International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 6, June 2012)

Application of Distributed Control System in automation

of Process Industries
Megha Anand S.A. 1, Suprathik Sarkar 2 , Sree Rajendra 3
1
Department of Mechanical Engineering, Malnad College of Engineering, Hassan-573201, Karnataka, INDIA
2
Training Manager, ABB Ltd., Bengaluru-560058, Karnataka, INDIA
3
Associate Professor, Department of Mechanical Engineering, Malnad College of Engineering, Hassan-573201,
Karnataka, INDIA
Abstract:The operation of modern day process plant This in turn requires new creative solutions to
cannot be visualized without the smart looking increase productivity, improve quality and reduce
Distributed Control System (DCS) situated in control cost through full utilization of raw materials,
rooms. Process plant automation has evolved from equipment and manpower. A systems approach is
pneumatics to electronics’ to DCS. Use of DCS leads to
needed to conceive these new generation process
various advantages like the overall optimization, ease of
operation and maintenance tasks, easy monitoring of plant, design, build and operate them.
more plant parameters and ensure tighter control on
them. The field instrumentation and control system A large variety of available Distributed Control
have to be integrated properly and must function Systems (DCS) architectures are designed by
optimally to achieve such a goal. different vendors therefore the classification of DCS
The main intent of this paper is to highlight the elements as described here, is only a possible
salient features of the present DCS used in the process classification.
industry and the working of it and discuss the future
trends in automation of large process plants. II. CLASSIFICATION OF DCS ELEMENTS
Case Studies:
This paper also deals with a case study to give a clear A. Domain:
view of DCS where it has been applied in process
control in Captive power plant. Domains are group of stations connected on the
network. Bus Converters (ABC) are used to link
Keywords: DCS, process industry, field instrumentation domains. Domains are classified into real domains
and virtual domains. Real or CS domains are
I. INTRODUCTION domains, which consists of stations that are directly
connected on the network. Virtual [1] Domains are
Today‟s competitive environment have placed domains, which consists of stations that are not
very high demands on the process industry to directly connected on the network. E.g. AC800M,
produce products economically and at the same time CS1000, Centum-XL stations, Micro-XL Stations
using latest technologies available in the market, etc.
justify the cost effectiveness by investing more time,
tools and manpower to achieve optimal controls. In B. Field control unit:
order to maintain a competitive edge and profitable
operation in this emerging industrial climate requires These are the “lowest ‟‟ hierarchical level of a
not only process plant automation but also total plant DCS, the function units of the system are distributed
management. and placed in the field.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 6, June 2012)
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.
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
With the fore listed functions it is evident that the
field stations have to be intelligent, CPU based,
autonomous system units, [1] provided by a series of
process interface modules, as well as with a number
of RAM and PROM blocks. They are connected to
the bus with the help of a bus interface coupler.
Typical analog inputs and outputs per field station are
4, 8, 16, 48 or 64 and binary inputs and outputs per
field station is 2, 4, 8, 16 and 256. In addition to this
some fields have special digital inputs such as timers,
counters etc. or digital outputs such as pulse and
stepper motor output, positioning and motor control
etc.
Figure2.1: Field Control Unit
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C. Intermediate Stations:
The intermediate functional system units which
are placed in between the lowest and the highest
hierarchical levels are known as group or supervisory
stations. The stations are the autonomous systems
elements with the restricted domain of influence to a
group of field stations, pertaining to a closed, well
defined, and relatively autonomous part of the plant.
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)
D. Central Computer Station:
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
 Plant oriented
 General application
E. 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.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 6, June 2012)
In most of the present process monitoring systems
the principle of defining different windows for
monitoring different process parameters and
massages are being practiced. In ABB 800xA these
are divided into two types they are:
F. Data Communication Link:
The present practice of is to divide the whole
plant controls into a number of distinguishable
control loops & envisaging standalone controllers for
them. All these controllers situated in a centrally
located control equipment room are connected
together through communication network called as
field bus .The main advantage of s field bus as
compared to the conventional point to point data
transfer links are.
 Higher information content of the signal to
be transferred, including the diagnostic &
calibration data
 Lower cabling expenses
 Simplified interface of the process control
unit.
B. Working of Captive Power Plant:
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.
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.

