Control System Engineer

Engineer Role

Moataz Sherif
Senior Instrumentation and Control Engineer
Control System Engineer Role

● Control System Definition

● Different types of control system

● Responsibilities

● Troubleshooting 2
Control System Engineering

• Control engineering or control systems engineering is an

engineering discipline that applies control theory to design systems
with desired behaviors in control environments.
• The discipline of controls overlaps and is usually taught along with
electrical engineering and mechanical engineering at many
institutions around the world. 3
Automation Engineering

• Automation engineers are experts who have the knowledge and

ability to design, create, develop and manage systems, for example,
factory automation, process automation.

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Control System Definition

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Control System

• A system which responds to input

signals from the process and/or
from an operator and generates
output signals causing the process
to operate in the desired manner.
• The control system include
● Input devices
● Controller
● Final elements Definition from IEC 61511-1 6
Control System

Control system choice depends on

● Purpose.

● Equipment Under Control (EUC).

● Scale.

● Available technology.

● Cost.
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● Technical support.
Control System

Control system can be Control system can used as a

• Pneumatic • Basic Process Control

• Electric System

• Electronic • Safety Instrumented System

• Programmable Electronic • Combined BPCS-SIS

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Basic Process Control System

• Basic Process Control System (BPCS) is a system which responds to

input signals from the process, its associated equipment, other

programmable systems and/or an operator and generates output
signals
• causing the process and its associated equipment to operate in the

desired manner but which does not perform any safety instrumented 9

functions with a claimed SIL ≥ 1

Pneumatic Control System

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Programmable Logic Control (PLC)

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Turbo machinery Control System

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Vibration Monitoring System

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Vibration Monitoring System

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Vibration Monitoring System

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Vibration Monitoring System

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Boiler Control System

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Safety Instrumented System

SIS takes some other names

• Trip and Alarm system

• Emergency Shutdown System (ESD)

• Safety Shutdown System

• Safety Interlock System

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• Safety Related Control System
BPCS vs. SIS

• SIS is a protection layer located to prevent the

Hazards from occurring.

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Safety Instrumented System

The system consists of

• Sensors
• Logic Solver
• Final control element

Vendors Like HIMA,

TRICONEX, ABB,
YOKOGAWA,
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HONEYWELL and
SIEMENS
Different Types of Control System

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Relay Vs. PLC-based Control Panels

Relay based control panels PLC-based control panels

Relay Vs. PLC-based Control Panels

● Relays have to be hardwired to perform a specific function.

● When the system requirements change, the relay wiring has to be
changed or modified.
● In extreme cases, such as in the auto industry, complete control
panels had to be replaced since it was not economically feasible to
rewire the old panels with each model changeover.

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Programmable Logic Controller (PLC)

• The logical combination of inputs to produce an output or outputs is

called control logic.

• Several logic combinations are usually required to carry out a control

plan or program.

• This control plan is stored in memory using a programming device

that inputs the program into the system.

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PLCs Benefits

● Increased Reliability
● More Flexibility
● Lower Cost
● Communications Capability
● Faster Response Time
● Easier to Troubleshoot

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PLCs Benefits

Increased Reliability
PLCs Benefits

Communications Capability More Flexibility

PLCs Benefits

High-speed counting
PLCs Benefits

Real-time display of control program

Parts of a PLC

1. Central processing unit (CPU)

2. The input/output (I/O) section

3. The power supply

4. Programming device.

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Parts of a PLC
Programmable Logic Controller (PLC)

• The processor (usually a high-speed microprocessor) periodically scans

the control plan in memory in a predetermined sequential order.

• The amount of time required to examine the inputs and outputs,

perform the control logic, and execute the outputs is called the scan

time.
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PLC Scan Cycle

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PLC Vs. PAC

● Programmable automation controllers combine PLC ruggedness

with PC functionality.
● Using PACs, you can build advanced systems incorporating
software capabilities such as advanced control, communication,
data logging, and signal processing with rugged hardware
performing logic, motion, process control, and vision.

