CENTUM CS has adopted ETHER NET as a LAN for information communication between ICS and a Work Station or between ICS and supervisory computer. Ether net is a local area networks, generally called LANs. they are widely used to connect personal computers and work station in company offices and factories to share resources and exchange informations. LANs are distinguished from other kinds of networks by three characteristics. 1. Their size 2. Their transmission technology 3. Their topology LANs often use a transmission technology consisting of a single cable to which all the machine are attached. traditional LANs run at speed of 10 to 100 Mbps, have low delay ( tens of micro seconds), and make very few error.. Newer LANs may be operate at higher speed. The IEEE802.3 standard is for a 1 -persistent CSMA/ CD (carrier sensed multiple access/ collision detection). In this protocol station listen for a carrier (i.e. is a transmission) and act accordingly. When station wants to transmit, it listen to the cable. If the cable is busy , the station waits until it goes idle; otherwise it transmit immediately. If two or more station simultaneously begin transmission on an idle cable, they will collide. All colliding station then terminate their transmission, wait a random time , and repeat the whole process all over again. In this way its avoid the any type of wrong data transfer due to collision of data frame. Mostly four types of cable are generally used which are given in following table. The notation 10Base5 means that it operates 10 Mbps, uses base band signaling, and can support segments of up to 500 meters.

NAME 10 Base5 10 Base2 10 Base-T 10 Base-F

CABLE thick coax thin coax twisted pair fiber optical

MAX. SEGMENT 500m 200m 100m 2000m

NODE/ SEGMENT 100 30 1,024 1,024

ADV. good for backbone cheapest easy maintenance best in buildings.

YOKOGAWA uses TCP/IP protocol. ( transmission control protocol/ Internet protocol) FTP (file transfer protocol) ETHER-NET SPECIFICATIONS: ITEMS Physical layer Communication rate Transmission route Media access control protocol SPECIFICATIONS IEEE 802.3 10 Mbps AUI, 16 pin connector CSMA-CD method, TCP/IP FTP

PAGE-33

PAGE-34

PAGE-35 E NET: E net is an important LAN which connects an ICS to other ICSs as shown in figure. An ICS uses E net to perform the following function. Display trend record data owned by other ICSs. Use the printer or other hard copy unit connected to the other ICSs. Pass engineering data created at the local ICS to an other ICS, and Equalize the database with other ICSs.

E NET SPECIFICATION: ITEM Transmission route Type Transmission distance Communication rate SPECIFICATION coaxial cable Bus type 185 m 10 Mbps

RIO BUS: A remote input-output bus is communication bus which links the FCU (Field Control Unit) with the NODE (IO Unit) interface unit. Twisted pair cables are used for short distance transmission. Repeaters or optical repeaters are used for long distance transmission. The maximum transmission distance varies depending upon the specification of the repeater. The RIO bus can be dual redundant. ITEM Transmission Route Type Redundancy Transmission distance Number of connection nodes Communication rate SPECIFICATION Twisted pair cable or optical fiber Bus type, Multi-drop connection Single or dual redundant 20 km maximum 8 node per standard or expanded FCS 2 Mbps

AUXILIARY COMMUNICATION GATEWAY UNIT (ACG): Many networks exist in the world, often with different hardware and software. The computer connected to one network often want to communicate with computer attached to a different network. This desire requires connecting together different, and frequently incompatible networks some times by using a machine is called GATEWAY to make the connection and provide the necessary translation, both in terms of hardware and software. Here in DCS an ACG connected between EATHER NET and V net, enables communication between an existing computer system and V net network. The gateway is used by the computer to acquire and send data to the FCS.

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PAGE-37

PAGE-38

AUXILIARY BUS CONVERTER (ABC): An ABC connects a CENTUM CS to other CENTUM CS system, or to existing CENTUM-XL system, or any other system.