III. CASE STUDY

A. 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 Figure3.1Working of Power Plant
the user with headaches.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 6, June 2012)
C. Captive Power Plant Process Controlled
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.
An example, of process control logic is a set point
control loop consisting of a pressure sensor,
controller, and valves. Some of the areas of control
are:
a) Drum Level Control:
The aim of this control loop is to maintain the
drum level at normal operating level of the boiler.
Middle value of three transmitters (LT1, LT2 and
LT3) is selected for drum level control through Level
indicator (L1) block.
If reading of any two transmitters deviates by
10% then the controller should be forced to manual
mode. If greater than 10% deviation is observed in all
the three transmitters then the boiler should be
tripped. In case of failure of one transmitter, average
of the other two transmitters should be referred for
control and in case of failure of two transmitters, the
boiler should be tripped.
The level signal acts as a Process variable (PV)
to the controller block LIC. The controller block will
vary the percentage opening of the valve LV and
hence level control is achieved.
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b) Steam Temperature 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.
c) 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).
d) 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.
The air flow controller is a slave controller with
the airflow as the Process variable (FI) and total heat
demand as remote set point. This remote set point is
total combustion air requirement. The air flow
controller generates an output signal comparing the
remote set point and the process variable. The output
is fed to the FD fan to control the net air flow.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 6, June 2012)
e) CBD 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).
f) Deaerator Level Control:
This control loop is used to control the deaerator
storage tank level. The Deaerator level transmitter
(LT) senses deaerator tank level and level is fed to a
Level indicating controller (LIC) as a measured
variable. The measured signal is compared with the
fixed set point in the level indicating controller. The
resultant control signal operates the deaerator control
valve (LV) which controls the deaerator level.
g) Deaerator Pressure Control
given to Pressure indicating controller (PIC) and
Temperature indicating controller (TIC) as process
variable respectively.
The output of the Pressure indicating controller
(PIC) is used to provide to operate the Pressure
control valve (PV) to control the pressure of steam.
Output of the Temperature indicating controller
(TIC) is provided to operate the Temperature control
valve (TV) to control the temperature of steam.
Similarly for steam header pressure transmitter,
the Pressure transmitter (PT) senses the pressure of
the steam and the Temperature transmitter (TT)
senses the temperature of the steam going into the
header. These signals are given to the Pressure
indicating controller (PIC) and Temperature
indicating controller (TIC) and act as process
variables respectively.
The output of the Pressure indicating controller
(PIC) is used to operate the pressure control valve to
control the pressure of steam.
These are provisions to view the valve position
through the Position transmitter (ZT) in the DCS.

This control loop is [4] used to control deaerator D. System configuration of DCS:
pressure. The deaerator Pressure transmitter (PT)
senses the deaerator tank pressure and pressure signal
is fed to a Pressure indicating controller (PIC) as a
measured variable. The measured variable signal is
compared with fixed set point in pressure indicating
controller. The resultant control signal operates the
Deaerator pressure control valve (PV) to control the
deaerator pressure.

h) PRDS Control:

This loop is used to control the pressure and

temperature of the steam going to deaerator and
steam header.

For Deaerator steam, the [3] Pressure transmitter

(PT) senses the pressure of the steam and
Temperature transmitter (TT) senses the temperature
of the steam going to deaerator. These signals are Figure3.2: System Configuration Drawing

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 6, June 2012)
All connected to plant server and all controllers
are connected connectivity server to It has two
redundant servers where both the servers are
connected to switch 1 and switch 2. Switch 1 and
switch 2 helps to communicated between the server,
client and controllers. DCSs may employ one or
several workstations and can be configured at the
workstation or by an off-line personal computer.
Local communication is handled by a control
network with transmission over twisted pair, coaxial,
or fiber optic cable. A server and/or applications
processor may be included in the system for extra
computational, data collection, and reporting
capability.
A typical DCS consists of functionally and/or
geographically distributed digital controllers capable
of executing from 1 to 256 or more regulatory control
loops in one control box. The input/output devices
(I/O) can be integral with the controller or located
remotely via a field network. Today‟s controllers
have extensive computational capabilities and, in
addition to proportional, integral, and derivative
(PID) control, can generally perform logic and
sequential control.
E. Human Machine Interface:
Figure3.3: Simulation of the Water and Steam Lines
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A DCS typically [1] uses custom designed
processors as controllers and uses both proprietary
interconnections and Communications protocol for
communication. Input & output modules form
component parts of the DCS. The processor receives
information from input modules and sends
information to output modules. The input modules
receive information from input instruments in the
process and transmit instructions to the output
instruments in the field. Computer buses or electrical
buses connect the processor and modules through
multiplexer or demultiplexers. Buses also connect the
distributed controllers with the central controller and
finally to the Human Machine Interface (HMI) or
control consoles. The figure shows the simulation of
the drum level control.
IV. CONCLUSION
DCS has made the process monitoring and
controlling in plants simple as it is an easy to handle
powerful system.Process plant operation and
maintenance has been simplified with the wide
spread use of DCS base control architecture. But with
the success of field bus-based architecture in some of
the smaller process control industries, it is becoming
increasingly obvious that the decision to switch over
from conventional DCS centric architecture to a more
open field bus-based inevitable.
In future, going by current trends, process
automation will be totally based on Artificial
Intelligence. Artificial Intelligence seems to be the
key technology in the near future, wherein the entire
concept of Computer Integrated Manufacturing will
be powered by this technology.
This has resulted in man power. But reduction in
man power has not affected the safe operation of the
plant as the processes are being monitored by
operating station. As a result; in case of faults, alarms
and alerts are being issued without any delay, through
the provisions of „horn‟ in Control Builder. Therefore
an error message is sent both to field and operating
stations and the process is halted by tripping the
faulty part.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 6, June 2012)
Therefore DCS monitored captive power plants
function safely and with greater efficiency.

REFERENCES

[1] ABB Instruction Manual

[2] Coal Fired Thermal Power Plant: The Basic

Steps and Facts, Written by: johnzactruba•
Edited by: Lamar Stonecypher
Updated Sep 8, 2011

[3] http://indianpowersector.com/power-
station/thermal-power-plant/

[4] "Thermal Power Plant Simulation and

Control" ed. by Damian Flynn
IEE Power and Energy Series

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