DISTRIBUTED CONTROL SYSTEMS

(DCS) OVERVIEW
A course for the Cadet Engineers and CEDC O&M Employees.

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Facilitated by:
ZYRA FE TELLIDUA-QUIJANO

Enlightening Lives. Empowering Progress.

Objectives
By the end of this session, the participants must
be able to:
 Understand the meaning of Control system and its types
 Know what is Distributed Control Systems (DCS) and its
importance to CEDCthis
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 Be familiar with the CEDC DCS Hardware and their
fundamental functions
 Learn solutions to the common problems encountered in
our CEDC DCS
 Know the basic logic gates and interpret a simple Logic
Diagram
Course Outline
Topic Methodology Duration

I. Control Systems Lecture/Discussion 10 min

a. Definition of Control Systems
b. Basic Types of Control Systems
c. Examples of Control Systems
II. Distributed Control Systems Lecture/Discussion 5 min
a. Definition of DCS
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b. Benefits of DCS in the Power Plant

III. CEDC DCS Architecture Discussion/Site Tour 30 min

a. Four Stations
b. Hardware and Software
IV. Common Problems and Basic Solutions Discussion 5 min
V. Master Fuel Trip Discussion 10 min
V. DCS Color Codes Discussion 10 min
IV. Basic Logic Gates cussion/Presentation/ Workshop 15 min
Course Outline
Topic Methodology Duration

V. Q & A Discussion 5 min

VI. Summary Lecture 5 min

VII. Site Tour Discussion/Site Tour 15

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I. Control Systems
CONTROL SYSTEMS

In general,
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- is a collection of electronic devices and

equipment put in place to ensure the stability,
accuracy and smooth transition of a process.
I. Control Systems
CONTROL SYSTEMS

- is an interconnection
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file forming
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system configuration that will provide a desired
system response.
I. Types of Control Systems
BASIC TYPES OF CONTROL SYSTEMS

• OPEN-LOOP
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• CLOSED-LOOP
I. Control Systems
OPEN-LOOP
- type of control system in which the output has no
influence or effect on the control action of the input
signal.
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Input Controller Output
(Set Value) Output (Process Value)
CONTROLLER PROCESS
(Process Input)
I. Control Systems
CLOSED-LOOP
- a system that uses a measurement of the output and
compares it with the set value; also known as
feedback control system.
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Measured Controller
Error
Input Output / Output
CONTROLLER PROCESS
(Set Value) Process Input (Process
Value)

FEEDBACK
Measured Output
I. Control Systems
• Examples of Control Systems
 Automatic Hot Water Heater

 Automatic Traffic Control (signal) System at

Roadway
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 Activation of a home lightings

 Human controlling the speed of an automobile by

regulating the gas supply to the engine
II. Distributed Control Systems
• DCS
(definition)

- a Please
type of automated control system that is distributed
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throughout the process to provide instructions to its
different parts.

- each section of a process has its own

computer/controller that controls the operation.
II. Distributed Control Systems
• Benefits of DCS

 High Plant Reliability

 Improved process response time
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 Easier operator interface to the plant
 Real time access to plant process parameters
 Historical data storage and retrieval
 Convenience
II. Distributed Control Systems
• Benefits of DCS (continued)

 See trends of past process conditions by calling

archival data storage.
 Readjust controllerthis
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software.
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 Implement latest controller design ideas on the host
computer or on the main control computer
Imagine Operating a Boiler without DCS

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III. CEDC DCS ARCHITECTURE
GPS FOR TIME LED SWITCH HUB Remote Monitoring & Maintenance
SYNCHRONIZATION DISPLAY (Terminal Service)
VPN
52” #3 #2 #1 SERVER & INTERNET & PC
FIREWALL (Taiwan)
LARGE CES CES CES INTRANET
SCREEN
OPC SERVER #3 R-COS #2 R-COS
DCS
OPC Server
#1 R-COS SUB-SYSTEM INTEGRATED SYSTEM
Information LAN
Notebook
(AB PLC ES)

#1 MMI #2 MMI #3 MMI

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OPC TREND CES COS-1 COS-2 COS-3 COS-4

CDS-A CDS-B

Control LAN (FL-NET)

Optical Fiber Optical Fiber

FL-NET#1
GCS
POWER GCS FCS- FCS- FCS- FCS- FCS- FCS- FCS-
PANEL 1011 1012 1021 1022 1031 1032 1041 10A CAH PLC WTP PLC FLY ASH PLC
10B

SER ARP/IRP TCP

SCADA
RELAY/MARSHALLING PANELS TG PLC
MODBUS
III. CEDC DCS ARCHITECTURE
• CEDC DCS uses 4 Stations per Unit
- Each station uses a redundant system---has two
controllers (A & B)

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MASTER SLAVE

A B

SLAVE MASTER

A B
III. CEDC DCS ARCHITECTURE
• Station 1

 Boiler Master Control

 Combustion Air Control
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Pressure Control Reading Mode

 Fuel Control
 Drum Level Control
 Main Steam Temperature Control
III. CEDC DCS ARCHITECTURE
• Station 2

 HPH/LPH Level Control

 Deaerator Level Control
 Please Steam
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 T/G Signal I/O

 SCADA Signals
 Soot blower System
III. CEDC DCS ARCHITECTURE
• Station 3

 Auxiliary Equipment
 Furnace Temperature Control
 Please Ash
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 Bottom Ash Feeding/Recirculation System

 Sand Injection System
III. CEDC DCS ARCHITECTURE
• Station 4

 Burner Management System

 Furnace Purge/MFT Interlock
 Please
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 Limestone Feeding System

 Annunciator Alarms
III. CEDC DCS ARCHITECTURE
• DCS Consoles & Panels

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III. CEDC DCS ARCHITECTURE
• ENGINEERING STATION (CES)
- Create/edit/download program, graphics, loop parameters,
trends, data log and alarms using “FPROCESS” software.

