MATHITRA TVC

ELECTRICAL AND ELECTRONICS ENGINEERING

DEPARTMENT

DIPLOMA IN ELECTRICAL &

ELECTRONICS ENGINEERING (POWER
OPTION)
Topic 1. Introduction to Industrial PLC
PROCESS CONTROL
 Process control consists of monitoring the state of a critical
parameter, detecting when it varies from desired state, and
taking action to restore it.
 It involves the process variable, set points and manipulated
variable.
 Most basic process control systems consist of a control loop.
 This has four main components which are:
 A measurement of the state or condition of a process
 A controller calculating an action based on this measured value
against a pre-set or desired value (set point)
 An output signal resulting from the controller calculation which is
used to manipulate the process action through some form of
actuator
 The process itself reacting to this signal, and changing its state or
 Two of the most important signals used in process
control are called
 Process Variable or PV
 Manipulated Variable or MV
 In industrial process control, the Process Variable
(PV) is measured by an instrument in the field and
acts as an input to an automatic controller which
takes action based on the value of it.
 The PV is the parameter that is to be controlled. To
be controlled, the PV must be capable of being
measured and that measurement converted into a
signal that can be acted on by the controller.
 Devices that measure PV are transducers or sensors. In many
cases, the PV sensor consists of a direct measurement device
called an element and a separate signal processor called a
transmitter.
 The set-point is the desired value of the PV, normally preset
into the control system by an operator, or derived as an output
of another control calculation.
 The error signal is the difference between the PV and the set-
point, and is the basis for control action.
 The controller is the device that processes the error signal,
determines the required control action and provides a control
output Manipulated Variable (MV) to the process.
 The device that converts the control output into control action
is the actuator.
 CONTROL MODES
 In control, there are control systems which can be
discrete or analog, manual or automated, periodic or
continuous.
 There are five basic forms of control available in
Process Control:
 On-Off control: The oldest strategy for control is to use a
switch giving simple on-off control.
 This is a discontinuous form of control action, and is also
referred to as two-position control.
 A perfect on-off controller is 'on' when the measurement is
below the set-point (SP) and the manipulated variable (MV) is
at its maximum value.
 Above the SP, the controller is 'off' and the MV is at a
 Modulating control: If the output of a controller can
move through a range of values, this is modulating
control.
 Modulation Control takes place within a defined operating
range only.
 That is, it must have upper and lower limits.
 Modulating control is a smoother form of control than step
control.
 It can be used in both open loop and closed loop control
systems.
 Open loop control: Open loop control is thus called
because the control action (Controller Output Signal) is
not a function of the PV (Process Variable) or load
changes.
 The open loop control does not self-correct, when these
PV’s drift.
 Feed forward control: Feed forward control is a form
of control based on anticipating the correct
manipulated variables required to deliver the required
output variable.
 It is seen as a form of open loop control as the PV is not
used directly in the control action.
 Closed loop or feedback control: If the PV, the
objective of control, is used to determine the control
INDUSTRIAL CONTROL SYSTEM (ICS)
 Industrial Automation is a discipline that includes knowledge and
expertise from various branches of engineering including electrical,
electronics, chemical, mechanical, communications and more
recently computer and software engineering.
 ICS is a term that encompasses several types of control systems
used in industrial production.
 These include:
 Supervisory Control and Data Acquisition (SCADA) systems,
 Distributed Control Systems (DCS) and
 other smaller control systems configuration such as Programmable Logic
controllers (PLC).
 The application for industrial process control systems are diverse
ranging from simple traffic control to complex electrical grid, from
environmental control system to oil refinery process control.
 The intelligence of these automated systems lies in their
 SCADA is a combination of telemetry and data
acquisition.
 It encompasses the collecting of the information,
transferring it back to the central site, carrying out
any necessary analysis and control and then
displaying that information on a number of
operator screens or displays.
 The SCADA is a centralized system and is
composed of various subsystems like
 Remote Telemetry Units,
 Human Machine Interface,
 Programmable Logic Controller (PLC) and
 Communications networks.
 DCS is a process-oriented system and it treats the
control of the process as its main task, and it
presents data to operators as part of its job.
 Embedded Control: In this control system,
small components are attached to the
industrial computer system with the help of
a network and control is exercised.
 PLC is an industrial computer control system that
continuously monitors the state of input devices
and makes decision based upon a custom program,
to control the state of devices connected as output.
 They are based on the Boolean logic operations
whereas some models use timers and some have
continuous control.
 These devices are computer based and are used to
control various process and equipments within a
facility.
 PLCs control the components in the DCS and SCADA
systems but they are primary/main components in
smaller control configurations.
 User Configuration Open System (UCOS) is a
control system that employs object-oriented
technique at every level of its system architecture,
and includes a number of subsystems which
segment the functionality of UCOS.
 The main subsystems include:
 Engineering Workstation Subsystem (EWS),
 Operator Workstation Subsystem(OWS), and
 Field Control Unit (FCU) Controller Subsystem.
 The subsystems communicate via a Control
Network.
 END