Instrument Control Concept And Block Diagram

By… Mr. Yongyuth Lokloung

Instrument Department
Objective ……

To Understand….

1. DCS system basic structure.

2. DCS Hardware.

3. To make the same understanding among each disciplines about

scope of work and supply.

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What is DCS ……

DISTRIBUTED CONTROL SYSTEM

DCS is a very broad term used in a variety of industries, to monitor and co
ntrol for distributed equipments. It is system that monitoring and controls in
struments or elements in the plant,

DCS which will be mainly used in process industries plant to control a entir
e plant operation. The entire plant will be diveded into sub areas.

DCS is a control system in which the controller elements are

not central in location but are distributed throughout the
system with each component sub-system under the control of
one or more controllers

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Instrument Work Flow Diagram ……

1. Field Instrument
2. Construction
3. Control system

1 2 3
Field Construction Controls system
Operation

JB

M/R SYS

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What Does DCS System Consists Of? ……
DCS System consists minimum of the following components.

1. Controller : It consists of CPU modules and communication bus.

Controller will be receiving signals from i/o card and computing of
any requirement function and send output to control the final
elements or display process in operator station.
2. I/O Card : It consists of input/output modules to send or received
signals from outside of DCS system.
3. Operator Station : It is basically human interface machine with
monitor, the operator man can view the process in the plant and
check if any alarm is presents and he can change any setting, print
reports.. etc.
4. Engineering station : It is used to configure all input and output
and drawing and any things required to be monitored on operator
station monitor.

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DCS Basic System Configuration ……

OPS = Operator Station

OPS 3 EWS 4
EWS = Engineering Work Station
I/O = Input/Output

DATA HIWAY

1
Controller

I/O CARD

I/O CARD 2

I/O CARD

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DCS Advance System Configuration ……
Internet
PRINTING NETWORK

OPS OPS OPS PRINTER APC PIMS AMS EWS

DATA HIWAY

Controller Controller Controller ESD

Package
Control System
Mod bus
I/O CARD I/O CARD I/O CARD PLC

I/O CARD I/O CARD I/O CARD

MCC & SWGR
Pro-if bus
I/O CARD I/O CARD I/O CARD IMCS

OPS = Operator Station AMS = Accesses Management System

EWS = Engineering Work Station APC = Advance Process Control

06/16/22 PIMS = Plant Information Management System

DCS Advance System Configuration ……
CONTROL ROOM ENGINEERING ROOM
Internet
PRINTING NETWORK

OPS OPS OPS SOE PRINTER APC AMS PIMS EWS

DATA HIWAY

INSTRUMENT RACK ROOM ELECTRICAL SUBSTATION

SYS SYS SYS M/R M/R M/R M/R M/R M/R IPR MCC SWGR
Hardwired
CPU CPU CPU Ai/Ao Ai/Ao Ai/Ao Di/Do Di/Do Di/Do
I/O I/O I/O

Pro-if bus
Mod bus

Package Unit
PLC

OPS = Operator Station AMS = Accesses Management System

EWS = Engineering Work Station APC = Advance Process Control
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PIMS = Plant Information Management System IPR = Interposing Relay
SOE = Sequence Of Event
How Does it Work? ……
Basically, DCS system receives input signals from other devices, these
signals will be processed and analyzed by DCS controller and base on
the result an action will be taken.
Fig(1) show an example of simple control mechanism. The water in the tank is required to
be controlled, the level transmitter will measure the water level and send PV signal (4-
20mA) to DCS, Input module in the controller will be receive this signal and pass it to
controller after converting it to digital signal. The PV data can be monitored on the
operator station screen in small window called faceplate,

Fig(1) DCS System

SP

PV MV
PID
Level Transmitter Level Control Valve
CV
PT

Storage
To Process Tank

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Pump
Mixer Tank
Controller and I/O Modules……
Normally, the controller and I/O modules will be install in the I/O rack
or I/O chassis and will be received power supply from power supply
module.

Transmitter

Control Valve

M/R
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System Cabinet……

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Remote I/O Panel……

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Controller and I/O Modules……

I/O RACK

DCS I/O Card

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Operator Work Station……

Operator Work Station

DCS Console

DCS Graphic

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Alarm and Event Display ……

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Control Faceplate……

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Historical / Real Time Trend Display ……

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Group Display ……

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Turning Display ……

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Control Drawing……

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DCS And ESD Concept……

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ESD Protection Level……

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You Should Know……
 Interposing Relay

Interposing
Relay Panel

Relay Module
24VDC 220VAC
DCS MCC
System System

START/STOP
Signals

Relay Module

24VDC 220VAC
DCS MCC
System System

RUNNING/FAULT
Signals

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You Should Know……
 Intrinsically Safe

