Distributed

Control System
Chapter- 4

Date

Presented By: Praful Chudasama

Contents:
• Overview of DCS
• DCS software configuration
• DCS communication
• DCS Supervisory Computer Task
• DCS integration with PLC and
Computers
• Features of DCS
• Advantages of DCS.
Distributed Control System (DCS) ?
DCS ?
• Distributed Control Systems (DCS) is a computerized control system
for a process or plant that consists of a large number of control
loops, in which autonomous controllers are distributed throughout
the system, but there is central operator supervisory control.
• DCS can be used to enhance reliability and reduce installation costs
by localizing control functions near the process plant, with remote
monitoring and supervision.
• These systems are used on large continuous process plants where
high reliability and security is required.
Structure of DCS:
Structure of DCS:
• Level 0: It consists of the field devices such as temperature
sensors, flow, and final control elements such as control valves.
• Level 1: It consists of the industrialized Input / Output (I/O) modules,
and their associated distributed electronic processors.
• Level 2: It is included with supervisory computers that help to gather
information from processor nodes on the system, and provide the
operator control screens.
• Level 3: It is the production control level, which does not directly
control the process, but is concerned with monitoring production and
monitoring targets.
• Level 4: It is the production scheduling level
Structure of DCS:
• On the other hand, Level 1 and Level 2 are the functional levels of a
traditional DCS, in which all equipment's are part of integrated
systems from a single manufacturer.
• Levels 3 and 4 do not strictly process control in the traditional sense,
but where production control and scheduling takes place.
The architecture of DCS:
• Distribution Control Systems (DCS) consists of three major qualities.
1. Various control functions can be distributed into small sets of subsystems that
are of semiautonomous. These are interconnected by a high-speed
communication bus and their functions include data presentation, data
acquisition, process control, process supervision, reporting information,
storing and retrieval of information.
2. The second characteristic is the automation of manufacturing process by
integrating advanced control strategies.
3. The third characteristic is arranging the things as a system.
• The organizing of the entire control structure as a single automation system can
be done with DCS as it unites sub-systems through a proper command
structure and information flow. DCS is included with basic elements such as
engineering workstation, operating station or HMI, process control unit, smart
devices, and communication system.
Features of DCS:
• System redundancy
• More sophisticated HMI
• Scalable platform
• System security
Applications of DCS include:
• Chemical plants
• Petrochemical (oil) and refineries
• Pulp and Paper Mills
• Boiler controls and power plant systems
• Nuclear power plants
• Environmental control systems
• Water management systems
• Water treatment plants
• Sewage treatment plants
• Food and food processing
Applications of DCS include:
• Agrochemical and fertilizer
• Metal and mines
• Automobile manufacturing
• Metallurgical process plants
• Pharmaceutical manufacturing
• Sugar refining plants
• Agriculture Applications
Benefits of using DCS include:
• It requires minimal troubleshooting
• It contains HMI graphics and faceplates
• Alarms
• Lends itself to better organization and consistency than a
PLC/HMI combo
• Batch management is possible
• OPC server
• Reduced engineering time
• Redundant operator system servers
How is DCS different from PLC?
• It requires minimal troubleshooting
• It contains HMI graphics and faceplates
• Alarms
• Lends itself to better organization and consistency than a
PLC/HMI combo
• Batch management is possible
• OPC server
• Reduced engineering time
• Redundant operator system servers
Applications of DCS include:
• Agrochemical and fertilizer
• Metal and mines
• Automobile manufacturing
• Metallurgical process plants
• Pharmaceutical manufacturing
• Sugar refining plants
• Agriculture Applications
Basic Components of a Typical DCS Network
1. Operator Stations:
• A typical plant starts with a centralized operator control center
typically called Operator Stations.
• Operator Stations, in a DCS, are the heart of the system.
• This is where the operator can observe the operations of the plant,
view process warnings and alarms, monitor production, and more.
Basic Components of a Typical DCS Network
2. Servers, Archiving and Engineering Computers:
• The next level of components may contain servers, archiving
computers, and engineering stations.
