Distributed Control Systems

Ajay Kumar
Dept of Instrumentation and Control
NIT Jalandhar
DEFINATION
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

DCS (Distributed Control System) is a

computerized control system used to control the
production line in the industry controlled by one or
more controllers.
DCS is a very broad term used in a variety of industries,
to monitor and control distributed equipment.
APPLICATION AREA
Electrical power grids and electrical generation plants
Environmental control systems
Traffic signals
Radio signals
Water management systems
Oil refining plants
Metallurgical process plants
Chemical plants
Pharmaceutical manufacturing
Sensor networks
Dry cargo and bulk oil carrier ships
HISTORY
 The DCS was introduced in 1975. Both Honeywell
and Japanese electrical engineering firm Yokogawa
introduced their own independently produced DCSs
at roughly the same time, with the TDC 2000 and
CENTUM[3] systems, respectively. US-based Bristol
also introduced their UCS 3000 universal controller
in 1975. In 1978 Metso(known as Valmet in 1978)
introduced their own DCS system called Damatic
(latest generation named Metso DNA[4]). In 1980,
Bailey (now part of ABB[5]) introduced the
NETWORK 90 system. Also in 1980, Fischer & Porter
Company (now also part of ABB[6]) introduced DCI-
4000 (DCI stands for Distributed Control
Instrumentation).
Distributed Control Systems

 Collection of hardware and

instrumentation necessary for
implementing control systems

 Provide the infrastructure (platform) for

implementing advanced control
algorithms
History of Control Hardware

 Pneumatic Implementation:
◦ Transmission: the signals transmitted
pneumatically are slow responding and
susceptible to interference.

◦ Calculation: Mechanical computation devices

must be relatively simple and tend to wear
out quickly.
History (cont.)
 Electron analog implementation:
◦ Transmission: analog signals are susceptible
to noise, and signal quality degrades over
long transmission line.

◦ Calculation: the type of computations

possible with electronic analog devices is
still limited.
ADVANTAGES OF DIGITAL SYSTEMS-

 Digital computers are more flexible

because they are programmable and no
limitation to the complexity of the
computations it can carry out.
 Digital systems are more precise.
 Digital system cost less to install and
maintain
 Digital data in electronic files can be
printed out, displayed on color terminals,
stored in highly compressed form.
 COMPUTER CONTROL NETWORKS

1. PC Control: Display

 Good for small

processes such as
laboratory prototype or Main

pilot plants, where the Computer

number of control loops

is relatively small Final
control P ROCESS
Data
acquisition
element
COMPUTER CONTROL NETWORKS

2. Programmable Logic Controllers:

 specialized for non-continuous systems such as batch
processes.

 It can be used when interlocks are required; e.g., a flow

control loop cannot be actuated unless a pump has
been turned on.

 During startup or shutdown of continuous processes.

BLOCK DIAGRAM
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 CONTROL
signals from digital
1. Manual computer

Local PID
2. Automatic controller

• PID with local set

point
Supervisory Control mode

3. Supervisory Flow measurement

to computer
• PID with remote set valve setting
from computer
point (supervisory)

4. Advanced Direct digital Control mode

CLASSIFICATION OF DCS
ELEMENTS
1.DOMAIN
 Domains are group of stations connected on the
network. Bus Converters (ABC) are used to link
domains. Domains are classified into real domains
and virtual domains. Real or CS domains are
domains, which consists of stations that are directly
connected on the network.Virtual [1] Domains are
domains, which consists of stations that are not
directly connected on the network. E.g. AC800M,
CS1000, Centum-XL stations, Micro-XL Stations
etc.
2.FIELD CONTROL UNIT

 These are the “lowest ‟‟ hierarchical level of a DCS,

the function units of the system are distributed and
placed in the field.
 The units are strong autonomous automation
subsystem, whose domain of influence is restricted
to a few (1 to 8,16,32) measuring points or control
loops. Being functionally autonomous and situated
in field, the subsystems are called field stations.
FCS cont-

 The primary function of field station is to:

Collect and preprocess analog and digital signals.