PAGE-39

PAGE-40

PAGE-41

FIELD CONTROL STATION (FCS): HARDWARE SPECIFICATIONS AND MODEL CODE OF FCS: PROCESSOR: R 3000 (25M Hz) + R 3010 ( MOTOROLA 32 Bit)

MAIN MEMORY SIZE: Standard Type: 8 M Bytes (AFE20S, AFE 20D) Enhance Type: 16 M Bytes (AFH20S, AFH20D) MEMORY PROTECTION TIME OF POWER FAILURE (BATTERY): Backup Time: 72 hours max. Recharging Time: 48 hours or longer COMMUNICATION INTERFACE: V-net Interface: RIO Bus Interface: Duplex or Single Duplex or Single

FCU STATUS CONTACT OUTPUT: Contact open or close upon fault in the cpu; Three Terminals (NO,NC and C) POWER SUPPLY: Voltage: 100 to 120 VAC Frequency: 50 or 60 Hz + 3Hz POWER CONSUMPTION (INCLUDING NODE): 300 VA to 450 VA GROUNDING: JIS Class 3 dedicated grounding (100 ohm or lower) INSULATION RESISTANCE: 20 M ohm or higher / 500 Vdc WITHSTAND VOLTAGE: 1500 Vac / 1 minute.

PAGE-42

PAGE-43

PAGE-44

PW 301

R B 3 0 1 1

C P 3 1 3 D

C P 3 1 3 D

R B 3 0 1 2 PW 301

AIP 502

AIP 502

AIP 512

AIP 512 FAN FAN

HKU

FIGURE: FCS HARDWARE CONFIGURATION

FCS HARDWARE CONFIGURATION:

CP 313D : PROCESSOR CARD RB 301 : RIO BUS INTERFACE CARD PW 301 : POWER SUPPLY UNIT AIP 502 : V-NET COUPLER UNIT AIP 512 : RIO BUS COUPLER UNIT HKU : INTERNAL INTERFACE UNIT

PAGE-45 CARD CONFIGURATION IN FCS:

PAGE-46

PAGE-47

NODE INTERFACE UNIT:

V-NET1 V-NET2 AIP 502 AIP 502

CP 313 (L)

PW 301 BAT

PW 301 BAT

CP 313 (R) EN-1 EN-2

RB 301

RB 301

AIP 512

AIP 512 RIO BUS1 RIO BUS2

FIGURE: CARD CONFIGURATION IN FCS

PAGE-48

PAGE-49 All NIU is the section of the FCS which communicate with the FCU via RIO bus. The unit consisting of a communication card & power supply card. Five different type of input can be connected to NIU.

IO MODULE

C C O O M M M M

P S

P S

I/O MODULE: This unit module converts process analog input signal into digital input so that FCS can process them. The output module coverts the FCS digital data into analog and contact signal and then generates output data.
FIGURE: NODE INTERFACE UNIT

TYPE OF SIGNAL Analog I/O

Pulse input Multiplexer / I/O

Digital input / output Communication Module

MODULE Current and voltage, 4 to 20 mA, 0 -10V Small electric power (mV, T/C, RTD, Potentiometer I/P Output 0-10 V, 4-20 mA. Pulse input 0- 10 KHz pulse signal Voltage input, mV input, T/C, RTD multiplexer Current output Multiplexer Contact output (30Vdc, 100 mA) RS 232 RS 422 RS 485

DUAL REDUNDANCY AND HIGH-RELIABILITY OF THE FCS PROCESSOR: The following figure shows the redundant configuration of the FCS, where the V -net communication couplers and internal bus can be made dual redundant. The CENTUM-CS system realizes the dual redundancy of the FCU processor card by adopting a "pair and spare" system, dual collation system, which never been introduce in any DCS in the world. As described below, this offer solutions to the several problems which conventional dual redundant system could not solve. * If a transient computation error owing to electric noise or at the initial stage of a failure, the collator (comparator) detected the error by collating the calculation result of both CPUs, where upon the processor card is switched to the standby processor card. * The standby processor card also constantly performs control computations, synchronized with the control * The standby processor card also constantly performs control computations, synchronized with the control side processor card, allowing a bumpless transfer of the data in control side processor card to the standby card.

PAGE-50

V-NET

PROCESSOR L V-NET I/F MAIN MEMORY V-NET I/F

PROCESSOR R

CPU1

CPU1

CPU2

CPU2

RIO BUS CARD

RIO BUS CARD

FIGURE: SHOWIING PROCESSOR REDUNDANCY CONFIGURATION

The processor card are provided on left and right sides; one serves as the control side processor and other as the standby processor card. The following how the processor card detect and correct a computation error, transferring its rights of control. (1) A processor card has two CPUs each of which programs the same control computations. The collator collates the result computed by each CPU during every computation p eriod. When both CPUs result are consistent, the control computation are assumed to be correct and the data are sent to the main storage unit or bus interface card. The main storage unit with the error correcting code (ECC) correct transient bitreverse error to prevent serious error in the memory.

