DISTRIBUTED CONTROL
SYSTEM
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Roll no :35 to 59
WHAT IS DISTRIBUTED CONTROL
SYSTEMS?
•A distributed control system (DCS) refers to a control
system usually of a manufacturing system, process or any kind
of dynamic system.
•In which the controller elements are not central in location (like
the brain) but are distributed throughout the system
•With each component sub-system controlled by one or more
controllers.
•The entire system of controllers is connected by networks for
communication and monitoring.
GENERATIONS OF DCS
First Generation: The Early
DCS
• The introduction of microprocessor-based control occurred shortly
before 1980 with simple single-loop controllers. This technology
quickly evolved into a DCS with control processor redundancy,
high-density input/output (I/O) systems, and a human machine
interface (HMI).
• Perhaps the most significant feature of the early DCS was the
ability to geographically distribute control system processors and
I/O components
econd Generation: The Open System DCS
• The open system DCS provided standard
communication interfaces for connecting the various
automation subsystems.
• Enterprise management solutions, also enabled by
the open system, provided new opportunities for fleet
management centers to improve operations by
remotely monitoring processes, analyzing unit
efficiencies, and supporting coordination between
operating units.
Third Generation: The Extended
Automation DCSgoals focus on increasing operational efficiency
•The current business
and overall equipment effectiveness (OEE).
•The third-generation DCS employ powerful object-oriented design
technology to enable efficiency improvements within daily operations
and maintenance (O&M) activities.
•Asset optimization is available to improve production reliability
through improved process stability as well as through asset monitoring
for predictive maintenance.
• Control system technology also now integrates several field bus
protocols, thus enabling more flexibility in designs as well as improved
data for maintenance.
Distributed Control System
Architecture
Components In The
Architecture
• Engineering Workstation (EWS)
for project development, including
configuration of graphics, logic,
alarms, security, etc.
• Operator Workstation (OWS)
provides the operator interface,
including color graphics, faceplates,
alarms, logging, trends, diagnostics,
etc.
• Process Historical Archiver (PHA)
stores and retrieves historical data
• Field Control Unit (FCU)
executes sequential and regulatory
logic and directly scans I/O.
• I/O Subsystem supports I/O from all
the standard industry suppliers
• SCADA Data Server (SDS)
interfaces UCOS to PLCs, Field bus
technologies, RTUs, PLC I/O, and
other devices.
• microFCU small PLC that executes
sequential and regulatory logic and
directly scans onboard I/O.
• Networking and Communications
supports redundant and non-
redundant fiber optic and Ethernet
local networks
The LAN/WAN can be extended to
other sites inside or outside the plant
using such remote
communications
DCS Elements
• Local Control Unit
• Data Acquisition Unit
• Batch Sequencing Unit
• Local Display
• Bulk Memory Unit
CONTROLLERS IN DCS
• Basic Controller (CB)
• Extended Controller (EC)
• Multifunction Controller (MC)
• Advanced Multifunction Controller
(AMC)
How DCS control is better
• Back up scheme
-A back up computer
-Analog Controller
-Manual loading stations
-Various combinations of above
• Reduction of wiring cost
SCADA V/S DCS
1. DCS is process oriented, while SCADA is data
acquisition oriented.
2. DCS is process state driven, while SCADA is event
driven.
3. DCS is commonly used to handle operations on a
single locale, while SCADA is preferred for
applications that are spread over a wide
geographic location.
4. DCS operator stations are always connected to its
I/O, while SCADA is expected to operate despite
failure of field communications.
Computer Control Networks
Supervisory (host)
Computer
Operator Main Operator Archival
Control Control Control Data
Panel Computer Panel Storage
Data highway
To other Processes To other Processes
Local data acquisition and Local Local Local
control computers Computer Computer Computer
Local Display Local Display
PROCESS
DCS Elements-1
• Local Control Unit: This unit can handle 8 to 16
individual PID loops.
• Data Acquisition Unit: Digital (discrete) and
analog I/O can be handle.
• Batch Sequencing Unit: This unit controls a
timing counters, arbitrary function generators,
and internal logic.
