Introduction to

Industrial Process

CHAPTER 4
Control Systems

 Distributed Control System (DCS)

 Supervisory Control and Data
Acquisition (SCADA)
 Safety Interlock System (SIS)

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 OBJECTIVES
After you study this chapter, you should be able to
1. Explain the working principles of common
industrial control systems such as DCS and SCADA.
2. Explain the working principles of common
industrial control systems such as SCADA.
3. Explain the working principles of common
industrial control systems such as interlock system.

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 Introduction
• Industrial control systems has undergone extensive
changes in the past 30 years with advancement of
microprocessors and software technology.
• Digital control system have largely replaced traditional
analog instrument panels – allowing computers to
control process equipments while operators monitoring
process conditions.
• Distributed Control System (DSC), Supervisory Control
and Data Acquisition (SCADA), and Interlock System are
digital control systems that are widely used in industry.

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 Distributed Control System (DCS)
• Control system in which the controller elements
(transducer, transmitter, controller, final control devices)
are not central in location (like the brain) but are distributed
throughout the system with each component sub-system
controlled by one or more controllers.
• However, the entire system of controllers is connected by
networks for communication and monitoring.

Why DCS ?
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• 1st generation of DCS (1970s) was designed to
replace the single-mainframe computers (host).
• Problem occur when the host computer fail – lead to
entire system failure.
• So, in DCS, host computer functions are
distributed/divided functionally and are
implemented in separate computers/ stations, but
sharing the same data (by networking).
• If one station fail, the interface to the process still
can be maintained by other station within the
network.
• Same principle also being used in business/ banking
data centers or server facilities.
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 Single
Computer

Mainframe computer 6
 DCS components
1. Control network – communication link (coaxial cable or fiber-optic)
between individual components within the network. Dual redundant
highway cables normally used to reduce the possibility of link failure.
2. Workstations – most powerful computer in the DCS, capable of
performing functions not normally available in other units. It acts as
database server. All actions/instructions can be override on this
workstations.
3. Real time clocks – process control systems must respond in real-
time to maintain accuracy and efficiency.
4. Operator stations – typically consists of color graphics monitors with
special keyboards to perform dedicated functions. Operators can
supervise and control processes from these workstations.
5. Engineering workstations – similar to operator stations but can also
be used as programming terminals to develop system software. This
arrangement reduces compatibility problems between the
development and application environments for the system software.
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 DCS components
6. Remote control units (RCU) – used to implement basic control
functions such as PID controller. Some RCUs is configured to
acquire or supply set points to single-loop controller. Radio telemetry
(wireless) is also installed to communicate with multiplexer MUX
units located at great distances.
7. Application stations – separate computers that run application
software such as databases, spreadsheet, financial software, and
simulation software via an OPC (standard interface like windows)
interface. Is the only computers in entire DCS that connected to the
“outside world” via internet / internet protocol (IP) address. This
station can communicate with main database contained in on-line
mass storage systems.
8. Mass storage devices – typically hard disk drives to store active
and archive data.
9. Field buses/smart device – field-mounted devices that support
digital communication of the process I/O (input/output).
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Entire Distributed Control System (DSC)
 Alarm
Control
System

Distributed Control System (DCS) – control room scene 10

Mass storage facility

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 Multiplexer (MUX)
a device that performs multiplexing; it selects one of many
analog or digital input signals and outputs that into a single line.

Signal A
Signal B

Signal C

Signal D

Signal E

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Typical I/O ports of PC

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 Plant Area – valves, transmitters
I/O cards/ports

Engineering
Workstation

Multiplexer
(MUX) hub

I/O cards are specific to device requirements

•4-20 mA input, 4-20 mA output
•24 VDC input, 24 VDC output, etc.
Operator workstations
•Foundation Fieldbus Interface

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 SCADA

• SCADA is the acronym for Supervisory Control

And Data Acquisition
• SCADA systems are used to monitor or to
control chemical, physical or transport
processes, in municipal water supply systems,
to control electric power distribution and
generation, gas and oil pipelines, and other
distributed processes

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SCADA architecture

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 Master Station
•The master station supports the following components and
functionality:
•The Engineering Workstation (EWS) is for project development,
including configuration of graphics, logic, alarms, security, etc.
Typically, the EWS is a PC running Windows 2000/XP.
•The Operator Workstation (OWS) provides the operator interface,
including color graphics, faceplates, alarms, logging, trends,
diagnostics, etc. The EWS includes an OWS for testing and
troubleshooting. Typically, the OWS is a PC running Windows
2000/XP.
•The Process Historical Archiver (PHA) stores and retrieves
historical data collected by the FCU, microFCU, SDS, or any other
intelligent device in the system. The PHA can run standalone or can
share an OWS workstation. Typically, the PHA is a PC running
Windows 2000/XP.
•The SCADA Data Server (SDS) interfaces UCOS to PLCs, Fieldbus
technologies, RTUs, PLC I/O, and other third-party devices. The SDS
acts as a data gateway allowing UCOS to work with just about any
device you can think of
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SCADA architecture

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Remote Terminal Unit (RTU)

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 Task of the Interlock System
 Guarantee operator / persons safety
 Prevent any damage from the cost expensive
components/instrument of process plant.

Action Taken:
 Closing or opening the gateway of the power
supply / valve
 Giving alarm and dealing with error

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 Safety Interlock System
• The automation strategy is usually simple, for example,

If L123 < L123min; then, reduce fuel to zero

How do we
steam
automate this SIS
PC when PC is adjusting
the valve?

LC

water

fuel

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 If L123 < L123min; then, reduce fuel to zero

LS = level switch, note that separate sensor is used

s = solenoid valve (open/closed) fc = fail closed

steam
15 psig
PC

LC LS s s

water

fuel

fc fc

Extra valve with tight shutoff

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