POWER SUPPLY

POWER SUPPLY

RIO BUS

MAIN MEMORY

COLLATOR

COLLATOR

PAGE-51

PAGE-52

PAGE-53 (2) If the computed result in the CPUs are not consistent, the control computation are assumed to be wrong and the rights of control is transferred to the standby processor card. (3) Since it performs synchronously the same control computations as the control side processor card, the standby processor immediately sends the control computation data to the bus interface upon receiving the right of control. (4) The processor card which has detected computation error perform the self diagnosis. If no abnormality is found after the diagnosis, the computation error is assumed to be a transient error, and the abnormal status is recovered to the standby status. The standby processor performs control computation, synchronized with the control side processor. CONTROL FUNCTIONS IN FCU: The FCS provide control functions within a common architecture. They can be combined to build process control system that meet the need for a wide variety of applications with different control requirements. The basic control unit of the FCS is the control function. Control function are organized into groups called function block. Basic function blocks receive signal through their input terminals process them internally, and generate signal through their output terminals. Other types of function block receive input signals and display them on the screen, or simply output setpoints held internally. CONTROL DRAWING: A control drawing is a small set of control consisting of two or more function blocks. For example, a control drawing could specify partial control of a process unit (or entire control of a small process unit), such as jacket and internal temperature cascade control in a reactor, or an air fuel ration control in a combustion control in a combustion process. Example of a control drawing is given below.

PID IN

OUT SET PID IN OUT IN PVI

INPUT 1 INPUT 2

OUTPUT

INPUT 1

FIGURE: CONTROL DRAWING OF A CONTROL & INDICATION LOOP

PAGE-54

PAGE-55 APPLICATION SIZE OF THE FCS: Application size refers to the number of function blocks supported by the FCS, the number of I/O points handled, and the user program size. ITEM REFERENCE SIZE VALUE MAXIMUM SIZE VALUE

PROCES S I/O Total number of analog I/O points Total number of contact I/O points Number of annunciator messages Number of messages print & operator guide MESSAGE OUTPUT NUMBER OF CONTROL AREA INTERNAL SWITCHES Number of global switches Number of common switches 256 4,096 256 4,096 1 8 256 768 1,280 4,096

500 1,000

1,000 1,000

BASIC CONTROL FUNCTION Number of control drawing Number of function block 100 1,200 256 4,000

FUNCTION OVERVIEW: There are three type of control function are available at the FCS:

PAGE-56

* Basic control function * Batch control function * User programming function The basic control function provide basically four type of control. 1. 2. 3. 4. Regulatory control function Sequence control function Calculation function User-defined function

REGULATORY CONTROL BLOCK: Regulatory control blocks are primarily along process measurement to perform calculation processing. These provides process supervision and control. The list of regulatory control blocks are given below.

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PAGE-58

PAGE-59

BLOCK TYPE Input indicator

MODEL PVI PVI-DV PID PID-HLD PID-BSW ON-OFF ONOFF-G PID-TP PD-MR PI-BLEND PID-STC

Controllers

Manual loaders

MLD MLD-PVI MLD-SW MC-2 MC-3

Signal setter

RATIO PG-L13 BSETU-2 BSETU-3

Signal limiter Signal selector

Signal distributor

VELLIM AS-H/M/L SS-H/M/L SS-DUAL FOUT FFSUM XCPL SPLIT

Alarms

ALM-R

NAME Input indication block Input indication block with deviation alarm PID controller block Sampling PI controller block PID controller block with batch switch Two position ON-OFF controller block Three position ON-OFF controller block Time proportioning ONOFF controller block PID controller block with manual reset Blending PI controller block Self- tuning PID controller block Manual loader block Manual loader block with input indicator Auto/manual station block Two position motor control block Three position motor control block Ratio set block 13-zone program set block Batch set block for flow measurement Batch set block for weight measurement Velocity limiter block Auto selector block Signal selector block Dual signal selector block Cascade control signal distribution block Feed forward control signal addition block Noninteractig control output addition block Split control signal distribution block Representative alarm block