Safe Area Hazardous Area

Safety Barrier

Analog signal
1+ 8+ from transmitter

DCS/ESD 2- 9-

11 +

12 - 10-40V
supply

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You Should Know……
 Redundancy System

OUTPUT CARD

CONTROLLER CONTROLLER
(Main) (Backup)

INPUT CARD

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You Should Know……
 Sink And Souse

Transmitter
Souse (From DCS) (Two wire system)

+ 24VDC (Power Supply) 4-20mA +

DCS
- -

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You Should Know……
 Sink And Souse

Transmitter
Sink (Four wire system)

+ 4-20mA 24VDC (Power Supply) +

DCS
- -

+ -

+ 24VDC (Power Supply)

24VDC
PDB -

Transmitter
Sink (Three wire system)
S 4-20mA S

+ 24VDC (Power Supply) +

DCS
- (COMM) -

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Instrument Point of View for Package Unit

1. Control System 2. Field Instrument

3. Motor 4. Power Feeder

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1. Control System Unit
 Does the package unit have their own control
system?
 Type of control system (PLC/Relay/Etc.)?
 Location of the Control System?
 Are there any communication with DCS/SIS?
 Any requirement of HMI?
 Local Control Panel/Local Operating Panel/Local
Control Station?

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2. Field Instrument
 General Instrument Specification
 Signal Type
 Explosion Protection
 Quantity
 Approved Project Vendor List

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3. Motor

 Location of Starter Unit

 VSD?
 Speed Sensor?
 Temperature Sensor?

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4. Power Feeder

 Quantity of Power Feeder

 UPS/Non UPS
 Power Condition (V/Hz/Phase)
 Where does the feeder came from?
 Power Consumption for each feeder

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Block Diagram

 Package Unit Name and Tag Number (Optional

P&ID Number)
 Location of each equipment in Package Unit
 Equipment Tag Number (If any)
 Cables
 Scope of Supply

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Instrument Control Concept And Block Diagram

Case-1: Vendor Provide Main Equipment Only

Control Room HMI

Rack Room EE Sub-Station

Communication Cable
Power Cable
PDB MCC/
DCS I IRP E SWGR
I
I I E
UPS PDB

I E E

Field Area
Package Skid
I
JB
E

I
Power Cable
I M
Field Instrument Motor
V

06/16/22 I = Scope by Instrument V = Scope by Vendor Package

E = Scope by Electrical
Instrument Control Concept And Block Diagram

Case-2: Vendor Provide Instrument

Control Room HMI

Rack Room EE Sub-Station

Communication Cable
Power Cable
PDB MCC/
DCS I IRP E SWGR
I
I I E
UPS PDB

I E E
E
Field Area
Package Skid
V
JB
E
V
Power Cable
M
Field Instrument Motor
V

06/16/22 I = Scope by Instrument V = Scope by Vendor Package

E = Scope by Electrical
Instrument Control Concept And Block Diagram

Case-3: Vendor Provide Instrument and Local Control Panel-(1)

Control Room HMI

Starting Unit By Electrical

Rack Room EE Sub-Station

Communication Cable
Power Cable
PDB MCC/
DCS I IRP E SWGR
I
I I E
UPS PDB

I E E
I
Field Area Communication Cable RS-485, Fiber Optic
E
Package Skid
LCP
V
Control Power Cable E E
JB
V V Control Cable
V
Power Cable
M
Field Instrument Motor
V

06/16/22 I = Scope by Instrument V = Scope by Vendor Package

E = Scope by Electrical = Media Converter (If Any)

Instrument Control Concept And Block Diagram

Case-4: Vendor Provide Instrument and Local Control Panel-(2)

Control Room HMI

Starting Unit By LCP

Rack Room EE Sub-Station

Communication Cable
Power Cable
PDB MCC/
DCS I IRP E SWGR
I
I I E
UPS PDB

I E E
I
Field Area Communication Cable RS-485, Fiber Optic
E
Package Skid
LCP
V
Control Power Cable E
JB Power Cable
V V
V
V
M
Field Instrument Motor V

06/16/22 I = Scope by Instrument V = Scope by Vendor Package

E = Scope by Electrical = Media Converter (If Any)

Instrument Control Concept And Block Diagram

Case-5: Vendor Provide Instrument and Control Panel

Control Room HMI HMI

Rack Room EE Sub-Station

Communication Cable
Power Cable
PDB MCC/
DCS I IRP E SWGR
I CP I
I I UPS PDB
E
V
Power Cable
I E E VSD
I E
Field Area
Package Skid I E
I LCP Control Power Cable E
V
JB V
V
V
Power Cable
M
Field Instrument Motor
V

06/16/22 I = Scope by Instrument V = Scope by Vendor Package

E = Scope by Electrical = Media Converter (If Any)

Question ……

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