DISTRIBUTED CONTROL SYSTEMS (DCS) - IDC-Online

1 A solid understanding of the architecture and operation ofDistributed CONTROL SYSTEMS (DCSs) Ability to design the overall DCS and process CONTROL system Better specification of planned DCSs Improved process performance for your plant Understanding of the key ergonomic issues in design of operatordisplays Apply advanced CONTROL strategies to your plant CONTROL system More effective use of your existing DCS process controlcapabilities Design and create a consistent and effective alarm philosophy foryour installation Recognise and deal with human problems in interfacing to alarmsystems Process CONTROL Engineers & Technicians Automation

2 Engineers Operations Managers Operators & CONTROL Room Personnel Metallurgists Production Engineers Process Engineers Plant Engineers IT Managers working with Networks Electrical Engineers Project Engineers Electrical & Instrumentation Technicians Maintenance Engineers & SupervisorsPracticalDISTRIBUTED CONTROLSYSTEMS (DCS)WHAT YOU WILL LEARN:WHO SHOULD TWOALARM SYSTEM MANAGEMENT FORDCSS Philosophies of Alarm Management Human and Ergonomic Factors Structure of good Alarm System Safety Integrity Level (SIL) Design of Alarm System Measurement of PerformanceDISTRIBUTED CONTROL SYSTEMREPORTING Alarm reporting, types of alarms generatedand acceptance of alarms The different types of logs and reports whichcan be configured on a DCS system data history use in logs.

3 Reports and trend displaysDISTRIBUTED CONTROL SYSTEMCONFIGURATION The organisation of system data files data configuration procedures necessary forsetting up the DCS area database The need for different security levelsattached to various operating parameters Configuration CONTROL procedures adopted toensure data integrityADVANCED CONTROL STRATEGIESMAINTENANCE CONSIDERATIONS Maintenance requirements of system andsystem elements The requirements for in-built diagnostics andfor maintenance diagnostic routines The requirements for installation of UPS system Recovery of a DCS following a power outageTHREE TYPICAL APPLICATIONSCOMPARISON OF OFFERINGS FROMDCS VENDORS SUMMARY AND CLOSUREDAY ONEINTRODUCTIONSUMMARY OF TYPICAL DISTRIBUTEDCONTROL SYSTEMSDCS VERSUS SCADA VERSUS PLCS Comparison The Smart Instrument As A The KeyComponent In A DCS SystemDCS SYSTEM ELEMENTS Main differences between a distributedcontrol system and PLC/SCADA SYSTEMS .

4 Requirements of the operator interfacewithin the DCS Layout of a DCS system with data highwaycommunications paths Redundancy in the DCSDATA COMMUNICATIONS IN A DCS Overview of DCS & SCADAC ommunications (field/operator/longdistance) Network topologies Foundation Fieldbus Profibus Devicenet Industrial Ethernet Routers, switches, hubs TCP/IP Industrial Network security Links to MES and ERPTHE BASIC CONTROLLER Identification of the PCBs, which make up the controller Function of the central processing unit(CPU) The types of memory Discrete and logic CONTROL Sequential and batch controlBASIC DCS CONTROLLERCONFIGURATION CONTROL modes available within each controller slot Tracking and initialisation in CONTROL slotsused for cascade CONTROL CONTROL algorithms The use of diagnosticsPROGRAMMING OF DCS SYSTEMS Block Configuration IEC 61131-3 "open" Programminglanguages (structured text, functionblock,ladder, sequential)

5 Tips and tricks in programmingTHE OPERATOR INTERFACE The operators process 'window' The various operator display configurations The requirement for keyboard entry of data Ergonomic requirements in the operatorenvironmentTHE PROGRAMThis workshop will cover the practicalapplications of the modern DISTRIBUTED controlsystem (DCS). Whilst all CONTROL SYSTEMS aredistributed to a certain extent today and there isa definite mergingof the concepts of DCS,Programmable Logic Controller (PLC) andSCADA and despite the rapid growth in the useof PLCs and SCADA SYSTEMS , some of theadvantages of a DCS can still be said to be:Integrity:The expected process down-timecaused by a conventional DCS is significantlyless than with using a SCADA/PLC.

6 Oneincident in a refinery can cost more than thedifference in price between a DCS andSCADA/PLC. Reasons for this would includeredundancy, fault tolerance, diagnostic alarmingon I/O errors, system design, and others. Engineering time:A small SCADA/PLC systemis easy to design and configure. As the systemgrows bigger, the effort involved to properlydesign and configure the system growsexponentially, and also the risks that things cango wrong. To design and implement a single loopPID controller in a SCADA/PLC system is easyand quick.

7 To design and implement the baselayer CONTROL on a refinery using a SCADA/PLCsystem can be an absolute nightmare. Abnormal Situation Management andIntelligent Alarm Management is a veryimportant DCS issue that provides significantadvantages over PLC and SCADA DCSs do justice to the process; in terms ofcontrolling for superior performance - most ofthem merely do the basics and leave the rest tothe operators. Operators tend to operate withintheir comfort zone; they don't drive the process"like Schumacher drives his Ferrari".

8 If morethan one adverse condition developed at the sametime and the system is too basic to actprotectively, the operator would probably not beable to react adequately and risk a majordeviation. Not only is the process controlfunctionality normally underdeveloped but on-line process and CONTROL system performanceevaluation is rarely seen and alarm managementis often badly done. Operators consequently havelittle feedback on their own performance andexceptional adverse conditions are often nothandled as well as they should be.

9 This workshopgives suggestions on dealing with these are DCSs generally so under utilised? Oftenbecause the vendor minimises the applicationssoftware development costs to be sure of winningthe job, or because he does not know enoughabout the process or if it is a green-field situation,enough could not be known at commissioningtime but no allowance was made to add themissing functionality during the ramp-up the client does not have the technical skillsin-house to realise the desired functionality ismissing or to adequately specify the desiredfunctionality.

10 This workshop examines all these issues andgives suggestions in dealing with them and whilstby no means exhaustive, provides an excellentstarting point for you in working with SESSIONS Simulation Software - Simulation of a typicalDCS will be used. Specification of a DCS Configuration of a typical DCS CONTROL Loopusing a typical plant problem