Distributed Control Systems

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 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). In 1980,
Bailey (now part of ABB) introduced the NETWORK
90 system. Also in 1980, Fischer & Porter Company
(now also part of ABB) 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.
History (cont.)

•Digital Implementation:

• Transmission: Digital signals are far less

sensitive to noise.

• Calculation: The computational devices are

digital computers.
 Advantages of Digital System
 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
Display

1. PC Control:
• Good for small
processes such as Main
laboratory prototype or Computer

pilot plants, where the

number of control loops
Final
is relatively small control PROCESS
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.

 Computer Control Networks

3. DCS
Supervisory (host)

•Most
Computer

comprehensive Operator
Control
Main
Control
Operator
Control
Archival
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)
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.
 Supervisory Control

 Supervisory control, controls a number of integrated

unit operations in a cell:
 Machines
 Robots
Supervisory
Supervisory
 Conveyors Control
Control

Conveyor
Conveyor Machine
Machine Robot
Robot
Control
Control Control
Control Control
Control

Transformation
Transformation Processes
Processes
Distributed Control System

Materials
Materials Production
Production Design
Design Quality
Quality Shop
Shop Floor
Floor Financial
Financial
Planning
Planning Planning
Planning Control
Control Control
Control Planning
Planning

Enterprise
Enterprise Network
Network
Supervisory
Supervisory Supervisory
Supervisory
Control
Control Control
Control

Shop
Shop Floor
Floor Network
Network

Machine
Machine Storage
Storage Conveyor
Conveyor Machine
Machine Robot
Robot Assembly
Assembly
Control
Control Control
Control Control
Control Control
Control Control
Control Control
Control

Transformation
Transformation Processes
Processes
 Modes of Computer control
signals from digital
1. Manual computer

Local PID
FC
2. Automatic controller

• PID with local set point

3. Supervisory Supervisory Control mode

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

4. Advanced
Direct digital Control mode
Additional Advantage

Digital DCS systems are more flexible.

Control algorithms can be changed and
control configuration can be modified
without having rewiring the system.
Categories of process information

Example Type
Relay, Switch Digital .1
Solenoid valve
Motor drive
Alphanumerical displays Generalized .2
digital
Turbine flow meter Pulse .3
Stepping motor
Thermocouple or strain gauge (mill volt) Analog .4
Process instrumentation (4-20 am)
Other sensors (0-5 Volt)
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:

Analog range Analog Digital Binary

covered equivalent Equivalent representation
to 1/14 0 0 0 000
to 3/14 1/14 1/7 1 001
to 5/14 3/14 2/7 2 010
to 7/14 5/14 3/7 3 011
to 9/14 7/14 4/7 4 100
to 11/14 9/14 5/7 5 101
to 13/14 11/14 6/7 6 110
to 14/14 13/14 1 7 111
Data Resolution

6
Digital data

4
3
2

1
0
0 1/7 2/7 3/7 4/7 5/7 6/7 1
Analog data
Utilization of DCS

•DCS vendor job:

•installation
•Control Engineer Job:
•Configuration
•Built-in PID control:
•How to Tune the PID control?
Utilization of DCS

•Implementation of advanced control:

• Developed software for control algorithms,
DMC, Aspen, etc.
• Control-oriented programming language
supplied by the DCS vendors.
• Self-developed programs using high-level
programming languages (Fortran, C++)
Advanced control topology
Two-ways
Data Bus

Process
PI

DCS
system

PI interface

Online: Real-time data

PI interface: C++ or Fortran

Workstation
DCS Vendors
• Honeywell
• Fisher-Rosemont
• Baily
• Foxboro
• Yokogawa
• Siemens
• GE Fanuc Intelligent Platform
• Schneider Electrics
• ABB
Thank You