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PLC Vs. PAC

● The most notable difference between PLCs and PACs is their

programming interface.
● PACs are more intricate, using C or C++. PLCs, on the other hand,
PLCs are programmed using ladder logic.
● PLCs are ideal for both simple and high-speed machine control.
● PLCs are a more cost-efficient option for standard automation
control.
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PLC Vs. PAC

● A capable PLC will help many automation projects perform to the

best of their abilities.
● PACs are great for complex automation system architectures
composed of several PC-based software applications.
● Combine the previously mentioned systems into a single
automated process and a PAC will control all of them.

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PLC Vs. PAC

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PLC Size and Application

● PLCs can be categorized according to functionality, number of

inputs and outputs, cost, and physical size.
● the I/O count is the most important factor.
❖ the nano: is with less than 15 I/O points.
❖ micro types: 15 to 128 I/O points
❖ medium types: 128 to 512 I/O points
❖ large types: over 512 I/O points
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PLC Size and Application - SIEMENS

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PLC Size and Application - SIEMENS

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PLC Size and Application - Allen Bradley

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PLC Size and Application

● future conditions should be anticipated to ensure that the system

is the proper size to fill the current and possibly future
requirements of an application.
● There are three major types of PLC application: single-ended,
multitask, and control management.
● A single-ended or stand-alone PLC application involves one PLC
controlling one process.
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PLC Size and Application

● This would be a stand-alone unit and would not be used for

communicating with other computers or PLCs.
● Usually this category requires a small PLC.
● A multitask PLC application involves one PLC controlling several
processes.
● Adequate I/O capacity is a significant factor in this type of
installation.
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PLC Size and Application

● In addition, if the PLC would be a subsystem of a larger process

and would have to communicate with a central PLC or computer,
provisions for a data communications network are also required.
● A control management PLC application involves one PLC
controlling several others.
● This kind of application requires a large PLC processor designed
to communicate with other PLCs and possibly with a computer.
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PLC Size and Application

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PLC Size and Application

● Memory is the part of a PLC that stores data, instructions, and the
control program.
● Memory size is usually expressed in K values: 1 K, 6 K, 12 K, and so
on.
● The amount of memory required depends on the application.
● Factors affecting the memory size needed for a particular PLC
installation include:
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PLC Size and Application

• Number of I/O points used

• Size of control program

• Data-collecting requirements

• Supervisory functions required

• Future expansion
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Supervisory Control And Data Acquisition (SCADA)

• SCADA refers to a system that collects data from various sensors at a

factory, plant or in other remote locations and then sends this data to
a central computer which then manages and controls the data.

• A collection of equipment that will provide an operator at remote

location with enough information to determine the status of a
particular piece of a equipment or entire substation and cause actions
to take place regarding the equipment or network.
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SCADA System Overview

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Supervisory Control And Data Acquisition (SCADA)

• A typical SCADA system comprises of i/o signal hardware, controllers,

software, networks and communication.

• SCADA system is normally used to monitor and control a remote site or a

distribution that is spread out for a long distance.

• An RTU (Remote Terminal Unit) or a PLC (Programmable Logic

Controller) is usually used to control a site automatically. 50

SCADA System Overview

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Supervisory Control And Data Acquisition (SCADA)

• The SCADA system also provides a host control functions for the

supervisor to control and define settings.

• SCADA systems are used to monitor or to control chemical or transport

processes in municipal water supply systems, to control electric power

generation, transmission and distribution, gas and oil pipelines, and

other distributed processes.

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SCADA System Overview

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Usage of SCADA

1. Electric power generation, transmission and distribution: Electric

utilities use SCADA systems to detect current flow and line voltage,
to monitor the operation of circuit breakers, and to take sections of
the power grid online or offline.

2. Water and sewage: State and municipal water utilities use SCADA to
monitor and regulate water flow, reservoir levels, pipe pressure and
other factors.
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Usage of SCADA

3. Buildings, facilities and environments: Facility managers use SCADA to

control HVAC, refrigeration units, lighting and entry systems.

4. Manufacturing: SCADA systems manage parts inventories for just-in-time

manufacturing, regulate industrial automation and robots, and monitor

process and quality control.

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Usage of SCADA

5. Mass transit: Transit authorities use SCADA to regulate electricity to

subways, trams and trolley buses; to automate traffic signals for rail

systems; to track and locate trains and buses; and to control railroad

crossing gates.

