Distributed Automation Systems

Types of Automation Systems:

1. Introduction

 Localized processes (present over a small area)

 Distributed processes (present over a large/geographical area)

Physical process is a series of actions, operations, changes, or functions that takes place
within bringing about changes or producing an output or a result. Also, the physical process
as a sequence of interdependent operations or actions which, at every stage, consume one
or more inputs or resources to convert same into outputs or results to reach a known goal or
the desired end result.

Figure 1 below illustrates a typical electricity distribution process (localized as well as

distributed) in a municipal area.

Figure 1 Electricity distribution process

The overall structure of the systems required for the automation of the two different types of
processes differ significantly in nature. In the following sections, the automation systems
specially devised for these process types are discussed.

Elifas Ngonga AUT3300 Class Notes 2013 1

[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

2. Localized Process

The local processes are present in a relatively small physical area, and the control centre is
physically close to the process. Figure 2.1 illustrates the structure (logical and physical) of
the automation system for the localized process. Here, we see that the controller is locally
connected to the operator station over the local communication line through the
communication interface. Normally, an Ethernet interface is employed for communication
between the controller and the operator station. The automation systems for the localized
process can be either centralized or decentralized or distributed, as explained in the
following sections.

Figure 2.1: Automation system structure—localized process

2.1 Centralized Control System

A centralized control system (CCS) always employs a single communicable controller that
takes the full automation load of the entire process. However, the system can have either a
single operator station or multiple operator stations. In the case of CCS with multiple
operator stations, multiple operators simultaneously share interaction with the process. This
sharing improves operator efficiency, especially when the process is large. The sharing is
generally either on a functional basis or on an area basis.

Let's use the example of a power plant automation system. A power plant typically has three
functional subprocesses—boiler, generation, and auxiliary—that produce electricity from coal
and water, as illustrated in Figure 2.1. With a single large controller, the entire plant
automation, with single or multiple operator stations can be used for operator interaction.

Elifas Ngonga AUT3300 Class Notes 2013 2

[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

Figure 2.1: CCS with single and multiple operator stations

Important advantages and disadvantages of CCS are as follows.

Advantages:

 Ideal for small and less spread out processes because of minimum field cabling
between the instrumentation/process points and the controller
 Technically simple
 Less expensive

Disadvantages:

 Not economical for large and widely spread out processes because of extensive field
cabling between the instrumentation/process points and the controller
 Failure of the controller results in making the complete plant automation facility
unavailable
 Handling, troubleshooting, maintenance, etc., of a big controller are very
inconvenient

2.2 Decentralized/Distributed Control System

To overcome the problems associated with CCS for large or widely distributed processes, a
network of many distributed communicable controllers is formed. These controllers share the
full automation load of the entire process, as shown in Figure 2.2. Here, both the controllers
and operator stations share the load on a functional or area basis. As all the controllers and
operator stations are on the same network, the information in one controller can be shared
by other controllers and/or operator stations. This arrangement is called a decentralized or
distributed control system (DCS).

Elifas Ngonga AUT3300 Class Notes 2013 3

[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

Figure 2.2: DCS with multiple controllers and operator stations

A DCS is a local area network of controllers and operator stations.

The concept of a DCS is best explained using the example of the automation of the power
plant process with its three functional subprocesses—boiler, generation, and auxiliary. The
three smaller communicable controllers for the three subprocesses control the complete
process jointly. Important advantages and disadvantages of DCS are as follows.

Advantages:

 Ideal for large and widely spread out processes (minimum cabling between the
process/instrumentation points to the distributed controllers, as the controllers can be
placed closer to the subprocesses)
 Higher overall availability, as single controller failure does not lead to a total automation
system failure (affects only a function or a part of the plant)
 Each controller being smaller in size, handling, troubleshooting, maintenance, etc. are
relatively convenient

Disadvantages:

 Expensive
 Technically more complicated

Elifas Ngonga AUT3300 Class Notes 2013 4

[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

3. Distributed Automation Systems

The distributed process, a group of interconnected localized sub processes, is spread out
over a relatively large physical (or even geographical) area, and the control centre is
physically away from the sub processes. Figure 3 illustrates the structure (logical and
physical) of the automation system for one localized sub process in a distributed process.
The controller is remotely connected to the operator station over the remote communication
line through the communication interface. Normally, a serial communication interface is
employed for communication between the controller and the operator station. The
automation system for the distributed processes can be a simple remote control system
(RCS) or a large network control system (NCS), as explained in the following sections.

