MODULE 4

DISTRIBUTED CONTROL SYSTEM

Evolution of Industrial Control Technology
• The lines of technological development can be divided into two separate
streams
• The upper stream with its two branches is the more traditional one, and
includes the evolution of analog controllers and other discrete devices such as
relay logic and motor controllers.
• The second stream is a more recent one that includes the use of large scale
digital computers and their mini and micro descendants in industrial process
control.
• These streams have merged into the current main stream of distributed digital
control systems.
Traditional Control Systems Developments
• discrete device control systems listed were distributed around the plant.
• Individual control devices: such as governors and mechanical controllers were
located at the process equipment to be controlled.
• Local readouts of set points and control outputs were available and a means
of changing the control mode from manual to auto mode usually was provided.
• It was up to the operator to coordinate the control of many devices that
made up the total process.
• They did this by roaming around the plant and making corrections to the
control devices.
• This is a feasible approach to the control of early industrial processes because
the plant was small geographically and the processes were not too large or
complex.
• The same architecture was copied when direct connected pneumatic controllers
• These controllers provided more flexibility in selection and adjustment of control algorithms,
but all the control elements of the control loop were still located in the field.
• There was no communication between the controllers other than that provided by the each
operator to other operators
• Improvements where made to build a centralized control system using pneumatic
transmitters
• These transmitters were capable of making measurements in the plant and to transmit it to
a. central control room
• Another major advent in the field of control system is to replace the pneumatic transmitters
with electronic ones which reduced the pneumatic tubing in the field.
• Next milestone in the development of control system was the introduction of programmable
logic controllers ,where it is a computer based devices that could be used by someone who
was not a computer specialist. It was designed to be programmed by a user who was
familiar with relay logic diagrams
Computer-based Control System Developments
• The first application of computers to industrial processes was in the areas
of plant monitoring and supervisory control provided an automatic data
acquisition capability.

• The computer used the available input data to calculate control set points.

• The next step in the evolution of computer process control was the use
of the computer in the primary loop itself, in a mode usually known as
direct digital control or DDC.

• The advantages of digital control over analog control: tuning parameters

and set points, complex control algorithms can be implemented to
improve plant operation, and control tuning parameters can be set
adaptively to track changing operating conditions
Hybrid System Architecture
• Hybris architecture make use of a combination of discrete control hardware
and computer hardware in a central location to implement the required
control functions.
• In this approach, first level or local control of the plant unit operations is
implemented by using discrete analog and sequential logic controllers.
• Panel board instrumentation connected to these controllers is used for
operator interfacing and is located in the central control room area.
• A supervisory computer and associated data acquisition system are used to
implement the plant management functions, including operating point
optimization, alarming, data logging and historical data storage and retrieval.
• The computer also used to drive its own operator interface, usually consisting
of one or more video display units (VDUs).
Central Computer System Architecture
• In this type, all system functions are implemented in high-performance
computer hardware in a central location.
• redundant computers are required so that the failure of a single computer
does not shut the whole process down.
• Operator interfacing for plant management functions is provided using
computer driven VDUs.
• Operator interfacing for first-level continuous and sequential closed-loop
control also may be implemented using VDUs.
• Optionally, the computers can be interfaced to standard panel board
instrumentation so that the operator in charge of first-level control can use a
more familiar set of control and display hardware.
• Note both of the above systems use computers. The main difference between
the two systems is the location of the implementation of the first level
continuous and sequential logic control functions.
Distributed Control System (DCS) Architecture
• The devices in this (DCS) architecture are grouped into three categories;
1. those that interface directly to the process to be controlled or monitored,
2. those that perform high-level human interfacing and computing functions
3. those that provide the means of communication between the other devices.
(i) Local Control Unit (LCU): The smallest collection of hardware in the system
that can do closed loop control. The LCU interfaces directly to process.
(ii) Low Level Human Interface (LLHI): A device that allows the operator or
instrument engineer to interact with LCU (eg: to change set points, control
modes, control configurations, or tuning parameters) using a direct connection.
• LLHIs can also interface directly to the process.
• Operator-oriented hardware at this level is called Low Level Operator Interface (LLOI);
• instrument engineer–oriented hardware is called a Low Level Engineering Interface
(LLEI).
(iii) Data Input / Output Unit (DI/OU):
• A device that interfaces to the process alone for the purpose of acquiring or outputting
data.
• It performs no control functions.
• High Level Human Interfaces (HLHI):
• A collection of hardware that performs functions similar to the LLHI but with increased
capability and user friendliness.
• It interfaces to other devices only over the shared communication facilities.
• Operated-oriented hardware at this level is called a High Level Operator Interface (HLOI);
• instrument engineer-oriented hardware is called a High Level Engineering Interface (HLEI).
• High Level Computing Device (HLCD):
• A collection of microprocessor based hardware that performs plant management
functions traditionally performed by a plant computer.
• It interfaces to other devices only over the shared communication facilities.
• Computer Interface Device (CID):
• A collection of hardware that allows an external general purpose computer
to interact with devices in DCS using shared communication facilities.

