Exit Program

Plant Control Systems

Industrial Resources, Inc.
Power System Training
Exit Program
In this module we will:
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.
Exit Program
MAIN MENU
To Start, Click on one of the buttons below
You Should Start The Program In The System Function Section.

System
Function
Control
Diagrams
Work
Stations
Unit
Control
Review
Questions
Review
Questions
Review
Questions
Review
Questions
If you exit the program and want to re-start at a different
section or want to see the review questions, click on the
appropriate button.
Process
Control
Review
Questions
Exit Program
Distributive Control System Function
Exit Program
The Distributive Control System controls plant systems and equipment.
Motors Valves
Steam Turbine Generator and Exciter
Exit Program
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

Exit Program
Analog Data
Pressure Transducer
Temperature
Transducer
Flow
Transducer
Exit Program
Digital Data
Limit Switch
Valves Open
Valve Closed
Motors ON
Motor
OFF
Exit Program
Calculated Values

Water
Temperature

AIN

PID


Water Flow

AIN

PID

AOUT

Valve
Position
Signal
Temperature/Density Compensated Water
Flow Compound
Exit Program
Provides Data Access
Exit Program
CRT Alarms
Alarms
Exit Program
Allows for Control
Exit Program
Historical Data Retrieval
Deaerator Storage Tank
Level Trend
Exit Program
Control System Data Flowpath
Exit Program
Node Bus
Exit Program
Control Processors
Exit Program
Work Station
Work
Station
Exit Program
Work Station
CRTs (Monitors)
Trackball
Keyboard and
Annunciator Keypad
Exit Program
Communication
Exit Program
Types of Displays
Several types of displays are accessible from
the control system. These include:
P&ID Displays
Motor Control Displays
Process Control Displays

Exit Program
P&ID Displays
Exit Program
Motor Control Displays
Exit Program
Process Control Displays
Measured
Bias
Output
Exit Program
Review Questions
What three types of data received
from plant processes are collected
and stored by the DCS?

What is the typical origin of Analog data?

What is the function of the node bus?

Which type system display represents
system piping and instrumentation?

Review
Review
Review
Review
Exit Program
Process Control Basics
Exit Program
Control Processor
Exit Program
Control Loops Include:
Measured Variable (MEAS)
Sensor
Controller
Final Control element.


Exit Program
Relay Control
Start/Stop Controls Open/Close Controls
Exit Program
Modulating Control
Water
Temperature
AIN PID
Water
Flow
AIN PID AOUT
Valve
Position
Signal
Control Loop
Controller
Exit Program
Control Processor
Exit Program
DCS Control
Digital Signals (Zero and One)
Analog Signals (4 20 Ma)
Two (2) types of control signals
route to and from the DCS System
Controller:
Exit Program
Computer Logic Blocks
AIN Block
AOUT Block
CIN Block
LLAG Block
PID Block
There are several types of logic blocks used to
convert analog signals to digital signals for use
by the DCS. These include:
Exit Program
AIN and AOUT Blocks
AIN
AOUT
Temperature Transducer
Valve
Exit Program
CIN Block
CIN
Breakers
Exit Program
Lead Lag (LL Block)
Gland Exhaust Fans
LLAG
Select A
Select B
Exit Program
PID Block
3-element
Feedwater Master
PID
Steam Flow
Feedwater
Flow
Drum Level
Valve
Position
Signal
Exit Program
Compounds

Water
Temperature

AIN

PID


Water Flow

AIN

PID

AOUT

Valve
Position
Signal
Temperature/Density Compensated Water
Flow Compound
Exit Program
Review Questions
What is process control?



What is an Algorithm?



What two (2) types of control signals
route to and from the DCS System Controller?



What is a Compound?
Review
Review
Review
Review
Exit Program
Control Diagrams
Exit Program
Control Diagrams
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
Control Diagrams provide the following types of
information:
Exit Program
Control Diagram Symbols
Transmitter and/or sensing elements
Final Control Element/Operator
Converters
Signal Processors
The following types of control symbols
are found on Control Diagrams:
Exit Program
Sensing Elements and Symbols
Pitot Tubes
Flow Transmitter
FT
Pressure
Transducer
Pressure
Transmitter
PT
Level Sensors Level Transmitter
LT
Exit Program
Final Control Element
Valve
Positioner
Damper
Positioner
Motor Controller Hydraulic Coupling Controller
Exit Program
Converters
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)
Exit Program
Signal Processors
Single digital input conversion true = 1 (CIN)
Digital input conversion true = 0 (CIN) not
Single analog input conversion (AIN)
Analog output conversion (AOUT)

Exit Program
Control Diagram Symbols
Summer Comparator
Multiplier Averaging
Exit Program
Control Diagram Symbols
Proportional Controller Integral/Reset Controller
Derivative Rate Controller Multi-function Segment
Characterizer
Exit Program
Control Diagram Symbols
Time Function Characterizer Bias Unit
Signal Selector Signal Limiter
Exit Program
Control Diagram Symbols
Transfer or Trip Relay Switch Manual Output Driver
Analog Signal Generator
Exit Program
Logic Gates and Truth Tables
Building Blocks of Digital Logic
Most have 2 or more inputs
Operate in Binary
Low State is 0 Volts
High State is 5 Volts
Exit Program
AND GATE
AND Gate
Input 1 Input 2 Output
0 0 0
0 1 0
1 0 0
1 1 1
Truth Table
Input 1
Input 2
Output
Exit Program
OR GATE
Input 1
Input 2
Output
Input 1 Input 2 Output
0 0 0
0 1 1
1 0 1
1 1 1
OR Gate
Truth Table
Exit Program
NOT GATE
Input
Outp
ut
NOT Gate
Input Output
1 0
0 1
Truth Table
Exit Program
SET/RESET and TIME DELAY
SET/RESET
TD
On
TD
Off
TIME DELAY On/Off
Exit Program
Review Questions
What types of information are provided on
Control Diagrams?


