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PROCESS CONTROL FUNDAMENTALS RELATED TO DISTRIBUTED

CONTROL SYSTEM (DCS)

COURSE AIM:

The aim of this training course is to build up the procedural and declarative knowledge
required for the technicians in all levels who don’t have past background of DCS or Process
Control. This will help them to work in a projects dealing with control systems with a strong
background.

1) INTRODUCTION

1.1 Need for Process Control in industries

1.2 Components of control system
1.3 Controlled variables, manipulated variables and disturbances
1.4 Guidelines for selection of measurement points
1.5 Servo Control and Regulatory control

2) REGULATORY CONTROL

2.1 Feedback control – Block diagram

2.2 Components and signals of a typical control loop
2.3 Feedforward control
2.4 Cascade control
2.5 Split range control
2.6 Inferential control
2.7 Different types of FB controllers – P. PI, PID
2.8 Controller tuning – CC method, ZN method, IMC method
2.9 Tuning of Yokogawa PID controllers online
2.10 Practical Session on Flow, Level, Temperature and Pressure control using
virtual simulator

3) CONTROL VALVES
3.1 Pneumatic control valve
3.2 Motorized control valve
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3.3 Fail to open and fail to close control valves

3.4 Control valve Troubleshooting
3.5 Globe valve
3.6 Butterfly valve
3.7 Ball valve

4) DCS BENEFITS, USAGE AND HISTORY

4.1 Automation System Structure
4.2 What is DCS?
4.3 What is PLC?
4.4 Difference between DCS and PLC
4.5 Redundancy and Fault Tolerance
4.6 Microprocessor Control

5) DCS INFRASTRUCTURE

5.1 Communication Bus

5.2 Control Processor

5.3 Engineering Interface

5.3.1 Application Processor Functions

5.3.2 Diagnostics

5.3.3 Workstation Components

5.4 Operator Interface

5.5 Gateways

6) DCS HARDWARE

6.1 Fieldbus Modules

6.2 Fieldbus Interconnection

6.3 Cluster I/O Subsystem Interfacing

6.4 Fieldbus Cluster I/O Subsystem

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6.5 Fieldbus Processor

6.6 Fieldbus Cards

6.7 Foundation Fieldbus Technology

7) DCS SOFTWARE

7.1 Standard Application Packages

7.1.1 System Management
7.1.2 Database Management
7.1.3 Historian
7.1.4 View Display Manager
7.1.5 Draw Display Builder

7.2 Alarm System

7.3 Historian
7.4 Draw
7.4.1 Configuration
7.4.2 Operator Actions
7.4.3 Faceplates
7.4.4 Trends
7.4.5 Group Displays
7.5 View
7.6 Operator Action Journal
7.7 Control Configuration
7.7.1 Compound Functions
7.7.2 Compound/Block Process Alarming
7.7.3 Compound/Block Phasing
7.7.4 Compound Attributes
7.7.5 Compound/Block Parameters
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8) DCS INSTALLATION, MAINTENANCE & POWER DISTRIBUTION

8.1 Modular Industrial Console

8.2 System Equipment

8.3 Software Installation & Discussion

8.4 Maintenance Philosophy

8.5 Preventive Maintenance

8.6 Fault Analysis

8.7 Corrective Maintenance

8.8 Power Connections

8.9 Connection Procedure

8.10 Earth Connections

9) COMMERCIAL DCS EXAMPLES

9.1 Honeywell TDC 3000

9.2 Yokogawa Centum CS 3000
9.3 Siemens PCS7

Note:

We have simulator for temperature, pressure and level control. In that we can open controller face
plate and set the controller parameters, can view the process history, can set high and low level
alarm etc. It will be same like how we do the things in DCS window. Below are the screen shots
from our simulator and pictures of our lab facilities.
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Process Control Instrumentation Lab

1. Gas Temperature Process:

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2. Self-Regulating Level Process:

3 Gas Heater Element Temperature Process:

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4. Non Self Regulating Level Process:

5 Gas Mass Flow Process:

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6. Liquid Flow Process:

7 Gas Pressure Control (Single capacity & Multi-capacity)

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8. PID Controller and alarm limit setting:

Note:

In all these experiments we can open the PID face plate and can change the PID controller
parameters, alarm low and high values as shown in Figure 8. Also we can view the Process history
trends and the process parameter details as shown in Figure 9 & 10.
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9. Process History View:

10. Process parameter details:

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11. Alarm List:

12. Temperature, Pressure and Flow Control – Experimental Setup

Note: We are using Yokogawa PID controllers in the real time training systems
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13. Level and Pressure Control Training System:

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14. Various Valve Models:

15. Emerson Delta V DCS:

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