Figure 3 Automation system structure—distributed process

3.1 Remote Control System

In a remote control system, as shown in Figure 3.1, the operator station located in the
control center monitors and controls the remotely located process over a communication
line. The controller, connected to the instrumentation and the process, treats the process as
localized. It performs its automation functions locally without the assistance of an operator
station, and it communicates with the operator station in the control centre. The role of the
operator station is only to supervise and monitor the process and issue manual control
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[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

commands, if required. The RCS, generally, employs serial communication interfaces at

both ends. The system in the control centre is often called a master station.

Figure 3.1 Remote control system

3.2 Network Control System

A network control system is an extension of RCS, and it simultaneously monitors and

controls many geographically distributed localized processes from a central place. Multiple
communicable controllers, distributed geographically and interfaced to their own
instrumentation and processes, share the common long-distance communication network for
communication with the control centre (operator station). Each controller manages its own
local automation independently, while the operator station in the control centre supervises
the overall automation of the entire distributed process. Further, each controller can
communicate with the control centre only and not with other controllers in the network. In
other words, the control centre is always the master of the communication network, and any
communication among the controllers is always through the control centre. Figure 3.2
illustrates the structure of an NCS.

Elifas Ngonga AUT3300 Class Notes 2013 6

[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

Figure 3.2 Network control system

Further, the network in an NCS refers to the network of interconnected distributed localized
processes (not the communication network). For example, the electrical transmission
network is a distributed process where the localized processes are the substations, and
networking is through the transmission lines.

Elifas Ngonga AUT3300 Class Notes 2013 7

[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

Communication networks

Distributed industrial control systems categorized in closed architectures have three popular
network types:

1. Ethernet network. In 1985, International Standards Organization (ISO) made Ethernet an

international standard. It is very common for workstations and PCs shipping today to
include an Ethernet interface card for compatibility with both 10 Mbit/s and 100 Mbit/s
Ethernet networks.

The most popular uses for Ethernet networks today is to conduct program maintenance,
send plant-floor data to and from MIS (manufacturing information system) and MES
(manufacturing execution system) systems, perform supervisory control, provide
connectivity for operator interfaces, and log events and alarms. An Ethernet network is
ideal for applications requiring (1) large data transfers, (2) wide access (site to site), (3)
no timecritical data exchange.

2. CAN network. Controller Area Network (CAN) is a low-level network that provides
connections between simple industrial devices (such as sensors, actuators, and valves)
and higher-level devices (such as PLC controllers and computers). The CAN network is
a flexible, open network that works with devices from multiple vendors.

The CAN network can (1) provide a cost-effective networking solution to simple devices,
(2) let you access data in intelligent sensors and actuators from multiple vendors, (3)
provide master/slave and peer-to-peer capabilities (4) offer the producer–consumer
services that let you configure devices (5) have control, and collect information over a
single network.

3. SCADA network. SCADA network is a state-of-the-art control network that meets the
demands of real-time, high-throughput applications. The SCADA network combines the
functionality of an I/O network and supervisory equipment while providing high-speed
performance for both functions. Figure 6.2 is an example of the SCADA network.

Data Communication Model for Distributed Control System

Data communications concerns the transmission of digital messages to devices external

to the message source. “External” devices are generally thought of as being
independently powered circuitry that exists beyond the chassis of a computer, a
controller, or other digital message source. To perform the required data communication,
industrial control networks use multilayered models handling the message exchanges
between components or entities in the networks. In these models, each layer defines a
specific type of communication. Bottom layers define how to transmit bits across physical
links. Upper layers define how to build network control applications and manage the data
communication protocol. Intermediate layers define connectionless and connection-
oriented network services. Within each layer, specific types of protocols are available to
accomplish a specific task. For example, the lower layers define different link protocols
such as Ethernet, token ring, ATM, frame relay, and so on. There are perhaps hundreds
of protocols that occupy the different layers of the various network architectures.

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[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

Data Communication Models for Open Control Systems

OSI (Open System Interconnection) reference model. The ISO (International standards
Organisation) developed the OSI reference model. The OSI is accepted as a “reference”
model. This OSI reference model outlines the levels of networking protocols and the
relationship they have with one another. The layered OSI model is pictured in Fig. 6.3.
The stacks on the left and right represent two systems that are engaged in an end-to-end
communication session. The middle devices are routers that provide Internet work
connections between the devices.

The architecture of OSI reference model.

Each layer in the protocol stack provides a particular function. These functions provide
services to the layer just above. In addition, each layer communicates with its peer layer in
the system to which it is connected. For example, the transport layer on a server
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of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

communicates with its peer transport layer on a client. This takes place through the
underlying layers and across the network.

