DCS Control System

A correctly designed DCS control system is essential for the safe and efficient
operation of a process plant. Process Technical Services can provide qualified a
nd experienced instrument and control system engineers and technicians that will
review the P&I diagrams in detail to determine if the DCS control system will m
eet the needs of your operations.
Particular attention is to be paid to DCS control system feed-forward, feedback,
and cascade control systems. Although final tuning of DCS control system contro
llers can only be done with the plant in operation, the initial setting of the c
ontroller tuning coefficients is essential for a smooth start-up of the process.
PTS engineers and technicians utilize results from dynamic model simulations, p
rocess flowsheets, and equipment sizes to estimate the impact of dead-time and e
quipment holdup times on DCS control system tuning coefficients for the various
processing units throughout the process.
The process variables sent to a DCS control system include pressure, temperature
, level, and flow sensors. PTS' qualified and experienced instrument and control
system engineers and technicians can provide valuable insights and consultation
regarding the reliability and accuracy of a variety of sensors. Their advice ma
y help avoid installation of field instruments of questionable reliability and a
ccuracy during the installation phase of a project and possibly avoid countless
hours of poor operation, upsets and downtime after the process is commissioned.
PTS experienced instrument technicians can pre-commission DCS controls and provid
e a preliminary set of parameters that will provide for a smoother and more orde
rly start-up of process units utilizing accurate P&IDs.
Essential DCS control system elements in most modern process control system desi
gns include on-line and in-line process analyzers. An on-line analyzer is one th
at processes a sample extracted from the process and thus requires an automatic
sampling system to extract material from the process for analysis such as a gas
chromatograph (GC). Another method is the use of an in-line process analyzer wit
h the sensor inserted directly into the process material. A pH probe is an examp
le of an in-line analyzer. Another type of in-line analyzer might require a side
stream that causes process material to flow through a small bypass line.
It is important that the process design criteria specified by the DCS control sy
stem engineers be strictly followed during the procurement process. There is a s
trong incentive for the equipment purchasers to buy from the lowest qualified bi
dder, but one who has not necessarily met all of the design criteria. This can b
e a particular problem with process control valves. PTS control system quality a
ssurance (QA) technicians can insure that all control system equipment being pur
chased meets all of the design specifications.
Finally, even with a good design, and equipment that meets all the design specif
ications, there is still one area of activity where problems can develop. That i
s during the installation phase. Experienced and professional PTS Quality Contro
l (QC) technicians can monitor the installation process from start to finish ens
uring that the DCS control system installation follows industrial standards and
meets all of the design specification.
A well designed DCS control system, implemented with care and skill by PTS can p
rovide years of safe, efficient, and effective control of your process.