DCS

• DEFINE?
• PURPOSE OF USING DCS?
 Basic definition
• It is basically a series of microprocessor based multi loop
controllers distributed along the communication network
called as data highway
• A collection of small computers connected by a network to
form a system specifically designed for process control
• DCS (Distributed Control System) is a control system in
which the components that make up the system are
distributed geographically and functionally around the
process areas. The main function of the DCS is to receive
inputs from field mounted instruments (Flow, Pressure,
Level, Temperature, Analysis etc), process the information in
a predetermined program and provide control signal to final
control elements, generate reports
 PURPOSE
• To automate a process
• Define process?
• Different types of process-continuous and
sequential/batch
• Define continuous and give example
• Define batch/sequential and example
• What matters in the process: quality and
quantity of end product
Process of thermal power plant
 Objectives of process control
• Safety
• Environmental protections
• Equipment protection
• Productivity
• Quality
• Diagnosis and monitoring
 HIERARCHY LEVEL IN
AUTOMATIONS TECHNOLOGY

Process control level Ethernet

PROFIBUS-FMS
Cell level

PROFIBUS, Interbus-S,
Field level CAN

Actuator/
Sensor-
level
• The analysis of the information from the production process that the application
plan, such as the stipulation of guidelines and strategies for manufacturing take
place in the planning level. In longer periods, larger data heaps are transmitted
here over a large range.

• The coordination of a single production range takes place in the process

control level. Here the cell level is provided with jobs and program data and it
is decided, how the production has to occur. This process control computer
such as a computer for configuration, diagnosis, operation and protocol,
resides in this level.

• The cell level integrates the single manufacturing cells that are controlled from
the cell computer or the PLCs. Here in the foreground lies the specific
communication between intelligent systems.

• In the field level, you find programmable devices for open or closed loop control
and monitor like PLCs or industry computers that evaluate the data of the
sensor/actuator level. For the connection to the superposed systems, larger
data heaps with critical reaction time are transmitted.
• The actuator-/sensor level is an integral part of the field level and integrates
the technical process with the controller. This occurs with simple field devices
like sensors and actors. The faster cyclic actualization of the in- and output
data lies in the middle point, where small messages are transmitted. The
duration for the actualization of the in- and output data must circumstantially be
smaller as the cycle time of the controller.
 Process control techniques
• Open loop
• Closed loop
• Feed forward
• Ratio control
• etc
 SP Closed loop control

error amplifier Final control process

controller
element

Feedback Sensor/
amplifier transducer
 Techniques for closed loop control
• PC based control
• PLC based control
• DCS based control
• Standalone PID control
 PC based control
• For picture refer pdf
• Define it
• Advantages: What are SMART devices?
– more memory storage 1. IFD-intelligent field
– low hardware cost devices
2. Diff. bet SMART and
– only for small process normal instruments
• Disadvantages: 3. Diff bet data and signal
– Software dependent
– Integration with modern days protocols
– Communication with SMART devices
– Can't handle more than 10 control loops
– Programming is difficult
– Not reliable for industrial environment
 PLC based
• Define it
• Advantages
• Disadvantages:can not handle more
control loops/analog I/Os
• More conrol loops increases scan time
 DCS based
• Objectives
• Evolution
• Features
• Types
• Components
What must be in the DCS for it to be able to do so much?
• Operator Console: These are like the monitors of our computers. They provide
us with the feedback of what they are doing in the plant as well as the command we
issue to the control system. These are also the places where operators issue
commands to the field instruments.

• Engineering Station: These are stations for engineers to configure the system
and also to implement control algorithms.
• HistoryModule: This is like the harddisk of our PCs. They store the
configurations of the DCS as well as the configurations of all the points in the plant.
They also store the graphic files that are shown in the console and in most systems
these days they are able to store some plant operating data.