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SEQUENCE CONTROL BLOCK: Sequential control blocks perform general purpose sequence control of loop device levels, such as device interlock sequence and process supervision sequence. BLOCK TYPE Sequence Tables Logic charts LC64 MODEL ST16 ST16E STEX LC16 NAME Sequence table block Rule extension block Signal extension block Logic chart block with 8 inputs, 8 outputs, and 16 logic elements Logic chart block with 32 inputs, 32 outputs, and 64 logic elements Switch instrument block with 1 input Switch instrument block with 2 inputs Switch instrument block with 1 output Switch instrument block with 2 outputs Switch instrument block with 1 input and 1outputs Switch instrument block with 1 input and 2outputs Switch instrument block with 2 inputs and 1output Switch instrument block with 2 inputs and 2outputs Pulse type switch instrument block with 1 input and 2 outputs Pulse type switch instrument block with 2 inputs and 2 outputs 32 Point lacal switch block Timer block Software counter block Pulse train input counter block Code input block Code output block Relational expression block Resource scheduler block 16-valve monitor block

Switch Instruments

SI-1 SI-2 SO-1 SO-2 SIO-11 SIO-12 SIO-21 SIO-22 SIO-12P SIO-22P

Sequence elements

LSW TM CTS CTP CI CO RL RS VLVM

Valve monitor

PAGE-64 CALCULATION BLOCKS: Calculation blocks complement the performance of regulatory control or sequence control functions. Some blocks provide general purpose calculation functions directed at

PAGE-65 analog or contact signals. In addition, trend blocks implement high-speed trend functions.

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Block Type Arithmetic calculation

Model ADD MUL DIV AVE SQRT EXP LAG INTEG LD RAMP LDLAG DLAY DLAY-C AVE-M AVE-C FUNC FUNC-VAR TPCFL ASTM1 ASTM2

Analog calculation

Logic operation

AND OR NOT SRS1-S SRS1-R SRS2-S SRS2-R WOUT OND OFFD TON TOFF GT GE EQ BAND BOR BNOT

Name Addition block Multiplication block Division block Average block Squre root block Exponential block First-order lag block Integration block Derivative block Ramp block Lead/lag block Dead time block Dead time compensation block Moving average block Comulative average block Line-segement function block Variable line-segement function block Temprature and pressure correction block ASTM correction block (Old JIS) ASTM correction block (NEW JIS) Logical product block Logical sum block Negative block Set-dominant flip-flop block with 1 output Reset-dominant flip-flop block with 1 output Set-dominant flip-flop block with 2 outputs Reset-dominant flip-flop block with 2 outputs Wipeout block On-delay timer block Off-delay timer block Rise-trigger block Fall-trigger block Comprator block(>) Comprator block(>=) Comprator block(=) Bitwise AND block Bitwise OR block Bitwise NOT block

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SIGNAL FLOW PATH IN FCS: The FCS reads signal from the field through input module, performs a control calculation on them and issues the result (output) to the field through output module. following graphic shows the path that the signal follows through the FCS.

DETECTING ELEMENT

RIO BUS INTERFACE RB401 CARD

RIO BUS INTERFACE

INPUT MODULE OUTPUT MODULE

FINAL CONTROL ELEMENT

RIO

FCS CPU

RIO

I/O MODULE NEST NODE

RB301 CARD FIELD CONTROL STATION

FIELD

CONTROL ROOM NOTE: NODE UNIT MAY BE LOCATED IN FIELD ALSO FIGURE: SIGNAL FLOW PATH

In above figure

PAGE-72 1. INPUT MODULE PROCESSING: Input module converts the signal from the field ( analog or any other type of input like mA, mV,Volts, T/C, RTD or frequency ) into a digital signal (engineering unit data the form in which FCS processor can access). 2. INPUT DATA PROCESSING: This is communication link card (processor) used as communication interface between Node unit to the Field Control Station. It transmit the digital signal received from the input module to the FCU via a RIO bus. 3. PERIODIC PROCESSING: Control calculation period within the FCU. 4. OUTPUT DATA PROCESSING: This is also a communication interface processor which transmits the output signal from the FCU to the output module via a RIO bus. 5. OUTPUT MODULE PROCESSING: The output module card coverts for output, the output digital signal into a field signal ( such as an analog, pulse or status signal). PROCESSING TIMING OR SCAN TIMING OF THE FCU:

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PAGE-75 Processing timing determines the relative time at which function blocks perform their function or the interval of time between one run of the function and the next. Processing timing can be specified for each function block. The function blocks using periodic start within control area in an order specified beforehand using the builder. The three types of scan period are available at interval of which periodic processing is executed. 1. Basic Period of Scan ( 1 sec. ) 2. Mediu m- Speed Scan 3. High Speed Scan Medium & high speed period can be specified for each control area. The following table shows the typical application of the three scan period. Type of Processing Basic Period Medium Speed Period Scanning Interval 1 sec. ( fixed ) Standard 500 ms, selectable from among 200, 250 and 500 ms Standard 500 ms,selectable from among 50, 100, 200, 250 & 500 msec. Typical Application for all control calculation for high speed control of analog signal in regulatory control for high speed control of digital signal.

