Industrial Resources, Inc.
Power System Training
Plant Control Systems
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In this module we will:
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Describe the typical Distributed Control System
capabilities.
Describe how power plant processes are accessed
and controlled from the DCS controllers.
Describe how DCS control system diagrams are
used to interpret control system loops.
Describe basic Unit loading and control features.
This presentation is designed to provide you the
information you need to understand and operate
the Distributed Control System. You should
view all slides and read and study the
information presented.
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MAIN MENU
To Start, Click on one of the buttons below
You Should Start The Program In The System Function Section.
System
Function
Process
Control
Control
Diagrams
Work
Stations
Unit
Control
Review
Questions
Review
Questions
Review
Questions
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Questions
Review
Questions
If you exit the program and want to re-start at a different
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appropriate button.
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Distributive Control System Function
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The Distributive Control System controls plant systems and equipment.
Motors
Steam Turbine
Valves
Generator and Exciter
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Plant Control System Overview
The DCS System collects and stores three (3)
types of data received from plant processes:
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Analog data
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Digital data
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Calculated data
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Analog Data
Temperature
Transducer
Pressure Transducer
Flow
Transducer
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Digital Data
Motors “ON”
Motor
“OFF”
Valve Closed
Limit Switch
Valves Open
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Calculated Values
Water
Temperature
Water Flow
AIN
AIN
PID
PID
AOUT
Valve
Position
Signal
Temperature/Density Compensated Water
Flow Compound
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Provides Data Access
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CRT Alarms
Alarms
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Allows for Control
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Historical Data Retrieval
Deaerator Storage Tank
Level Trend
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Control System Data Flowpath
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Node Bus
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Control Processors
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Work Station
Work
Station
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Work Station
CRTs (Monitors)
Trackball
Keyboard and
Annunciator Keypad
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Communication
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Types of Displays
Several types of displays are accessible from
the control system. These include:
P&ID Displays
Motor Control Displays
Process Control Displays
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P&ID Displays
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Motor Control Displays
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Process Control Displays
Measured
Bias
Output
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Review Questions
What three types of data received
from plant processes are collected
and stored by the DCS?
Review
What is the typical origin of Analog data?
Review
What is the function of the “node” bus?
Review
Which type system display represents
system piping and instrumentation?
Review
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Process Control Basics
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Control Processor
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Control Loops Include:
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Measured Variable (MEAS)
Sensor
Controller
Final Control element.
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Relay Control
Start/Stop Controls
Open/Close Controls
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Modulating Control
Water
Temperature
AIN
PID
Water
Flow
AIN
PID
AOUT
Valve
Position
Signal
Control Loop
Controller
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Control Processor
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DCS Control
Two (2) types of control signals
route to and from the DCS System
Controller:
• Digital Signals (Zero and One)
• Analog Signals
(4 – 20 Ma)
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Computer Logic Blocks
There are several types of logic blocks used to
convert analog signals to digital signals for use
by the DCS. These include:
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AIN Block
AOUT Block
CIN Block
LLAG Block
PID Block
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AIN and AOUT Blocks
AIN
Temperature Transducer
AOUT
Valve
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CIN Block
CIN
Breakers
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Lead Lag (LL Block)
Gland Exhaust Fans
Select A
LLAG
Select B
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PID Block
3-element
Drum Level
Feedwater
Flow
Steam Flow
PID
Valve
Position
Signal
Feedwater Master
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Compounds
Water
Temperature
Water Flow
AIN
AIN
PID
PID
AOUT
Valve
Position
Signal
Temperature/Density Compensated Water
Flow Compound
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Review Questions
What is process control?
Review
What is an Algorithm?
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What two (2) types of control signals
route to and from the DCS System Controller?
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What is a Compound?