Monitor and log the alarming messages
Perform open and closed loop control functions
3.INTERMEDIATE STATIONS

The most common functions of the

intermediate stations are

 State observation of the process variables

 Calculation of reference values for control loops at “
lowest ‟‟ level (SV & PV) Tracking if order
processing and material and energy balances
 Efficiency analysis
 Reporting
 Data exchange with “higher” level stations (central
station)
4.CENTRAL COMPUTER STATIONS
 Central computer station enables
centralized plant monitoring, direct
operation on plant instrumentation, and
offers important program generation and
system diagnostics services. The stations
connected to other system through the
system bus which can initiate the necessary
data transfers.
Functions of the central computer control are
1.Plant oriented
2.General application
5.MONITORING AND COMMAND FACILITIES

 The DCS consists of a series of versatile,

intelligent, plant monitoring and command
facilities, by the use of which the plant state can
be supervised and the process with in the plant
directly influenced by the plant operator.
CASE STUDY
1.PROCESS CONTROL OF CPP
 The power plant is an industrial facility for the
generation of electricity. At the centre of nearly all
power stations is a generator, a rotating machine
that converts mechanical energy into electrical
energy by creating relative motion between a
magnetic field and a conductor. The energy source
harnessed to turn the generator varies widely. It
depends on what fuels are easily available and the
types of technology that Power Company has
accessed to.
 In automating the captive power plant processes
the use of equipment and software, which have not
been designed specifically for the industry, can land
the user with headaches.
WORKING OF CPP

 Steam is generated in the boiler of the thermal

power plant using heat of the fuel burnt in the
combustion chamber. The steam generated is
passed through steam turbine where part of its
thermal energy is converted into mechanical
energy which is further used for generating
electric power. The steam coming out of the
steam turbine is condensed in the condenser and
the condensate is supplied back to the boiler with
the help of the feed pump and the cycle is
repeated.
WORKING OF CPP cont-
 The function of the boiler is to [4] generate
steam. The function of the condenser is to
condense the steam coming out of the low
pressure turbine. The function of the steam
turbine is to convert heat energy into
mechanical energy. The function of the
condenser is to increase the pressure of the
condensate from the condenser pressure to
the boiler pressure. The other components
like economizer, super heater, air heater and
feed waters are used in the primary circuit
to increase the overall efficiency of the plant.
CPP PROCESS CONTROL THROUGH
DCS
 The process variables are controlled by DCS
through valves, pumps or other motors. A motor
has a provision to be either run locally (form
field) or from DCS (remote).
 Once it is in remote mode; the message flashes in
the operator screen and further option is
available to operate either in auto mode or
manual mode.
 When it is manual mode, it can be made to start
or stop by pressing the on-off buttons in Digivis.
When in auto mode, the command is issued from
DCS, based on the logic of the process station.
AREAS OF CONTROL
(1) STEAM TEMP CONTROL-

The main aim of this control loop is to maintain

the steam temperature at a certain set point.
The final steam temperature is measured with
the transmitter TT. The output is compared with
a fixed set point in the controller TIC. The
resultant control signal instructs the spray
control valve TV to control flow of water to the
attemperator.
(2) FURNACE PRESSURE CONTROL-

 The furnace pressure is measured with

the Pressure transmitter PT. This is used
as a Process variable (PV) and is then
compared with a fixed set point in the
controller PIC. The resultant control
varies the speed of the motor that
controls the pressure (ID fan).
(3)COMBUSTION CONTROL
 The aim of the combustion control loop is to
maintain rated steam pressure during fixed and
varying conditions. This is achieved by controlling the
firing rate and the air flow rate to have a proper
combustion in the furnace.

 The main steam pressure is measured by the pressure

transmitter PT and is used as a process variable for
the controller PIC. This controller generates an
output signal based on the difference between the
local set point and the process variable. The output of
this controller is then passed on to the boiler lading
stations HIC-M1, M2,M3,M4 which act as an
auto/manual station for rotary feeder for coal.
(4) TANK LEVEL CONTROL

 This control loop is used to [3] control the CBD

tank level. The CBD tank level is measured by the
transmitter LT. this level is fed to a level indicating
controller LIC as a measured variable. This
measured variable is compared with the fixed set
point in the Level indicating controller. The
controller then operates the CBD level control
valve.

 Acceptable limit then the corresponding alarm is

generated as Low (LAL), Low-Low (LALL), High
(LAH) and High-High (LAHH).
HUMAN MACHINE INTERFACE
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.
DCS VENDORS
 Honeywell
 Fisher-Rosemont
 Baily
 Foxboro
 Yokogawa
 Siemens
 GE Fanuc Intelligent Platform
 Schneider Electrics
 ABB
ANY QUESTIONS ?
THANK YOU