Distributed Control Systems

Dedicated Computer Control

 Dedicated computer control have wide applications in Small plant operation Large scale operations Signal and Image processing, etc.

Essential functions of a computer

Process monitoring Data acquisition Alarming and signaling Data processing Data archiving Process control

Centralized computer control

Distributed Vs centralized computer control

De-Centralized computer control system

Evolution of DCS

Famous DCS

Functional requirements of distributed computer control system

Plant operator requirements

Maintenance engineering requirements

Design/Development Engineer requirements

Manager/Supervisor requirements

System Architecture

DCS Hierarchy Structure

Hierarchical levels

AEG-Telefunken Logistat CP80

Hierarchical levels
Level 1 Process Level Level 2 Unit Control Level Level 3 Group Control Level Level 4 Process Control Level Level 5 Operation Control Level

DCS Hierarchy Structure

DCS Sub-system

Main sub systems of DCS

Field stations Presentation and monitoring devices Communication units

PROCONTROL Local field station

Local Field Station

Smallest intelligent unit of the DCS is the multi-loop control in the field attached to many local controllers. Honey well TDC 3000 field station is known as controller file Siemens TELEPARM field stations are known a Automation subsystem BBC PROCONTROL Field station is known as Compact processing station

Field station
Field station usually consists of 1. A microcomputer with 32 to 64Kb RAM 16 to 32 analog inputs 8 to 16 analog outputs upto 48 digital I/Os a serial and parallel bus interface 2. Hard copy output terminal 3. Local display terminal

Library of functions
Inputing signals Input signal conditioning Signal and hardware testing Limit values and trends check Alarming Reporting and logging Mathematical and logical signal processing On-line and off-line signal processing Visual display and printing Output signal conditioning Signal outputting

Presentation and monitoring devices

On the display screen the following will be usually represented
Current values of measuring data Positions of actuators Logs of the plant History of individual signals State of different plant parts, control loops, etc.

 The information displayed on the screen can be generally classified as follows:

Plant overview; Group overview; Local multi-loop representation of individual process variables reporting and logging Representation of secondary plant data ( statistical parameters, etc.)

TDC 3000 displays

TDC 3000 displays are used in three operating modes:
Normal conditions At time of process upset In the event of control equipment malfunction

Normal condition displays

Overview display

Schematic display

Group display

Group display with trends

Trend curve updating

Group display with hourly average

Detail display

Trend overview display

Batch/sequence operation display

Batch summary display

Batch display

Process upset displays

Alarm annunciator display

 Area and unit alarm display

Process management system display

Communication options in DCS

The communication system also follows hierarchy system For short distance applications star network is applicable At level 1 usually point-to-point connection is applicable to connect individual sensors and actuators to analog and digital inputs and output of the field station. For shorter distances instrumentation bus like IEEE 488, or special bus like k-110 of AEG Telefunken can be used. For level 2 and 3 long distance buses like IEEE 488, PDV BUS , PROWAY, etc which are extendable upto 5 to 10kms are used. Generally long distance buses are serial buses.

Field bus communication

Configuration of DCS

 Step 1: Configuration of operating system Composition of groups and overview displays Period for trend displays Hi-way station priorities Message tables

 Step 2: Configuration of controller functions

Some popular DCS

Leeds and Northup Max-1 System

Leeds and Northup Max-1 System

Control Bailey Micro-Z System

Honeywell TDC-2000, TDC 3000 system

TDC 3000 system architecture

The basic modules are;
Controller file Operator station Hiway traffic director(HTD) Analog unit Process interface unit

Honeywell TPS system

TPS Honeywell
The basic components of TPS system are:
Global user station (GUS) Total plant desktop module Total plant engineering tools Total plant history module Advanced application software packages like total plant batch control, multivariable control, optimization, etc.

Echelons Lonwork System

The basic building blocks of Lonworks are
Neuron chips Lontalk communication protocol Lonworks transceivers Network management services

Lonwork System

Features of DCS

Advantages of DCS