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Control Diagrams
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Control Diagrams
Control Diagrams provide the following types of
information:
• Control system component arrangement
• Control system component function indicating
the signal conditioning
• Operating characteristics of the control system
• Operator interface devices
• Setpoints, transfer points, permissives, Alarms
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Control Diagram Symbols
The following types of control symbols
are found on Control Diagrams:
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Transmitter and/or sensing elements
Final Control Element/Operator
Converters
Signal Processors
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Sensing Elements and Symbols
PT
LT
Pressure
Transducer
Pressure
Transmitter
Level Sensors
Level Transmitter
FT
Pitot Tubes
Flow Transmitter
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Final Control Element
Valve
Positioner
Motor Controller
Damper
Positioner
Hydraulic Coupling Controller
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Converters
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Current to digital converter (I/D)
Thermocouple to digital converter (MV/D)
Resistance to digital converter (R/D)
Digital to current converter (D/I)
Current to pneumatic converter (I/P)
Contact to digital converter (C/D)
Digital to contact converter (D/C)
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Signal Processors
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Single digital input conversion true = 1 (CIN)
Digital input conversion true = 0 (CIN) not
Single analog input conversion (AIN)
Analog output conversion (AOUT)
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Control Diagram Symbols
Summer
Comparator
Multiplier
Averaging
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Control Diagram Symbols
Proportional Controller
Derivative Rate Controller
Integral/Reset Controller
Multi-function Segment
Characterizer
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Control Diagram Symbols
Time Function Characterizer
Signal Selector
Bias Unit
Signal Limiter
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Control Diagram Symbols
Transfer or Trip Relay Switch
Manual Output Driver
Analog Signal Generator
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Logic Gates and Truth Tables
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Building Blocks of Digital Logic
Most have 2 or more inputs
Operate in Binary
Low State is 0 Volts
High State is 5 Volts
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“AND” GATE
Input 1
Output
Input 2
“AND” Gate
Input 1
Input 2
Output
0
0
0
0
1
0
1
0
0
1
1
1
Truth Table
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“OR” GATE
Input 1
Input 1
Input 2
Output
0
0
0
0
1
1
1
0
1
1
1
1
Output
Input 2
“OR” Gate
Truth Table
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“NOT” GATE
Input
Outp
ut
“NOT” Gate
Input
Output
1
0
0
1
Truth Table
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SET/RESET and TIME DELAY
TD
On
SET/RESET
TD
Off
TIME DELAY On/Off
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Review Questions
What types of information are provided on
Control Diagrams?
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Name 3 types of sensing elements.
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Name 3 types of final control elements.
Which type logic gate functions to reverse
the logic state?
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Work Station Environment
CRTs (Monitors)
Trackball
Keyboard and
Annunciator Keypad
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Historical Trend/Retrieval
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Operator Controllable Faceplates
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Controller and Trend Graphic
Deviation from Level
Setpoint
Level Setpoint
Valve Output
Percent/OPEN
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Face Plate Upper Portion
Controller
Name
Auto/Manual
Soft Keys
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Face Plate Lower Portion
High and Low Markers
Deviation from Level
Setpoint
Measured Variable
Block Setpoint
Output Signal
Level Setpoint
Valve Output
Percent/OPEN
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Additional Control
Letters
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Control Letters
Letter
Description
A
Indicates the block is in Automatic
M
Indicates the block is in Manual
L
Indicates the block is in local control/controlled by
the operator
R
Indicates the block is remotely controlled/controlled
internally by the control system
T
Indicates the block is tracking the output and trying
to maintain setpoint
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Control Block Values
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Control Block Values Abbreviations
Abbrevi
ation
Description
MEAS
Indicates the value of the measured variable. MEAS is in blue, the
same color as the vertical Measured Variable bar. Measurement
increments for the variable are provided.
SPT
Indicates the controller setpoint. SPT is in magenta, as is the
vertical Setpoint Bar. The numerical representation for the
setpoint is provided.
BIAS
If Bias control is available, there may be BIAS listed rather than
SPT.
OUT
Indicates the controller output, with the actual value indicated. The
OUT is represented in white, as is the vertical Output Bar.
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Soft Keys
Soft Keys
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Soft Key Functions
Alarm
Acknowledge Key
Block Detail
Display Key
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Soft Key Functions
Up Arrow
Key
Down Arrow
Key
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Soft Key Functions
Double Up Arrows
Key
Double Down
Arrows Key
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Soft Keys
Box Key
Side
Arrows
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Trend Graphs
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Trend Graph Information
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Trend Graphs
Days
Hours
Minute
s
Second
s
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Trend Graphs
Pause Bar
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Alarm Display
Alarm Display
Date
Time
Alarm
Desc.