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III. CEDC DCS ARCHITECTURE
• DATABASE STATION (CDS)
- acquires and records all data in the plant and executes
centralized management of such data.

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III. CEDC DCS ARCHITECTURE
• TREND/ALARM SERVER/CLIENT (TRD/ALM SERVER)
- Gathers and stores data (trend/alarm)
• TREND/ALARM CLIENT (TRD/ALM CLIENT)
- Retrieve past trends and alarms
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III. CEDC DCS ARCHITECTURE
• OPC SERVER (OPC)
- Collects and Stores data from FA, CAH and WTP.

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III. CEDC DCS ARCHITECTURE
• REMOTE OPERATOR’S STATION (R-COS)
- View/monitor the plant’s processes but cannot control.
• OPERATOR’S STATION (COS)
- View/monitor/control the plant’s processes
- SetPlease
loop parameters (alarms,
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III. CEDC DCS ARCHITECTURE
• SUBSYSTEMS PC (SUBSYS)
- View/monitor/operate the plant’s subsystems such as FA,
CAH, and WTP.

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III. CEDC DCS ARCHITECTURE
• ANNUNCIATOR PANEL (ANP)
- displays and alerts the operator of critical alarms (ex.
“Operator Sleeping” Alarm)

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III. CEDC DCS ARCHITECTURE
• RACK ROOM PANELS
 20 panels per unit

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III. CEDC DCS ARCHITECTURE
• RACK ROOM PANELS

 PDP – Power Distribution Panel

 GCS – General Purpose Communication Systems
 FCS – Formosa
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 SER – Sequential Event Recorder
 ARP – Auxiliary Relay Panel
(one panel only)
 IRP – Interlock Relay Panel
 RPL – Relay Panel
 MPL – Marshalling Panel
IV. Common Problems & Solutions

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IV. Common Problems & Solutions
PROBLEM SOLUTION
•Hang-up System Restart
•Loose Contact Tighten Connections
•Communication Delays Tighten Connections
System
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•Time Synchronization problem Replace GPS Antenna
System Restart
•Loss of Data Scheduled Data Back-up
•Loss of power Supply or System Restart
Equipment Malfunction Repair
Replace
V. Master Fuel Trip Signals
• Furnace Pressure H (>272 mmH2O)
• Drum Level LL (-254 mm)
• Furnace Pressure LL (<-272 mmH2O)
• Drum Level HH (>254 mm)
• SA Fan Off download this file and use
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• Instrument Air Pressure Low

• ID Fan Off
• Loss of Fuel Trip
• Both FA Blowers Off
V. Master Fuel Trip Signals (continued)
• Emergency Push Buttons (COS/ANN)
• PA Fan Off
• Furnace Temperature Inadequate for Coal Firing
• Air Flow less than 25%
• Primary Airdownload
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VI. DCS Color Codes
• Valves/Dampers
RED – full open

GREEN – full closed

BEIGE – not full open, not full closed

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YELLOW – (blinking) two active limit switches

GRAY – (blinking) no limit switch contact

PINK – (blinking) tripped (no power supply)

VI. DCS Color Codes
• Alarms
RED – (Level 0) System Alarms

RED – (Level 1) Heavy Fault/Tripping Signals

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YELLOW – (Level 2) Moderate Fault

PINK – (Level 3) Light Fault

VI. DCS Color Codes
• Equipment (Motor, Pump, Fan, etc.)

RED – Running

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GREEN – Stopped

PINK – Tripped/Trouble Condition

III. Basic Logic Gates
• LOGIC GATE

 An elementary building block of a

digital circuit
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 Performs a logical operation on
its one or more inputs and
produces one logical output

 Acts as switches
III. Basic Logic Gates
• AND GATE
 produces a logic 1 when all of its inputs are 1. In all other
cases the output is 0.

SYMBOL TRUTH TABLE

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out
B
III. Basic Logic Gates
• OR GATE
 logic gate whose output will be a 1 if any of it inputs is 1.

SYMBOL TRUTH TABLE

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A
out
B
III. Basic Logic Gates
• NOT GATE
 logic gate that acts as an Inverter.

SYMBOL TRUTH TABLE

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A out
0 1
A out 1 0
III. Basic Logic Gates
• Ladder Logic Equivalent

AND

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OR

NOT
III. Basic Logic Gates
• On-delay Timer
 a timer that waits for a predetermined amount of time
before switching on its output.
EXAMPLE:
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* When INPUT turns ON, TR0001 starts counting.

* When TR0001 reaches its preset time (10 sec), OUTPUT turns ON.
III. Basic Logic Gates
Example:
Design a ladder diagram for Starting and Stopping a
motor using two pushbutton switches.

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VI. Q & A
• Any Questions?

? ? ? ?
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? ? ? ?

? ? ?

? ? ?
VII. Summary
• Distributed Control Systems
 Control system
 Automated
 Controller is not central in location
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 Distributed throughout the process
 Each Section has its own controller/computer
VII. Summary
• Benefits of DCS in Boiler Operation
 Reliability
 Fast Response Time
 Convenience
 Easy retrieval
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 Real-time access to plant parameters
VII. Summary
• DCS has 4 Stations
 Redundant Stations (A&B)
 Master-Slave
 One station malfunctions, Other station is not affected
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Enlightening Lives. Empowering Progress.