Control Systems

The fundamentals of DCS and PLCs

 Objectives
• At the end of the session, participants will be able to grasp fundamental
knowledge of DCS and PLCs by identifying several different components
and functionalities of hardware and software. The participants will be able to
read and understand basic logic operands which they can apply in
troubleshooting problems in the power plant.
 What is DCS
• distributed control system (DCS) is a computerised control system for a
process or plant, in which autonomous controllers are distributed throughout
the system, but there is central operator supervisory control.
 History of DCS
In 1950s
• Analog Devices were used
• Has poor flexibility
• More Cost and needs more
manpower
• More control loops
 History of DCS
• The Harvard mark 1 computer from
1944
 History of DCS
• In 1961, DDC (Direct Digital
Control) was created to replace
analog controls
 DCS Basic Elements
Engineering PC or controller
• This controller is the supervisory controller over all the distributed processing
controllers. Control algorithms and configuration of various devices are executed in
this controller. Network communication between processing and engineering PC
can be implemented by simplex or redundant configurations.
• In SMC Malita, Compact Engineering Station (CES) is the engineering pc.
 DCS Basic Elements
Operating station or HMI
• It is used to monitor entire plant parameters graphically and to log the data in plant
database systems. Trend display of various process parameters provides the effective
display and easy monitoring.
• There are 6 operating stations in SMC Malita power plant. It is called compact
operating station (COS).
• COS1-5 and Remote COS (R-COS).
 DCS Basic Elements
Communication media and protocol
• Communication media consists of transmission cables to transmit the data
such as coaxial cables, copper wires, fiber optic cables and sometimes it
might be wireless. Communication protocols selected depends on the
number of devices to be connected to this network.
• In SMC Malita, General Communication System (GCS) is the controller
that governs the communication of DCS and plant sub-systems.
 DCS Basic Elements
Distributed controller or Local control unit
• It can be placed near to field devices (sensors and actuators) or certain location where these
field devices are connected via communication link. It receives the instructions from the
engineering station like set point and other parameters and directly controls field devices.
• It can sense and control both analog and digital inputs / outputs by analog and digital I/O
modules.
• Formosa Control System (FCS) is the distributed controller that commands and processes
the I/O of the system.
 Which of the four basic elements of DCS where you can check
and analyze the programs downloaded to the control units?

a. Engineering PC or controller
b. Operating station or HMI
c. Communication media and protocol
d. Distributed controller or Local control unit
 DCS

FCS-101 FCS-102 FCS-103 FCS-104 FCS-105

• Boiler Master • HPH/LPH Level • Sand Injection • Burner Management • Air Dryer
• Combustion air • Deaerator Level • Bottom Ash System • SCADA
• Fuel Control • Process Steam • Ash Conveyor • MFT Interlock • COAL
• Furnace Pressure • TG Signal IO • Furnace Purge HANDLING
• Drum Level • Auxiliary Equipment • Limestone Injection • WATER
• Main Steam Temp TREATMENT
• AIR
COMPRESSOR
Plant Supervisory
Level 2

Direct Control
Level 1

Field Level
Level 0

Field Level
Level 0
Field Level Level 0
Direct Control Level 1
Plant Supervisory Level 2
 Ethernet
TCS DCS DCS
TCS
PLC
Planned for
connection

Debris
CTCS Fly Ash EP
Filter

Air
Coal Water
SCADA Compresso Air Dryer
Handling Treatment
r

Reclaimer Ship
Hopper LPP
/Stacker Unloader
 PLC
• programmable logic controller (PLC) is an industrially hardened
computer-based unit that performs discrete or continuous control functions
in a variety of processing plant and factory environments.
 History of PLC
In 1960s, Control systems implemented using relay controller.
 History of PLC
• Bedford Associates (Morley, Greenberg, Landau, Schwenk and Boissevain)
already working from 1968 on the ”084”. They form Modicon and together
in 1969 build the ”Programmable Controller 084” also known as the
”Modicon 084”.
Which of the following control system is faster
in handling instruction and response time?
a. Programmable Logic Controller
b. Distributed Control System
 PLC vs DCS
PLC DCS
- Replacement for relays - Replacement for modular PID controllers
- Fast response time - Slow response time
- Can only handle few of thousands I/O - Can handle many of thousands of I/O
- Local controls - Global Controls
- Less complex - Much more complex
- best applied to a dedicated process that doesn’t - complex and requires frequent adjustments or
change often must aggregate and analyze a large amount of data
 Components of a Control Unit
• CPU
• I/O Modules
• Communication Modules
• Power Supply
• Rack
 Controlling Unit/CPU
• The brain of the whole PLC is the
CPU module.
• The CPU consists of a
microprocessor, memory chip and
other integrated circuits to control
logic, monitoring and
communications.
 I/O Modules
• The I/O system provides the physical
connection between the equipment
and the PLC.
 4 Basic Types of I/O Modules
• Digital Input
• Digital Output
• Analog Input
• Analog Output
 Digital I/O Modules
• are modules used to detect or
command two states. Example
1(ON) and 0 (OFF).
 Analog I/O Modules
• These are modules which detect/command analog signals such current (4-20
mA), resistance and voltage (1-5V).
• Analog input signals can represent such items as temperature or level or rate
of flow.
• Analog output signals are also variable and can be used for such things as
opening a valve to a desired position.
 Power Supply

