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Pneumatic Implementation:
In the early implementation of automatic control systems, information flow was accomplished by pneumatic transmission, and computation was done by mechanical devices using bellows, spring etc.
History (cont.)
History (cont.)
Digital Implementation: Transmission: Digital signals are far less
sensitive to noise.
Calculation: The computational devices
Display
Main Computer
PROCESS
Data acquisition
programmed to execute plant shutdown and / or interlock /sequence logics to the specified safety integrity levels. It uses a programmable memory to store instructions and specific functions.
Could withstand a harsh industrial environment They had no hard drive, they had battery backup
POWER SUPPLY Provides the voltage needed to run the primary PLC components. I/O MODULES Provides signal conversion and isolation between the internal logic-level signals inside the PLC and the fields high level signal. PROCESSOR Provides intelligence to command and govern the activities of the entire PLC systems. PROGRAMMING DEVICE used to enter the desired program that will determine the sequence of operation and control of process equipment or driven machine. USER INTERFACE PLCs may need to interact with people for the purpose of configuration, alarm reporting or everyday control . A Human-Machine Interface(HMI) is employed for this purpose. HMIs are also referred to as MMIs (Man Machine Interface) and GUIs (Graphical User Interface).Text displays are available as well as graphical touch screens. More complex systems use a programming and monitoring software installed on a computer, with the PLC connected via a communication interface.
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COMMUNICATIONS
PLCs have built in communications ports, usually 9-pin RS-232,but optionallyEIA-485 or Ethernet.Modbus,BACnet or DF1is usually included as one of the communication protocols. Other options include various fieldbuses such as Device Net or Profibus. Other communications protocols that may be used are listed in the List of automation protocols . Most modern PLCs can communicate over a network to some other system, such as a computer running a SCADA(Supervisory Control And Data Acquisition) system or web browser. PLCs used in larger I/O systems may have peer-to-peer (P2P) communication between processors. This allows separate parts of a complex process to have individual control while allowing the subsystems to co-ordinate over the communication link. These communication links are also often used for HMI devices such as keypads or PC-type workstations.
PROGRAMMING
PLC programs are typically written in a special application on a personal computer, then downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the PLC either in battery-backed-up RAM or some other nonvolatile flash memory. Often, a single PLC can be programmed to replace thousands of relays. Under the IEC 61131-3 standard, PLCs can be programmed using standards-based programming languages.PLC programs are never perfectly interchangeable between different makers.
PLC OPERATION
While the PLC is running, the scanning process includes the following four phases, which are repeated continuously as individual cycles of operation:
PHASE 1
Program Execution
PHASE 3
Diagnostics/ Comm
PHASE 4
Output Scan
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The time it takes to implement a scan cycle is called SCAN TIME. The scan time composed of the program scan time, which is the time required for solving the control program, and the I/O update time, or time required to read inputs and update outputs. The program scan time generally depends on the amount of memory taken by the control program and type of instructions used in the program. The time to make a single scan can vary from 1 ms to 100 ms.
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EUROPEAN
JAPANESE
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I/O Module:
I/O modules shall communicate with processor modules serially either through back-plane or through I/O communication network. I/O network shall always be redundant.
I/O MODULE
History Module
-Like the harddisk of PCs - Store the configurations of the DCS as well as the configurations of all the points in the plant - Store the graphic files that are shown in the console and in most systems these days they are able to store some plant operating data
Data Historian
- Software that are dedicated to store process variables, set points and output values - They are usually of higher scanning rates than that available in the history module.
- Group displays - Overview displays - Detail displays - Graphic displays - Trend displays
Shows the operating parameters of group of control loops such as four, eight, twelve, or sixteen control loops, arranged in rows so that they look like the faces of instruments on an instrument panel.
group display
Detail Displays
- Specific to a single loop or control function - Includes additional information defining constants, limits, and other characteristics of the function
Graphic Displays
Graphic display capability allows a picture to be drawn on the screen so that the operator can look at a portion of the process more realistically than by watching a row of bar graphs
Trend Displays
- Trend displays are the distributed control system equivalents of chart records. - Shows change in process value that have taken place over a period of time
Working of DCS
The working of DCS can be divided into two parts .
1. Hardware Flow
The flow of signal passes from sensors/ transmitters to a local field junction box. From field junction box through a multi core cable it goes to the main junction box. Again from main junction box it comes to a marshalling cabinet where the wires enter into the control panel. After signal entering the panel, the signal wire goes into the input card connected to the controller. Controller processes the data according to the logic created and gives output to the Final Control Element through output cards, following the same route.
Working of DCS
2. Software
There is a scan cycle which needs to be completed for the execution of an instruction needed to control the process.The following steps occur for each scan period: 1.The status of inputs from the process through the input card are checked. 2.Then the values are updated in the program and according to the logic prepared by the programmer output values are decided. 3.These outputs then go to the field through output cards. 4.The status is updated in the SCADA as well as the changes are stored for future reference in the historian. 5.Any alarms i.e. deviations in the process are there are also noted and stored.
Following functional requirements as a minimum should be met by DCS system: Control Data Acquisition Alarming Logging and report generation Historical data storage Trending System diagnostics. System security
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. Digital DCS systems are more flexible. Control algorithms can be changed and control configuration can be modified without having rewiring the system.
DCS Vendors
Honeywell
Fisher-Rosemont
Baily Foxboro Yokogawa Siemens
manufactured? and the cost of downtime? 3. What do you view as the "heart" of the system? 4. What does the operator need to be successful? 5. What system performance is required? 6. What degree of customization is required? 7. What are your engineering expectations?
Multiple products Recipe parameters: Constant or Variable Procedures: Single procedure or Multiple (different) procedures Equipment utilization and arbitration: Fixed/none or Flexible/often Frequency of changes to formulas and recipes: Never or Often
DCS
PLC
2. What is the value of the product being manufactured and the cost of downtime?
Value of the individual component being manufactured is relatively low. The value of a batch can be very high. Downtime not only results in lost production, but can result in dangerous conditions. Downtime can result in process equipment damage (product hardens, etc.)
PLC
Return to steady state production after an outage is short and relatively straightforward
Return to steady state production after an unplanned outage can be long, expensive, and difficult
DCS
PLC
DCS
PLC
DCS
PLC
Analog Control: Simple PID only. Diagnostics to tell you when something is broken.
Analog Control: Simple to advanced PID control up to Advanced Process Control. Failure of the HMI could force the shutdown of the process
DCS
DCS
PLC
System designed to make it "easy" to engineer process applications. Use of pre-defined, pre-tested functions saves time.
DCS
PLC