Topic: Direct digital control (DDC) and Distributed Control System (DCS)

Hierarchical Control

Fig. Automation pyramid.

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 Direct digital control (DDC) and Distributed Control System (DCS)

Hierarchical Control

Detailed structure of control system hierarchy

Fig. Automation pyramid.

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 Direct digital control (DDC) and Distributed Control System (DCS)
Hierarchical Control

Fig. A standard functional hierarchy by ANSI/ISA-95

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 Direct digital control (DDC) and Distributed Control System (DCS)

Building blocks of Automation

Sensors and actuators

Analog and digital I/O modules
DDC direct digital control
PLC and PACs Programmable automation controls
DCS distributed control systems
SCADA supervisory control and data acquisition
MES manufacturing execution system
ERP enterprise resource planning

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 Direct digital control (DDC) and Distributed Control System (DCS)

Building blocks of Automation

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 Direct digital control (DDC) and Distributed Control System (DCS)

Direct Digital control (DDC)

Block diagram of a direct digital control system.

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 Direct digital control (DDC) and Distributed Control System (DCS)
Modes of Computer control

1. Manual
2. Automatic
• PID with local set point
3. Supervisory
• PID with remote set point
(supervisory)
4. Advanced

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 Direct digital control (DDC) and Distributed Control System (DCS)
PC Network control system
In small processes such as laboratory prototype or pilot plants, the number of control loops is
relatively small. An inexpensive and straightforward way to deal with the systems is to
configure a network of personal computers for data acquisition and control. An example
configuration of a PC network control system is depicted in Figure

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 DCS: System Architecture
Distributed Control System is most popular which is specially designed with redundancy and diagnostic
capabilities to improve control reliability and performance. It gives greater flexibility to control distributed
discrete field devices and its operating stations.

Fig. Current DCS topology integrating multiple I/O buses such as Fieldbus, DeviceNet, AS-Interface, HART,
and conventional I/O into a single system.
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 DCS: System Architecture

Fig. The components of a DCS system, shown from the perspective of its physical structure.

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 DCS: System Architecture

Fig. The main components of a DCS system, shown from the perspective of its main functional components.

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Topic: Operation of Distributed Control System (DCS)
Definition

Distributed Control System (DCS) is a specially designed control system used to control
complex, large and geographically distributed applications in industrial processes. In this,
controllers are distributed throughout the entire plant area.

Distributed control system (DCS) is the most modern control platform. It stands as the
infrastructure not only for all advanced control strategies but also for the lowliest control
system.

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.

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 Distributed Control System (DCS)
Discrete Field devices such as sensors and actuators are directly connected to input
and output controller modules through communication bus. These field devices or smart
instruments are capable of communicating with PLC’s or other controllers while
interacting with real world parameters like temperature, pressure, etc.

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 Distributed Control System (DCS)

• Controllers are distributed geographically in various section of control area and are
connected to operating and engineering stations which are used for data monitoring,
data logging, alarming and controlling purpose via another high speed communication bus.
• These communication protocols are of different types such as foundation filed bus,
HART, Profibus, Modbus, etc. DCS provides information to multiple displays for user
interface.

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 Basic Elements of Distributed Control System (DCS)
Engineering PC or controller
This controller is the supervisory controller over all the distributed processing controllers.
Control algorithms and configuration of various devices are executed in this controller.
Network communication between processing and engineering PC can be implemented by
simplex or redundant configurations.

Distributed controller or Local control unit

It can be placed near to field devices (sensors and actuators) or certain location where these field
devices are connected via communication link. It receives the instructions from the engineering
station like set point and other parameters and directly controls field devices.

It can sense and control both analog and digital inputs / outputs by analog and digital I/O modules.
These modules are extendable according to the number of inputs and outputs. It collects the
information from discrete field devices and sends this information to operating and engineering
stations.
Operating station or HMI
It is used to monitor entire plant parameters graphically and to log the data in plant database
systems. Trend display of various process parameters provides the effective display and easy
monitoring.
These operating stations are of different types such as some operating stations (PC’s) used to
monitor only parameters, some for only trend display, some for data logging and alarming
requirements. These can also be configured to have control capabilities.