• Data Historian: These are usually extra pieces of software that are dedicated to
store process variables, set points and output values. They are usually of higher
scanning rates than that available in the historymodule.
• Control Modules: These are like the brains of the DCS. Specially customized
blocks are found here. These are customized to do control functions like PID
control, ratio control, simple arithmetic and dynamic compensation. These days,
advanced control features can also be found in them.
• I/O: These manage the input and output of the DCS. Input and output can be digital
or analogues. Digital I/Os are those like on/off, start/stop signals. Most of the
process measurements and controller outputs are considered analogue. These are the
points where the field instruments are hard-wired to.
Objectives
 Basic DCS Functions
• The DCS, like the programmable logic controller, is connected
to primary control elements such as temperature and pressure
transmitters, flow meters, gas analyzers, pH and conductivity
sensors, weigh scales, contact switches, valves and motors,
and so on. From these field devices it receives electrical
signals, for example, 4–20 mA, 1–5 V DC, 24 V AC, and 120 V
AC. The DCS converts these signals (digitizes them). Once
converted, they can be used by the computer to:
– control loops,
– execute special programmed logic,
– monitor inputs,
– alarm the plant operations,
– trend, log, and report data, and
– perform many other functions.
 Role of Computer in DCS
• Because a DCS is computer-based and all its information is in
digital form, it can easily combine analog control loops with
discrete logic (interlocks and sequences).
• A DCS can involve as few as a hundred inputs, outputs, control
loops, and logic interlocks or tens of thousands of them.
• It can scan all the primary elements or sensors, characterize
the input signals and alarm them, recalculate loop parameters
and execute logic, and then send the results to motors and
valves throughout the plant.
• It constantly reevaluates the status of the plant and makes
thousands of incremental decisions in fractions of a second.
 Role of Computer in DCS (Cont…)

• It is capable of all this and more for two main

reasons:
– A DCS is made up of many independent control
modules that can operate simultaneously and
independently.
– It has the ability to carry out rapid communications
between these and other modules by means of a
communications link called a real-time data highway.
 Role of Computer in DCS (Cont…)
• Close control is only the first step toward efficient production. Many
plants find that their process units need to make adjustments not only
for varying feedstock characteristics but also for changing end
product requirements and varying operating techniques.
• To keep track of and coordinate all these fluctuating circumstances, a
DCS incorporates extensive capacity for communications, data
storage, and data retrieval. This, then, is another key DCS function,
because it enables plant personnel to make the right decisions by
supplying information that is both accurate and timely.
• Most DCSs are capable of rapidly displaying process information and
storing it to be retrieved, reviewed, and analyzed at a later date.
Typically, this information would be used by all the departments in
the plant, from process engineering and maintenance to production
and plant management. A good DCS provides the appropriate
personnel with quick and easy access to the appropriate information.
DCS Architecture
 evolution
• LOCAL CONTROL : Initially control was performed local to the equipment control.
• ADVANTAGE was low wiring costs .
• DISADVANTAGES were - not much control, monitoring, alarming & history.

• CENTRALISED CONTROL: With the advent of minicomputer, sensors and actuators

were into the Central Control (Computer).

• DISTRIBUTED CONTROL: With the advent of microcomputer, Distributed control

systems were installed in the plants near to the control room via proprietary digital
communications lines called as Data Hiway. First DCS was developed by
Honeywell,U.S in 1975.
• The ADVANTAGES were greatly reduced wiring costs, much more limited
• failure and less cost to add more points.
• The DISADVANTAGES were that wiring costs were still significant and there was lack of
interoperability among controllers of various manufacturers due to the proprietary
protocols. Hence the user was locked into a single vendor.
DCS EVOLUTION-CENTRALISED CONTROL
DCS EVOLUTION-DISTRIBUTED CONTROL
DCS EVOLUTION-FIELDBUS CONTROL
Smart
DCS vs PLC vs PC based control system
 features
1. Networking
1. Plant
2. Process
3. field
2. Redundency
1. CPU
2. PS
3. I/O
4. Bus
5. communication
3. Memory
4. Multitasking/multiprogramming/multicomputing
5. Large I/O handling
6. Constant scan time
7. Support various protocols
 Types of DCS
• Conventional
• PLC based
• Hybrid
• Open
 Elements of DCS
• Engg station
• Automation station
• Operator station