6. Traffic signals: SCADA regulates traffic lights, controls traffic flow and

detects out-of-order signals. 56

Distributed Control System (DCS)

• the concept of automatic control includes accomplishing two

major operations; the transmission of signals (information flow)
back and forth and the calculation of control actions (decision
making).

• Carrying out these operations in real plant requires a set of

hardware and instrumentation that serve as the platform for these
tasks
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Distributed Control System (DCS)

• Distributed control system (DCS) is the most modern

control platform. It stands as the infrastructure not only for

all advanced control strategies but also for the lowliest

control system.

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DCS Architecture

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DCS Historical Background

• The DCS largely came about due to the increased availability of

microcomputers and the proliferation of microprocessors in the
world of process control.

• In 1975, both Honeywell and Japanese electrical engineering firm

Yokogawa introduced their own independently produced DCS's at
roughly the same time, with the TDC 2000 and CENTUM
systems, respectively. 60
DCS Historical Background

• The definition of a distributed control system (DCS) has dramatically

changed over its history.

• The DCS was originally conceived as a replacement for large panels,

located in central control rooms and containing hundreds, sometimes
thousands, of process instruments.

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Honeywell TDC 2000 DCS

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Yokogawa CENTUM DCS

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DCS Architecture

• The DCS architecture has always been focused on distributing

control on a network so that operators can monitor and interact
with the entire scope of the plant.

• As such, the classic DCS originated from an overall system

approach. Coordination, synchronization and integrity of process
data over a high-performance and deterministic network are at the
core of the DCS architecture.
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DCS Architecture

• These distributed controllers are connected to both field devices and

operating PCs through high-speed communication networks.

• Discrete Field devices such as sensors and actuators are directly

connected to input and output “ control racks “ modules through

communication bus.
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DCS Architecture

• These field devices or smart instruments are capable of communicating

with PLC’s or other controllers while interacting with real world
parameters like temperature, pressure, etc .

• Each control rack contains a microprocessor to implement all

necessary control functions, with individual I/O (input/output) “cards”
for converting analog field instrument signals into digital format, and
visa-versa.
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DCS Architecture

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DCS Architecture

• Redundant processors, redundant network cables, and even

redundant I/O cards address the possibility of component failure.

• DCS processors are usually programmed to perform routine self-

checks on redundant system components to ensure availability of the

spare components in the event of a failure

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DCS Architecture

• Controllers are distributed and connected to operating and

engineering stations, which are used for data monitoring, data logging,
alarming and controlling purpose via another high-speed
communication bus.

• The communication protocols are of different types such as

foundation filed bus, HART, Profibus, Modbus, etc. DCS provides
information to multiple displays for user interface
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DCS Basic Configuration

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Main Differences Between DCS and SCADA

DCS SCADA
Process driven hardware Event driven
Small geographic areas Large geographic areas
Suited to large integrated systems such Suited to multiple independent systems
as chemical processing and electricity such as discrete manufacturing and
generation utility distribution
Good data quality and media reliability Poor data quality and media reliability
Powerful, closed-loop control Power efficient hardware, often focused
on binary signal detection 71
Main Differences Between DCS and PLC

• The PLC is cost-effective from 0 to a few thousand I/O points; the DCS

becomes cost-effective starting from a few thousand points and beyond.

• A PLC becomes a subsystem of the DCS in rare occasions when the

situation calls for it.

• In large plants the DCS is king because most owners want a single source of

hardware support and service

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Main Differences Between DCS and PLC

• Generally, PLCs are stand alone and perform a particular task, where a

DCS is a network of PLCs that communicate in some fashion to

accomplish a particular task.

• PLC only handle sequential process than DCS can handled both

Continue process and large loop control.

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Main Differences Between DCS and PLC

• PLC is used mainly for interlocking different equipment’s.

DCS is used to control very big plants by using simple GUI

screens. PLCs are interfaced with DCS for interlocking.

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Responsibilities

• Automation engineers can design, program, simulate and test

automated machinery and processes, and usually are employed in

industries such as the energy sector in plants, car manufacturing

facilities or food processing plants and robots.

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Responsibilities

• Creating detailed design specifications and other documents

• Developing automation software based on specific requirements for
the process involved.
• Conforming to international standards like IEC-61508, local
standards, and other process specific guidelines and specifications.
• Simulate, test and commission developed software. 76