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 Basic Elements of Distributed Control System (DCS)

Communication media and protocol

Communication media consists of transmission cables to transmit the data such as coaxial
cables, copper wires, fiber optic cables and sometimes it might be wireless. Communication
protocols selected depends on the number of devices to be connected to this network.
For example, RS232 supports only for 2 devices and Profibus for 126 devices or nodes.
Some of these protocols include Ethernet, DeviceNet, foundation filed bus, modbus,
CAN, etc.

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 Important Features of Distributed Control System (DCS)

• To handle complex processes:

In factory automation structure, PLC-Programming Logic Controller is used to control and
monitor the process parameters at high speed requirements. However due to limitation of number
of I/O devices, PLC’s cannot handle complex structure. Hence DCS is preferred for complex
control applications with more number of I/O’s with dedicated controllers. These are used in
manufacturing processes where designing of multiple products are in multiple procedures such as
batch process control.
• System redundancy:
DCS facilitates system availability when needed by redundant feature at every level. Resuming
of the steady state operation after any outages, whether planned or unplanned is somewhat better
compared to other automation control devices. Redundancy raises the system reliability by
maintaining system operation continuously even in some abnormalities while system is in
operation.
• Lot of Predefined function blocks:
DCS offers many algorithms, more standard application libraries, pre-tested and predefined
functions to deal with large complex systems. This makes programming to
control various applications being easy and consuming less time to program and
control.

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 Important Features of Distributed Control System (DCS) (Contd.)
• Powerful programming languages:
It provides more number of programming languages like ladder, function block, sequential, etc
for creating the custom programming based on user interest.

• More sophisticated HMI:

DCS can monitor and control through HMI’s (Human Machine Interface) which provides
sufficient data to the operator to charge over various processes and it acts as heart of the system.
DCS completely takes the entire process plant to control room as a PC window. Trending,
logging and graphical representation of the HMI’s give effective user interface. Powerful
alarming system of DCS helps operators to respond more quickly to the plant conditions
• Scalable platform:
Structure of DCS can be scalable based on the number I/O’s from small to large server system
by adding more number of clients and servers in communication system and also by adding
more I/O modules in distributed controllers.
• System security:
Access to control various processes leads to plant safety. DCS design offers perfect secured
system to handle system functions for better factory automation control. Security is also
provided at different levels such as engineer level, entrepreneur level, operator level, etc.

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 Types of Distributed Control System (DCS)
According to network configuration and network protocol DCS can be divided into following
categories.
• STAR type DCS
• Ring type DCS
• Multidrop or shared bus type DCS

Star Topology
In a star topology, each device on the network is connected to a central hub by a single
communications circuit, as shown in the below figure. The hub performs the function of
passing messages between devices. In a star network, loss of a single communication circuit
affects only the single device at the end of that circuit, although the loss of a hub device
obviously affects the entire network. The star network has the highest installation cost per
device.

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 Types of Distributed Control System (DCS)

Ring type DCS

Ring Topology
In a ring topology, two communication ports are provided on each device and the network
circuit makes a loop through all of the devices, with an open point, as shown in the below figure.
Two-way communication allows messages to pass in either direction along the network.
Messages must be passed through the communication ports of each device on the network,
making it vulnerable to a break if a single device fails or is removed. If a means is provided to
bridge the open point on the failure of a particular device or circuit segment, this configuration
can have high reliability at a relatively low cost..

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 Types of Distributed Control System (DCS)

Multidrop or shared bus type DCS

In a tapped (or multi-drop) network the communications circuit is tapped to be connected to

each device so that the communication ports of the various devices are effectively electrically in
parallel. Tapped connections are applicable only to copper-based media; fiber-optic circuits are
limited to point-to-point operation.
The configuration in the figure below typically represents the lowest installed cost per device.

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 Types of Distributed Control System (DCS)

Multidrop or shared bus type DCS

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.

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 Types of Distributed Control System (DCS)

Multidrop or shared bus type DCS (Contd.)

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)

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 Advantage of Distributed Control System (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.

 Digital DCS systems are more flexible. Control algorithms can be

changed and control configuration can be modified without having
rewiring the system.

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 DCS Vendors

 Honeywell
 Fisher-Rosemont
 Baily
 Foxboro
 Yokogawa
 Siemens
 GE Fanuc Intelligent Platform
 Schneider Electrics
 ABB

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