DISTRIBUTED CONTROL SYSTEM
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WHAT IS DISTRIBUTED CONTROL SYSTEMS?
Adistributed control system(DCS) refers to acontrol systemusually of amanufacturing system, processor any kind ofdynamicsystem. In which thecontrollerelements are not central in location (like thebrain)butaredistributedthroughoutthesystem With each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communicationandmonitoring.
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 SystemDCS
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 operatingunits.
Third Generation: The Extended AutomationDCS focus on increasing operational efficiency Thecurrent business goals
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 formaintenance.
Distributed Control System 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
Components In The Architecture
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 nonredundant fiber optic and Ethernet localnetworks The LAN/WAN can be extended to other sites inside or outside the plant using such remote communications
DCSElements
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 Control Panel Main Control Computer Operator Control Panel Archival Data Storage
To other Processes
Data highway
To other Processes
Local data acquisition and control computers
Local Computer
Local Computer
LocalDisplay
Local Computer
LocalDisplay
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 Mode [Link] Digital Control Mode
signalsfromdigital computer
FC
LocalPID controller
SupervisoryControlmode Flowmeasurement tocomputer valvesetting fromcomputer
DirectdigitalControlmode
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 representation 000 001 010 011 100 101 110 111 Digital Equivalent 0 1 2 3 4 5 6 7 Analog equivalent 0 1/7 2/7 3/7 4/7 5/7 6/7 1 Analogrange covered to1/140 to3/141/14 to5/143/14 to7/145/14 to9/147/14 to11/149/14 to13/1411/14 to14/1413/14
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
PI system PI interface
Online:Real-timedata
++ PIinterface:C orFortran
Workstation
Process
DCS
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
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