• Local Display: This device provides analog
display stations, and video display for readout.
• Bulk Memory Unit: This unit is used to store and
recall process data.
DCS Elements-2
• General Purpose Computer : This unit is
programmed by a customer or third party to
perform optimization, advance control, expert
system, etc
• Central Operator Display: This unit typically
contain several consoles for operator
communication with the system, and multiple
video color graphics display units
• Data Highway : A serial digital data
transmission link connecting all other
components in the system. It allow for
redundant data highway to reduce the risk of
data loss
• Local area Network (LAN)
Modes of Computer control
[Link] Control signals from digital
computer
Mode FC
Local PID
controller
[Link] Digital
Control Mode Supervisory Control mode
Flow measurement
to computer
valve setting
from computer
Direct digital Control mode
Interface between digital computer
and analog instruments
• (A/D) Transducers convert analog
signals to digital signals. (Sensor
Computer)
• (D/A) Transducers convert digital
signals to analog signals.
(Computer Valve)
Data resolution due to
digitization
• Accuracy depends on resolution.
• Resolution depends on number of
bits:
Resolution = signal range × 1/(2m -1)
m = number of bits used by the
digitizer (A/D) to represent the
analog data
Data Resolution
• Signal = 0 - 1 Volt, 3 bit digitizer:
Binary Digital Analog Analog range
representation Equivalent equivalent covered
000 0 0 to 1/14 0
001 1 1/7 to 3/14 1/14
010 2 2/7 to 5/14 3/14
011 3 3/7 to 7/14 5/14
100 4 4/7 to 9/14 7/14
101 5 5/7 to 11/14 9/14
110 6 6/7 to 13/14 11/14
111 7 1 to 14/14 13/14
Utilization of DCS
• DCS vendor job:
– installation
• Control Engineer Job:
– Configuration
• Built-in PID control:
– How to Tune the PID control?
Advanced control topology
Two-ways
Data Bus
Process
DCS
PI
system
PI interface
Online: Real-time data
++ or Fortran
PI interface: C
Workstation
DCS Vendors
• Honeywell
• Fisher-Rosemont
• Baily
• Foxboro
• Yokogawa
• Siemens
Advantages of DCS
Access a large amount of current information from
the data highway.
Monitoring trends of past process conditions.
Readily install new on-line measurements together
with local computers.
Alternate quickly among standard control strategies
and readjust controller parameters in software.
A sight full engineer can use the flexibility of the
framework to implement his latest controller design
ideas on the host computer.
Additional Advantage
Digital DCS systems are more
flexible. Control algorithms can be
changed and control configuration
can be modified without having
rewiring the system.
Distributed Control System
Example Of Thermal
Power Plant
Objective
• Safe operation of plant
• Lowest cost of generation
• Longest equipment life
• Minimum environmental effect
• Maximum efficiency
• Energy conservation
Benefits of DCS
• High reliability
• Improved response time
• Improve operator interface to plant
• Improve accessibility of plant data to
engineering & management
personals
• Historical storage and retrieval
system
DCS hardware
• Controller card
- Input cards(4-20 mA,
thermocouple,RTD,Digital)
.
-Outputs cards(4-20mA,
digital)
-Power supply module.
-Commnucation card
-Cables
• Controller with
input/output card
DCS architecture
Operator work station
• Alarm monitoring
• graphic display
• Trend display
• operator guidance display
• System & diagnostic display
• Control
• Bar chart
• Sequence display
• Fault analysis display
Logs/Reports
• Event activated logs- alarm
log,trip analysis,start up log
• Time activated logs-shift log,daily
log
• Operator demand logs-summary
log,performancelog,maintenance log
• Sequence of events log
Boiler control system
• Burner management system
• Secondary air damper control
• Aux pressure desuper heating
system
• Soot blower control
• Hp by pass
Turbine control system
• Turbine governing system
• Turbine protection
• Automatic turbine run up system
• Turbine stress controller
• Lp by pass
• Sequence controls for turbine driver
• Generator aux monitoring
THANK YOU