Peer-layer communication is handled through message exchange between peers. For

example, assume the receiver is getting data faster than it can process it. To “slow down”
the sender, it needs to send it a message. The transport layer handles this sort of “throttling.”
So the transport layer creates a message for its peer transport layer in the sending system.
The message is passed down the protocol stack where it is packaged and sent across the
network. The message is then passed up to the protocol stack where it is read by the
transport protocol, which then initiates a procedure to throttle back. The main point is that
lower layers provide services to upper layers. Applications are the usual source of messages
and data that are passed down through the protocol stack, but each protocol layer may also
generate its own messages to manage the communication session.

One other thing to note is that the lower-layer physical and data link protocols operate
across physical point-to-point links while the transport layer protocols operate on end-to-end
virtual circuits that are created across the underlying network.

Each layer of the OSI model is described here for what it defines. The lowest layer is
discussed first, because it represents the physical network components.

1. The physical layer. The physical layer defines the physical characteristics of the
interface, such as mechanical components and connectors, electrical aspects such as
voltage levels representing binary values, and functional aspects such as setting up,
maintaining, and taking down the physical link. Well-known physical layer interfaces for
data communication include serial interfaces, parallel interfaces, and the physical
specifications for LAN systems such as Ethernet and token ring. Wireless systems have
“air” interfaces that define how data is transmitted using radio, microwave, or infrared
signals.

Funtions:

Defines connector & interface specifications as well as medium (cable) requirements.

Electrical, mechanical, functional and procedural specifications are provided for
sending bit stream on a computer network.

Components:

Cabling system components

Adapters that media to physical interfaces
Connector design and pin assignments
Wireless system components
Network interface cards (NIC)

2. The data link layer. The data link layer defines the rules for sending and receiving
information across a physical connection between two systems. Data links are typically

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of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

network segments (not Internet works) and point-to-point links. Data is packaged into
frames for transport across the underlying physical network. Some reliability functions
may be used, such as acknowledgment of received data. In broadcast networks such as
Ethernet, a MAC (medium access control) sublayer was added to allow multiple devices
to share the same medium.

Functions:

Allow a device to access the network to send and receive messages

Offer physical addressbso a device’s data can be sent on the network
Work with device’s networking software when sending and receiving messages
Provides error-detection capability

Components:

Network interface cards

Ethernet and token ring switches – forward data to destination devices or address

3. The network layer. This layer provides internetworking services that deliver data across
multiple networks. An internetworking addressing scheme assigns each network and
each node a unique address. The network layer supports multiple data link connections.
In the Internet Protocol (IP) suite, IP is the network layer internetworking protocol.

Functions:

Provide end-end logical addressing system so that a packet data can be routed
across several layer 2 networks.

4. The transport layer. The transport layer provides end-to-end communication services
and ensures that data is reliably delivered between those end systems. Both end
systems establish a connection and engage in a dialog to track the delivery of packets
across the Internet work. The protocol also regulates the flow of packets to
accommodate slow receivers and ensures that the transmission is not completely halted
if a disruption in the link occurs.

Function:

Offer end-end communication between end devices through a network.

Confirmation that the entire message arrived intact
Transmission error detection
Realignment of segmented data in the correct order on the receiving side

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of Industrial Process Automation by KLS Sharma and other online sources]
 Distributed Automation Systems

5. The session layer. The session layer coordinates the exchange of information between
systems by using conversational techniques, or dialogs. Dialogs are not always required,
but some applications may require a way of knowing where to restart the transmission of
data if a connection is temporarily lost, or may require a periodic dialog to indicate the
end of one data set and the start of a new one.

Function:

Acknowledgement of data received during session

Retransmission of data if not received by the a device

6. The presentation layer. Protocols at this layer are part of the operating system and
application the user runs on a workstation. Information is formatted for display or printing
in this layer. Codes within the data, such as tabs or special graphics sequences, are
interpreted. Data encryption and the translation of other character sets are also handled
in this layer.

Functions:

Encryption and decryption of a message for security

Compression and expansion of a message so that it travels efficiently
Content translation

7. The application layer. Applications access the underlying network services using
defined procedures in this layer. The application layer is used to define a range of
applications that handle file transfers, terminal sessions, and message exchange (e.g.,
electronic mail).

Functions:

Support for file transfers

Electronic mail
Browsing the world web

Elifas Ngonga AUT3300 Class Notes 2013 12

[Sources: Wikipedia, Concise Higher Electrical Engineering by [Link] Chikuni, Overview

of Industrial Process Automation by KLS Sharma and other online sources]