Name 3 types of sensing elements.


Name 3 types of final control elements.


Which type logic gate functions to reverse
the logic state?
Review
Review
Review
Review
Exit Program
Work Station Environment
CRTs (Monitors)
Trackball
Keyboard and
Annunciator Keypad
Exit Program
Historical Trend/Retrieval
Exit Program
Operator Controllable Faceplates
Exit Program
Controller and Trend Graphic
Level Setpoint
Deviation from Level
Setpoint
Valve Output
Percent/OPEN
Exit Program
Face Plate Upper Portion
Controller
Name
Auto/Manual
Soft Keys
Exit Program
Face Plate Lower Portion
Level Setpoint
Deviation from Level
Setpoint
Valve Output
Percent/OPEN
Measured Variable
Block Setpoint
Output Signal
High and Low Markers
Exit Program
Additional Control
Letters
Exit Program
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
Exit Program
Control Block Values
Exit Program
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.
Exit Program
Soft Keys
Soft Keys
Exit Program
Soft Key Functions
Alarm
Acknowledge Key
Block Detail
Display Key
Exit Program
Soft Key Functions
Up Arrow
Key
Down Arrow
Key
Exit Program
Soft Key Functions
Double Up Arrows
Key
Double Down
Arrows Key
Exit Program
Soft Keys
Box Key
Side
Arrows
Exit Program
Trend Graphs
Exit Program
Trend Graph Information
Exit Program
Trend Graphs
Days Hours Minute
s
Second
s
Exit Program
Trend Graphs
Pause Bar
Exit Program
Alarm Display
Alarm Display
Date Time Alarm
Desc.
Engr
Units
Value Alarm
Limit
Alarm
Type
Alarm
Priority
ACK
State
Exit Program
Alarm Display Screen
Alarm Display
Date Time Alarm
Description
Engineering
Units
Value at
time of
alarm
Alarm
Limit
Alarm
Type
Alarm
Priority
ACK
State
050106 0807 MS temp Hi DegF 1015 1010 2 UnAck
050106 0803 MS temp Hi DegF 1010 1010 2 Ack
Exit Program
Alarm Priority
Priority 1
Priority 2
Priority 3
Priority 4
Priority 5.
Exit Program
Alarm Priority (typical Definitions)
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
Exit Program
Alarm Display
Most Recent Alarms Display
New Alarms Display
Unacknowledged Return Alarms Display
Acknowledged Alarms Display
Alarm History Display
Exit Program
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?



What types of information/controls can be
found on the sections of the Group Display?

Review
Review
Exit Program
Basic Unit loading and Control
Exit Program
Megawatt Demand Signal
Exit Program
Unit Demand Limiter
Exit Program
Unit Demand Limiter
Exit Program
Runbacks
Exit Program
LMCC
Exit Program
Operator Adjustable Setpoints
Exit Program
LMCC Controls
Exit Program
Control Modes
Exit Program
LMCC Controls
Exit Program
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?
Review
Review
Review
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.
Exit Program
Electrical Maintenance Modules
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)

Exit Program
I & E Maintenance Modules
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)
Exit Program
Mechanical Maintenance Modules

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)
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)


Exit Program
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)

Machine Shop Modules
Exit Program
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)
Exit Program
For More Information about our training
Programs please contact IRI Sales at
228 392 3973 or Indresinc@aol.com
Industrial Resources, Inc.
A Training Services Company
Exit Program
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

Return to Review
Questions
Analog Data
Pressure Transducer
Temperature
Transducer
Flow
Transducer
Return to Review
Questions
Node Bus
Return to Review
Questions
P&ID Displays
Return to Review
Questions
Process Control Basics
Return to Review
Questions
Control Processor
Return to Review
Questions
DCS Control
Digital Signals (Zero and One)
Analog Signals (4 20 Ma)
Two (2) types of control signals
route to and from the DCS System
Controller:
Return to Review
Questions
PID Block
3-element
Feedwater Master
PID
Steam Flow
Feedwater
Flow
Drum Level
Valve
Position
Signal
Return to Review
Questions
Control Diagrams
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
Control Diagrams provide the following types of
information:
Return to Review
Questions
Sensing Elements and Symbols
Pitot Tubes
Flow Transmitter
FT
Pressure
Transducer
Pressure
Transmitter
PT
Level Sensors Level Transmitter
LT
Return to Review
Questions
Final Control Element
Valve
Positioner
Damper
Positioner
Motor Controller Hydraulic Coupling Controller
Return to Review
Questions
NOT GATE
Input
Outp
ut
NOT Gate
Input Output
1 0
0 1
Truth Table
Return to Review
Questions
Historical Trend/Retrieval
Return to Review
Questions
Controller and Trend Graphic
Level Setpoint
Deviation from Level
Setpoint
Valve Output
Percent/OPEN
Return to Review
Questions
Basic Unit loading and Control
Return to Review
Questions
Megawatt Demand Signal
Return to Review
Questions
LMCC Controls
Return to Review
Questions