• Communications with the Operator Station level is typically
Industrial Ethernet.
• Servers are used for the collection of data at the processor level.
• They are responsible for the data that moves between the
Operator Station and the processors on the plant floor.
• Archiving computers are used for storing historical data that may
be used for trends or compliance.
Basic Components of a Typical DCS Network
2. Servers, Archiving and Engineering Computers:
• Engineering stations are used for creating the projects on which
the processes run. This includes;
• Hardware configurations
• Logic for tasks
• Graphical displays for operator interaction
• Administration of all of those tasks through installed software
packages.
• This is the station that is used to download the projects to the
processors and the graphical displays.
Basic Components of a Typical DCS Network
2. Servers, Archiving and Engineering Computers:
Basic Components of a Typical DCS Network
3. DCS Controllers:
• At the next level, you have the master controllers that supervise
the individual processors as well as I/O modules.
• These controllers are also responsible for providing the data to
the servers, which in turn, supply the data for the graphical
interface.
• Industrial Ethernet is typically used for communication with the
previous level. Fiber Optic may be used here when Ethernet
cabling runs would be too long.
• At this level, the processor executes the logic and does what it
needs to do in order to control the process.
Basic Components of a Typical DCS Network
3. DCS Controllers:
Basic Components of a Typical DCS Network
3. DCS Controllers:
• Industrial Ethernet is typically used for communication with the
previous level. Fiber Optic may be used here when Ethernet
cabling runs would be too long.
• At this level, the processor executes the logic and does what it
needs to do in order to control the process.
Basic Components of a Typical DCS Network
4. Field Devices:
• The next level is the field device level. Communications
between this level and the processor level can be nearly any
type that may be compatible with the components.
• Those include Industrial Ethernet, Profibus DP, EtherCAT, Fiber
Optic, or other proprietary communication protocols.
• Components at this level would be devices such as transmitters,
switches, valves, motors, remote or distributed I/O, etc.
Basic Components of a Typical DCS Network
4. Field Devices:
Working & Operation of DCS System
• The operation of DCS goes like this; Sensors senses the
process information and send it to the local I/O modules, to
which actuators are also connected so as to control the process
parameters.
• The information or data from these remote modules is gathered
to the process control unit via field bus.
• If smart field devices are used, the sensed information directly
transferred to process control unit via field bus.
Working & Operation of DCS System
• The collected information is further processed, analyzed and
produces the output results based on the control logic
implemented in the controller.
• The results or control actions are then carried to the actuator
devices via field bus.
• The DCS configuring, commissioning and control logic
implementation are carried at the engineering station as
mentioned earlier.
• The operator able to view and send control actions manually at
operation stations.
Overview of DCS and PLC Systems
• PLCs, traditionally, were used for single batch or high-speed
control, have a relatively simple, low-cost design, and are the
core of the system. Their design is flexible and generic but
completely customizable.
• Processing time for tasks are typically very fast, operators
usually interact and control the system using some sort of
graphical display such as SCADA.
• A DCS is used for continuous, complex controls, have an
integrated control center much like a SCADA, which is the core
of the system versus the processors in a PLC system.
Overview of DCS and PLC Systems
• The DCS has a number of predefined functions that come ready to
customize and deploy for various applications.
• Processing times are somewhat slower. Operators interact with the
control system via an integrated graphical display.
• DCS also have a claim that when safety is a top priority, it is the
most reliable system.
• The reason for this is because the manufacturer supplies both the
control and supervisory equipment as an integrated package, the
risks of integration errors are greatly reduced.
Differences between DCS & PLC
Differences between DCS & PLC
DCS Systems from Different Vendors:
• ABB- Freelance 800F and 800 xA
• Yokogawa- Centum CS 3000 and 1000
• Honeywell-TDC 3000
• Emerson- Delta V Digital Automation
• Siemens- Simatic PCS 7
• Allen- Bradley- NetLinx
THANKS!!