Engr
Units
Value
Alarm Alarm Alarm
Limit Type Priority
ACK
State
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Alarm Display Screen
Alarm Display
Date
Time
Alarm
Description
Engineering
Units
Value at
time of
alarm
Alarm
Limit
050106
0807
MS temp Hi
DegF
1015
050106
0803
MS temp Hi
DegF
1010
Alarm
Type
Alarm
Priority
ACK
State
1010
2
UnAck
1010
2
Ack
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Alarm Priority
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Priority 1
Priority 2
Priority 3
Priority 4
Priority 5….
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Alarm Priority (typical Definitions)
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Priority 1 - when active, alerts the operator to a Loss of the Unit or unsafe
operating condition. This priority alerts the operator to a time-critical
condition for which immediate action is required to prevent a loss of the unit,
operating capacity, personal injury or which may result in equipment
damage.
Priority 2– when active, alerts the operator to a condition which results in a
loss of unit load (MW). This priority alerts the operator to a condition
requiring immediate investigation and operator action to prevent a loss of
generation, an environmental exceedance, or impending condition
degradation to a Priority 1.
Priority 3 – when active, alerts the operator to a condition that can result in
the loss of a major piece of equipment. This priority requires the operator to
monitor the condition/equipment and take corrective action and to report the
condition to the associated maintenance group as required.
Priority 4 – when active, alerts the operator to a condition that can result in
the loss of a piece of minor equipment. Typically this alarm occurs on loss
of process feedback or in the event of a disparate device signal (bad
quality).
Priority 5– may be reserved for Maintenance Alarms
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Alarm Display
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Most Recent Alarms Display
New Alarms Display
Unacknowledged Return Alarms Display
Acknowledged Alarms Display
Alarm History Display
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Review Questions
Which portion of the control system collects,
stores, processes and archives process data
from the control system to provide data for trends,
logs, and reports?
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What types of information/controls can be
found on the sections of the Group Display?
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Basic Unit loading and Control
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Megawatt Demand Signal
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Unit Demand Limiter
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Unit Demand Limiter
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Runbacks
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LMCC
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Operator Adjustable Setpoints
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LMCC Controls
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Control Modes
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LMCC Controls
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Review Questions
What type of control between the boiler
and turbine/generator produces the
best load response?
What information is used to set upper
and lower megawatt limits on the
Control System?
What is the function of the LMCC “HOLD” Button?
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After you have answered these question you may exit the program, or
continue to to the next 6 slides for a list all the IRI Maintenance Modules
which are available.
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Electrical Maintenance Modules
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High Intensity Discharge Lighting (EM01)
Conduit Bending (EM02)
Battery System (EM03)
Medium Voltage Overhead Distribution Lines (EM04)
Medium Voltage Underground Distribution Lines (EM05)
(AV) Multiamp SR90 Relay Tester (EM06
Protective Relays (EM07)
Kilowatt-hour Meters (EM08)
Emergency Generator EM09)
Liquid Filled Transformer (EM10)
Medium Voltage Switchgear (EM11)
Primary Current Injection (AVO) (EM12)
Medium voltage Drawout Circuit Breaker (EM13)
Medium Voltage Vacuum Circuit Breaker (EM14)
Low Voltage Drawout Circuit Breaker (EM15)
Power Quality Monitoring Equipment (EM16)
Automatic Transfer Switches (EM17)
Manual Wrap-Around Bypass Switches (EM18)
Cable Splicing and Termination (EM19)
Cable Pulling and Installation (EM20)
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I & E Maintenance Modules
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Hart Communicator (IE01)
Protective Relays (IE02)
DC Motors (IE03)
Three-Phase Motors (IE04)
Cable and Wire Terminations (IE05)
Low Voltage Breakers (IE06)
Medium Voltage Breakers (IE07)
Variable Frequency Drives (IE08)