High Speed Period

ORDER OF EXECUTION AND PROCESSING TECHNIQUE IN FCS: If a periodic processing function block is assigned to control area, its processing executes once each period. unless otherwise specified, function blocks in a control drawing execute in a predefined order. Periodic processing blocks execute in a group for each control drawing they are associated with, and for each kind of processing involved in the control drawing. Therefore, it is not possible to specify that a particular function block execute before or after another function block. The execution of high-speed periodic function blocks has priority over that of medium-periodic and basic periodic function blocks. Where there are multiple control areas, they are processed in the order of their control area number. EXAMPLE OF PERIODIC PROCESSING: The following figure illustrates how periodic processing function blocks execute. For simplicitys sake only basic and high-speed periodic function block are shown. The boxes labled A, B and C and a, b and c represent control drawings. The lower part of the figure is an enlarged view of the basic period. Boxes enclosing numerals under a control drawing name indicate the execution of a function block associate with the control drawing. The numerals in a box indicates the order of execution of the function block. Other processing refers to batch control and user programming functions. Basic period processing occurs at integer multiples of high-speed period interval. Therefore, its execution timing concurs with the high-speed period. As shown in figure, execution of highspeed periodic function blocks takes precedence over the basic periodic function blocks. Execution of the basic periodic function blocks does not start until the execution of high-speed periodic function blocks in all the control drawings completes.

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If the execution timing of the high-speed period becomes due while a basic periodic function

PAGE-77 block is executed, the execution of the high-speed periodic function block start as soon as the ongoing execution of the basic periodic block completes. INPUT-OUTPUT EXECUTION TIMING IN FCU:

BASIC PERIOD ( 1 SEC. ) HIGH SPEED PERIOD TIME

HIGH SPEED PROCESSING

A B C

A B C

A B C

A B C

BASIC PROCESSING

b c

----

a b

OTHER PROCESSING

BATCH CONTROL

CONTROL DRAWING

a b 1 2 3 -------- 1 2 3

c
FUNCTION BLOCK

4 5 6 -------- 1 2 3

FIGURE: EXAMPLE OF PERIODIC PROCESSING

This section describe how function blocks execute I/O processing within a control drawing. The I/O processing described in this section involves asynchronous exchanges with remote I/O at the processing timing within the FCU. The following figure shows the I/O Execution Timing. ANALOG INPUT EXECUTION: Analog input data coming from the input module is read into a PI/O image in the FCU at each interval of the timing defined below. Function blocks connected to an analog input read its data from a PI/O image at run time for control calculation.

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PAGE-80 PI/O INPUT TIMING: Analog input with high-speed periodic processing specified is read at the beginning of the highest-speed scan period in the FCU, while analog input with slow-speed periodic processing specified is read at the beginning of the slow-speed period. EXAMPLE: In following figure At the beginning of the highest-speed scan period: 1,1 (Analog input with high-speed periodic processing specified) At the beginning of the slow-speed scan period: 2 (Analog input with slow-speed periodic processing specified)

BASIC PERIOD ( 1 SEC. ) HIGH SPEED PERIOD TIME

HIGH SPEED PROCESSING A B C 1

A B C
1' 4'

A B C

A B C

BASIC PROCESSING 2 OTHER PROCESSING

b
5

2'

b c ---5' 3 6 3' 6'

a b

a b 1 2 3 -------- 1 2 3

4 5 6 -------- 1 2 3

FIGURE: EXAMPLE OF I/O EXECUTION TIMING

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ANALOG OUTPUT TIMING: Function blocks connected to an analog output write analog output data to a PI/O image at run time. The analog output data is then transmitted to the output module at each interval of the timing defined below. PI/O IMAGE OUTPUT TIMING:

PAGE-82 Function block connected to analog output write output data to PI/O image at run time. The analog output data is then transmitted to the output module at each interval of the timing defined below.