• Power supply for a PLC/DCS converts the input source power into
voltages required for internal circuitry. In some cases, it also provides
an isolated VDC supply to power DC input circuits, switches and
other indicators.
• The Power Supply of the PLC is an essential component.
• The most popular power supplies work with 120 VAC or 24 VDC
sources.
 The Rack
• The rack is the component that holds
everything together. Depending on
the needs of the control system it can
be ordered in different sizes to hold
more modules. Like a human spine
the rack has a backplane at the rear
which allows the cards to
communicate with the CPU.
 Communication Module
• communication modules provide a variety
of communication possibilities to the
control and field level and can be integrated
into various combinations, forming great
network nodes from smallest to largest
automation solutions.
• Provides communication between
controllers and remote I/O modules with a
specific protocol by which the system can
understand.
 Communication Protocols
• Ethernet
• EtherCAT
• PROFINET
• PROFIBUS DP
• CANopen
• DeviceNet
• Modbus TCP
• Modbus RTU
• RCOM
• Serial
 Which of the following modules handles discrete devices
which gives a signal that is either on or off such as a
pushbutton, limit switch, sensors or selector switches?
a. Digital Input c. Analog Input
b. Digital Output d. Analog Output
Which of the following modules gives 4-20 mA
that can control the opening/closing of the
valve?
a. Digital Input c. Analog Input
b. Digital Output d. Analog Output
 Binary Number System
• a binary number is a number expressed in the binary numeral
system or base-2 numeral system which represents numeric values
using two different symbols: typically 0 (zero) and 1 (one).
 Boolean Algebra
• is the branch of algebra in which the values of the variables are
the truth values true and false, usually denoted 1 and 0 respectively
 Logic Gates
• a logic gate is an idealized or physical device implementing a Boolean
function; that is, it performs a logical operation on one or
more binary inputs and produces a single binary output.
 Basic Logic Gates
• Inverter or NOT Gate
 Basic Logic Gates
• AND Gate
 Basic Logic Gates
• OR Gate
 Universal Gates
• NOR Gate
 Universal Gates
• NAND Gate
 OTHER BASIC LOGIC GATES
• XOR GATE
 OTHER BASIC LOGIC GATES
• XNOR GATE
 Which of the following logic gates satisfies the statement? one input must be
true and other must be false to have an output which is true. However if both
input is false or both input is true the output is false.

a.) AND GATE

b.) OR GATE
c.) XOR GATE
d.) XNOR GATE
 Exercise your brain
• Use basic logic gates to create a program according to the following statements
• The pump will start if and only if:
a.) it is in remote mode and there is no fault and the level of the tank is not low.
b.) it is in local mode and push button is pressed.
Inputs:
a.) selector switch (1: remote, 0: local)
b.) Fault indicator (1: fault, 0: no fault)
c.) Level switch (1: low, 0: normal)
d.) Local Push button (1: energize, 0: de-energize)
Ouput:
a.) Relay (1:Start Pump, 0: Stop Pump)
 Ladder Logic Diagram
• Ladder diagrams are specialized
schematics commonly used to
document industrial
control logic systems. They are called
“ladder” diagrams because they
resemble a ladder, with two vertical
rails (supply power) and as many
“rungs” (horizontal lines) as there are
control circuits to represent.
Ladder Logic Symbols
Ladder Diagram How does it work

L1 L2
Ladder Logic – AND Gate
Ladder Logic – OR Gate
Ladder Logic – NOT Gate
Ladder Logic- NAND Gate
Ladder Logic- NOR Gate
Ladder Logic- XOR Gate
 Exercise your brain
• Use ladder logic to create a program according to the following statements
• The pump will start if and only if:
a.) it is in remote mode and there is no fault and the level of the tank is not low.
b.) it is in local mode and push button is pressed.
Inputs:
a.) selector switch (1: remote, 0: local)
b.) Fault indicator (1: fault, 0: no fault)
c.) Level switch (1: low, 0: normal)
d.) Local Push button (1: energize, 0: de-energize)
Ouput:
a.) Relay (1:Start Pump, 0: Stop Pump)
 Exercise your brain
• Use logic gates and ladder logic diagram to create a program for
Condensate pump A auto start according to the following:
• Pump A must be in remote and auto mode when the condensate pump B is running
while the common discharge pressure is low OR
• Pump A must be in remote and auto mode when the condensate pump B tripped OR
• Pump A must be in remote and auto mode when the condensate pump B DP is high.
 Inputs
• Pump A remote (1:remote, 0:local)
• Pump A auto (1:auto, 0:manual)
• Condensate B running signal (1:running, 0: Stop)
• Discharge pressure switch (0: Low, 1: normal)
• Condensate B trip signal (1:trip, 0:normal)
• Condensate B DP switch High (1:High, 0:normal)