Allen Bradley PLC Model 5/30 (IE09)
Station Batteries (IE10)
Bench Grinder (IE11)
Drill Press (IE 12)
Pressure Switch (IE-13)
Emission Monitoring Equipment (IE14)
Flow Transmitters (IE15)
Pressure Transmitters (1E16)
Level Transmitters (IE17)
Temperature Transmitters (IE18)
Valve Pneumatic Positioners (IE19)
Electrical Positioners (IE20)
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Mechanical Maintenance Modules
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Air Compressor Maintenance (MM01)
Bobcat-Loader (MM02)
Bobcat-Sweeper (MM03)
Bobcat-Backhoe (MM04
Pipe Locator (MM05)
Explosion Meter (MM06)
Valves (MM07)
Bearings and Seals (MM08)
Pedestal Grinders (MM09)
Metal Cutting Band Saw (MM10)
Drill Press (MM11)
Steam Trap (MM12)
Portable Threader (MM13)
Hydraulic Steel Pipe Cutters (MM14)
Ultrasonic Thickness Gauge (MM15)
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Coupling and Shaft Alignment (MM16)
Oxy Acetlene Cutting (MM17)
Water Meter Testing (MM18)
Centrifugal Pumps *(MM19)
Silver Solder (MM20)
Pipe Cutter (MM21)
Tubing Cutter (MM22)
Sewer Auger (MM23)
Backhoe Jackhammer (MM24)
Dump Truck (MM25)
Fire Hydrant (MM26)
Trench Shoring (MM27)
Water Main Repair/Replacement (MM28)
Backhoe Loader (MM29)
Truck Mounted Valve Operator (MM30)
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Machine Shop Modules
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Manual Lathe “DRO” (MS01)
Manual Mill “DRO” (MS02)
Automatic Surface Grinder (MS03)
Overhead Hoist (MS04)
Bolt Threading Machine (MS05)
Sander MS 06 Shears (MS07)
Sheet Metal Brake (MS 08)
Radial Drill (MS09)
Computer Controlled Mill “CNC” (MS-10)
Dry Blast Cabinet (MS-11)
Presses/Floor and Arbor (MS12)
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System Maintenance Modules
• Single-Stage Centrifugal Pumps (SM06)
• Soot Blower Maintenance (SM-07)
• Oxy-Acetylene Cutting (SM08)
• Pulverizer Maintenance MPS 89 (SM09)
• Air Compressor Maintenance (SM10)
• Conveyor Belt Maintenance (SM12)
• Chemical Feed Pump (SM13)
• Multi-stage Vertical Condensate Pump (SM-14)
• FD Fans (SM-15)
• Fuel / Coal Feeders (SM-16)
• Gauge Glass Maintenance (SM-17)
• Heat Exchangers (SM-18)
• Dry Vacuum Exhauster Maintenance (SM19)
• Riley Ball Tube Mill Maintenance (SM20)
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Industrial Resources, Inc.
A Training Services Company
For More Information about our training
Programs please contact IRI Sales at
228 392 3973 or Indresinc@aol.com
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Plant Control System Overview
The DCS System collects and stores three (3)
types of data received from plant processes:
•
Analog data
•
Digital data
•
Calculated data
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Questions
Analog Data
Temperature
Transducer
Pressure Transducer
Flow
Transducer
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Questions
Node Bus
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Questions
P&ID Displays
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Questions
Process Control Basics
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Questions
Control Processor
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Questions
DCS Control
Two (2) types of control signals
route to and from the DCS System
Controller:
• Digital Signals (Zero and One)
• Analog Signals
(4 – 20 Ma)
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Questions
PID Block
3-element
Drum Level
Feedwater
Flow
Steam Flow
PID
Valve
Position
Signal
Feedwater Master
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Questions
Control Diagrams
Control Diagrams provide the following types of
information:
• Control system component arrangement
• Control system component function indicating
the signal conditioning
• Operating characteristics of the control system
• Operator interface devices
• Setpoints, transfer points, permissives, Alarms
Return to Review
Questions
Sensing Elements and Symbols
PT
LT
Pressure
Transducer
Pressure
Transmitter
Level Sensors
Level Transmitter
FT
Pitot Tubes
Flow Transmitter
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Questions
Final Control Element
Valve
Positioner
Motor Controller
Damper
Positioner
Hydraulic Coupling Controller
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Questions
“NOT” GATE
Input
Outp
ut
“NOT” Gate
Input
Output
1
0
0
1
Truth Table
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Questions
Historical Trend/Retrieval
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Questions
Controller and Trend Graphic
Deviation from Level
Setpoint
Level Setpoint
Valve Output
Percent/OPEN
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Questions
Basic Unit loading and Control
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Questions
Megawatt Demand Signal
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Questions
LMCC Controls
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Questions