PRESENTATION ON

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The control system is that means by which any quantity of interest in a
machine, mechanism or other equipments is maintained or altered in
accordance with ad-desired manner.

REFERENCE ACTUATING CONTROLLED CONTROLL

CONTROLLER SIGNAL
INPUT ELEMENT ED OUTPUT

Examples-Traffic Light Controller, Electric Washing Machine ,Bread Toaster

etc.
CLOSE LOOP CONTROL SYSTEM

Reference Signal
Desired
Output
Error Signal CONTROLLED
Input CONTROLLER
ELEMENT

Feedback Signal

Feedback
Element

Example-Missile Launching System, Human Respiratory System,

Autopilot System etc.
ANALOG CONTROL SYSTEM
Operational Amplifier
Transmitter 1 to 5V DC
Signal
Conversion

4-20 mA DC
I/P

Set Point

Final Control Element

Examples- Volume Control of Radio, Room Temperature Control With

Thermostat etc.
DIGITAL CONTROL SYSTEM

Examples-PLC, DCS, SCADA, Embedded System etc.

 TYPES OF DIGITAL CONTROL

Centralized Control System Distributed Control System

PV1 MV1

PV2 Centralized MV2

PV3 Processing MV3

PV4 MV4
Unit
PVn MVn
CPU
SV1 SV2 SV3 SV4 SVn
Drawbacks of CCS:

•If the CPU fails the entire plant gets affected.

•Redundancy concept is not available.

Distributed Control System is a specially designed control system used to control
complex, large and geographically distributed applications in industrial processes. In
this, controllers are distributed throughout the entire plant area. These distributed
controllers are connected to both field devices and operating PCs through high speed
communication networks.

Example scenarios where a DCS might be used include:

• Chemical Plants
• Petrochemical (Oil) And Refineries
• Pulp And Paper Mills
• Boiler Controls And Power Plant Systems
• Nuclear Power Plants
• Environmental Control Systems
• Water Management Systems
1. Field devices

2. Input/output modules

3. Controllers

4. Human machine interface (HMI)

5. Control Engineering
Field devices control local operations such as opening and closing valves ,
breakers, collecting data from sensor systems and monitoring the local
environment for alarm conditions.

Examples- Transmitter, Electrical Drives etc.

I/O modules are building blocks of industrial control system used in end
equipments such as PLC, PAC, DCS. Digital input modules measure and
capture digital input signals from a wide variety of sensors like proximity
switches, limit switches and push button switches. Input typically are 0-24V with
tolerances up to 30V.

It is a versatile method for interconnecting real world analog and digital
signals to data acquisition, monitoring, or control systems. All modules provide
an optically isolated barrier between sensitive microprocessor or digital logic
circuits and field power devices.

Types of Module :

• Digital Input Module

• Digital Output Module

• Digital Input Module-

Digital input modules are used to monitor the status of a load or a sensor (such as a limit
switch, pressure switch, or temperature switch). The output of these modules is a logic
level signal which corresponds to the status of the device being monitored. A high level
output signal indicates the load is off (the switch is open). A low level output signal
indicates the load is on (the switch is closed)

• Digital Output Module-

Digital output modules are used to switch AC and DC loads such as solenoids, motors,
or lamps from logic signal levels.
A controller is a comparative device that receives an input signal from a
measured process variable, compares this value with that of a predetermined
control point value (set point), and determines the appropriate amount of output
signal required by the final control element to provide corrective action within a
control loop.

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 I/O
modules. These modules are extendable according to the number of inputs
and outputs. It collects the information from discrete field devices and sends
this information to operating and engineering stations.
Redundant Fast
Ethernet Network (100 mB)

Redundant
Existing Cabinet Ovation
and Field Terminations Controller

Q-line I/O

Controllers Setup
The user interface (UI), in the industrial design field of human–machine
interaction, is the space where interactions between humans and machines
occur. The goal of this interaction is to allow effective operation and control of
the machine from the human end, whilst the machine simultaneously feeds
back information that aids the operators decision making process.

Generally, the goal of user interface design is to produce a user interface

which makes it easy (self explanatory), efficient, and enjoyable (user friendly) to
operate a machine in the way which produces the desired result. This generally
means that the operator needs to provide minimum input to achieve the desired
output, and also that the machine minimizes undesired outputs to the human.
Real Time HMI
Control engineering or control systems engineering is the engineering
discipline that applies control theory to design systems with desired behaviors.
The practice uses sensors to measure the output performance of the device
being controlled and those measurements can be used to give feedback to the
input actuators that can make corrections toward desired performance.

Electrical circuits, digital signal processors and microcontrollers can all be

used to implement control systems.
• DCS’s are designed to control processes. • PLC is in discrete control of manufacturing
processes.

• DCS are made available to the user in a • In PLC complete programming has to be
way that only configuration in form of a implemented using any one of the different
Functional Block has to be carried out. languages available in the system.

• Scan time of the DCS is comparatively • Scan time of the PLC is lower.
higher.

• A DCS has inherently multiple processor • This is possible now in PLC but more efforts
capability thus Engineer has to put in less have to be put in.
efforts for intercommunication of the
processors.

• A DCS takes much longer to process data, • Response times of 1/10 of a second
so it’s not the right solution when response make the PLC an ideal controller for near
times are critical. In fact, safety systems real time actions such as a safety shutdown
require a separate controller. or firing control.

• Highly redundant. • Redundancy is not possible at greater levels.