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PAGE-84 Analog output data is written at the end of the highest- speed scan period in the FCU or at the end of the slow-speed period. EXAMPLE: At the end of the highest speed scan period: 4, 4 (Analog output that has been updated) At the end of the slow-speed period: 5 (Analog output that has been updated) DIGITAL INPUT : Digital data input is different from analog data input. As shown in figure data transmitted from the PI/O card is read into a PI/O image. From there it is read into a PI/O image in the main storage. From there it is read into DI images ( data buffer areas) at beginning control area and scan period. Reading occurs at the beginning of each scan period. Logic operation e xecute using this data. Data is stored in DI images so it can be used in sequence table, otherwise needed. User C programs read station-common DI image data. DIGITAL OUTPUT : Similar to analog output.

CONTROL AREA 3 CONTROL AREA 2 CONTROL AREA 1 DI IMAGE FOR HIGH-SPEED PERIOD

FCU

DI IMAGE FOR MEDIUM-SPEED PERIOD

DI IMAGECOMMON TO ALL STATION S

Reading at begning of basic period

PI/O IMAGE

MAIN STORAGE Output processing at begning and end of fastest period (only if the PI/O image has been updated)

Read processing at begning of fastest period

PI/O CARD

FIGURE: READING OF DIGITAL INPUT

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PAGE-88 FUZZY LOGIC CONTROL: The fuzzy logic control function block is used for the following applications. * When conventional feed forward and feedback PID control can not provide satisfactory results because of long dead time in the process. * When a process can not be represented by mathematical models. * When process measurements can not be taken directly of the process. * When an experienced operator can demonstrate unique ways of manipulating a process to keep it under control. As shown in figure, the fuzzy logic control block uses a knowledge base consisting IF-THEN statements, membership functions, and intensity. The knowledge base contains the expressed experience and knowledge of skilled operators and engineers. When equipped with such a knowledge base, the fuzzy logic control block can automatically monitor, respond to, and control just like an expert operator.

MEMBER SHIP FUNCTION 1 MEMBERSHIP

IF AND THEN RULES IF A=PS AND B=NB THEN C=NM IFA=NB AND B=ZE THEN C=PS

0 PROCESS VARIABLE

FUZZY LOGIC CONTRL COMPUTATION SECTION

KNOWLEDGE BASE

DETECTING ELEMENT

FINAL CONTROL ELEMENT

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Where the following intensities are used. PS= Positive Small NB= Negative Big NM= Negative Medium ZE= Zero

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PAGE-92 Fuzzy logic control is very power full method of reasoning when mathematical model of the plant or process are not available and input data are imprecise. The fuzzy logic comes to control systems or process which are complex. Fuzzy logic control solution is tolerant to the imprecision in inputs and the model of the system and still process output that is desired out of the system. In most application of fuzzy logic exploit its tolerance for imprecision. Because precision is costly, it makes sense to minimize the precision needed to perform a task. BASIC TECHNIQUES OF THE FUZZY LOGIC CONTROL: The main objective behind fuzzy logic is to represent and reason with some particular form of knowledge expressed in linguistic form. However, when using a language oriented approach for knowledge representation, one has to build a conceptual framework to tackle its inherent vagueness. So let's start with a brief introduction to fuzzy set concepts. The traditional (or crisp) set are based on a two valued logic: objects are either members or not member. Every object is assigned a membership value of either 1 or 0 that discriminates between member and nonmember of the crisp set for exp: in following figure.

DEGREE OF MEMBERSHIP

FUZZY SET

CRISP SET

0 10 20 30 40 50

TEMPERATURE DEG.C

in temperature may be defined such that High = 0 if T < 30C 1 if T 30C

The crisp-set High terms of

Where T is the actual temperature. High is the Linguistic variable that describes members of the set. The membership functi n High measure o of "belonginess" to category of High. If T = 50C, High ( 50C ) = 1, and the temperature is 100% high and definitely not low. Fuzzy set theory on the other hand, is based on multi valued. In fuzzy logics, and deals Fuzzy set theory on the other hand, is based on multi valued. In fuzzy logics, and deals with the concepts that are not sharply defined. In fuzzy logic membership in the Linguistic variable High may be defined as:

PAGE-93 High = if T < 30C if 20C T 30C if 30C < T 40C

0 ( T-20 ) / 10 1

The domain of a fuzzy-set is range of allowable values of the variable. In above example, the domain of the fuzzy-setHigh is any value of T from 0 to 40C. The membership value High goes from zero ( no membership ) to unity ( complete membership ) through intermediate values ( partial membership ). A temperature of 25C has a degree of membership of ( T-20 ) / 10 = 0.50 in the fuzzy-set High i.e. High (25C) = 0.50 The variable temperature may have many fuzzy-sets associated with it (for example Low, Medium, High etc.) and the domain of all the fuzzy-sets constitutes what is known as the Universe of Discourse. The fuzzy-sets Low, Medium and High associated with T may be defined as shown in figure:

LOW

MEDIUM

HIGH

DEGREE OF MEMBERSHIP

0 10 20 30 40 50

Here the universe of of 0 to 40C . A temperature of 22C belongs to the set Low to a degree of 0 ( Low

TEMPERATURE DEG.C discourse is the range 22C

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(22C) = 0 ), to the set Medium to degree of 0.8 ( Medium (22C) = .8 ) and to the set High to a degree of 0.2 ( High (22C) = .2).

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PAGE-96 Let us take a practical example of temperature control through fuzzy logic control system.

KNOWLEDGE BASE DATA BASE SET VALUE RULE BASE

FUZZY LOGIC CONTROLLER

+ -

e FUZZYFICATION

FUZZY CONTROL

DEFUZZYFICATION

OUTPUT

FEEDBACK

TEMP. SENSOR

STEAM

The temperature of hot process liquid has to be maintained at TC by regulating the steam flow rate through heater coil. For this temperature controller, the error e between the process fluid temperature and its set point can be taken as one of the input variable, and can be partitioned into fuzzy-set as Negative Large (NL), Negative Small (NS), Zero (ZE), Positive Small (PS) and Positive Large (PL). Similarly the change in error e can be taken as the second input and it can also classified NL, NS, ZE, PS and PL in their range. Suppose if the previous process fluid temperature is 40C , the current temperature is 41.2C and the set point is 50C, the error e = 50-41.2 = 8.8C and the change in error e = (50-41.2)-(50-40) = -1.2C.

PAGE-97 Then the crisp value of error can be converted into fuzzy-set representation based on following figure and is classified as an element of ZE and PS.

1 8.8 PS

NL

NS

ZE

PS

PL NL: NEGATIVE LARGE NS: NEGATIVE SMALL ZE: ZERO PS: POSITIVE SMALL PL: POSITIVE LARGE

1.2 ZE 0 -30 e = 8.8C -20 -10 0 10 20 TEMPERATURE ERROR e (C)

FIGURE: ERROR FUZZY-SET

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PAGE-99 Crisp value of change in error based on figure can be classified as an element of NS & NL.

1 .8 NS

NL

NS

ZE

PS

PL NL: NEGATIVE LARGE NS: NEGATIVE SMALL ZE: ZERO PS: POSITIVE SMALL PL: POSITIVE LARGE

.2 NL 0 -3 de = -1.2C -2 -1 0 1 2 CHANGE IN TEMPERATURE ERRORde (C)

FIGURE: CHANGE IN ERROR FUZZY-SET

In this case the output variable is a value action of Fc ( is the function of both, error fuzzy-set and change in error fuzzy-set) that can be partitioned into fuzzy-sets NL, NS, ZE, PS and PL. In this example the control action (output) from FLC is given (as per change in the error -1.2 C , .2 NL and .8 NS) as on NL or NS which is shown in following figure.

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In above figure .2 NL or .8 NS (as per change in error fuzzy-set) corresponds to -3% change in controller output to valve. All these fuzzy-sets are data are stored in data base module in the controller.

1 .8 NS

NL

NS

ZE

PS

PL NL: NEGATIVE LARGE NS: NEGATIVE SMALL ZE: ZERO PS: POSITIVE SMALL PL: POSITIVE LARGE

.2 NL 0 CHANGE IN OUTPUT -3% -7.5 -5 -2.5 0 2.5 5.0 CHANGE IN OUTPUT % FIGURE: CHANGE IN OUTPUT FUZZY-SET

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INFORMATION AND COMMAND STATION ( ICS ):

The ICS is a powerful and user-friendly operator interface. It provides operation, graphic, data base, user programming and engineering functions. ICS display panels are designed for easy operation. The touch screen function allows an operator to display several windows at the same t me. Engineering functions for i the ICS are standardized through the use of the Motif graphical user interface ( GUI ) Graphic operations simplify and facilitate the engineering work.

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PAGE-106 FUNCTION OVERVIEW: ICS provides efficient plant monitoring and control through the use of operation panels, windows and advance application functions.