• Shared Communication Facilities:

• One or more levels of communication hardware and associated software that
allow the sharing of data among all devices in DCS.
• Shared communication facilities do not include dedicated communication
channels between hardware elements within the device.
Local Control Unit (LCU) Architecture
• The LCU is the smallest collection of hardware in the DCS that performs closed
loop control.

• it takes inputs from process-measuring devices and commands from operator

and computes the control outputs needed to make the process follow the
command.

• It then sends control output to actuators, drives valves and other mechanical
devices that regulate the flows, temperatures, pressures, and other variables
to be controlled in the plant.

• An LCU malfunction can cause a condition that is hazardous to both people

and equipment.

• Its proper design is critical to the safe and efficient operation of the plant
Basic Elements of a Microprocessor-Based Controller
• The microprocessor along with the associated clock comprises the central
processing unit (CPU) of the controller.
• ROM : for permanent storage of controller programs.
• RAM : for temporary storage of information.
• Based on the type of microprocessor used,
• RAM and ROM can be located on the microprocessor chip or on separate memory chip.
• The LCU must have I/O circuitry so that it can communicate with the external
world by reading in, or receiving analog and digital data as well as sending
similar signals out.
• The CPU communicates with the other elements in the LCU over an internal
shared bus that transmits addressing, data control and status information in
addition to the data.
• The controller structure shown in figure is the minimum required to perform
basic control functions.
• The control algorithms could be coded in assembly language and loaded into
ROM.
• After the controller was turned on:
• it would read inputs, execute the control algorithms, and generate control inputs in a
fixed cycle indefinitely.
• the controller structure shown in figure must be enhanced to include the following:
• Flexibility of changing control configuration.
• Ability to use the controller without being computer expert.
• Ability to bypass the controller in case it fails so that the process still can be
controlled manually.
• Ability of the LCU to communicate with other LCUs and other elements in the
system.
LCU Architecture
• There are three configurations are shown in LCU architecture.
• i) Configuration A ii) Configuration B and iii) Configuration C.
• Configuration A:
• In configuration A the controller size is the minimum required to perform a
single loop of control or a single motor control function or other simple
sequencing function.
• LCU that provides both analog and digital inputs and outputs and executes
both continuous and logic function blocks.
• All outputs in the range of 0.1 to 0.5 seconds maximum.
• Controller size: Number of functions needed for single PID loop or motor
controller.
• Controller functionality: Uses both continuous and logic function blocks.
• Controller scalability: High degree of scalability from small to large systems.
• Controller performance: Requirement can be met with simple and inexpensive
set of microprocessor based hardware.
• Communication channels: Need inter module communications for control.
• Controller output security: Controller has single loop integrity; usually only
manual backup is needed
• Configuration B:
• Configuration B represents architecture in which two different types of LCUs are used
to provide the full range of required continuous and logic functions. Outputs in the
range of 0.1 to 0.5 seconds.
• Controller Size: Includes functions and I/O needed for eight control loops and a small
logic controller.
• Controller functionality: Continuous and logic function blocks split between controllers.

• Controller scalability: Requires both types even in small systems.

• Controller performance: Because of functional split, performance requirements are
not excessive. It is usually implemented using a high-performance eight bit or an
average performance 16bit microprocessor and matching memory components.
• Communication channels: Functional separation requires close interface between
controller types.
• Controller output security: Lack of single loop integrity requires redundancy in critical
applications.
• Configuration C
• Configuration C represents a multi loop controller architecture in which both
continuous and logic functions are performed. Outputs in the range of 0.5
seconds of less.
• Controller size: System size is equivalent to small DDC system.
• Controller functionality: Uses both continuous and logic function blocks: can
support high level languages.
• Controller scalability: Not scalable to very small systems.
• Controller performance: Hardware must be high performance to execute large
number of functions. Usually implemented with one or more 16bit or 32bit
microprocessor in conjunction with support hardware such as arithmetic co
processors to attain the required speed.
• Communication channels: Large communication requirement to human
interface: minimal between controllers.
• Controller output security: Size of controller requires redundancy in all
applications
LCU-Process Interfacing Issues
• This figure expands on the basic LCU elements through the addition
of interfaces to external communication facilities and to a low-level
human interface device. The communication interfaces permit the
LCU to interact with the rest of the distributed system to accomplish
several functions:
• To allow several LCUs to implement control strategies that is larger
in scope than possible with a single LCU.
• To allow transmission of process data to higher-level elements.
• To allow these Higher-level elements to transmit information
requests and control commands to the LCUs.
• To allow two or more LCUs to act together as redundant controllers
to perform the same control or computational functions.
• To augment I/O capability of LCUs with that of data input/output
units in system
• The LLHI device and its associated interface hardware allow several
important human interfacing functions to be accomplished through
hardware that is connected directly to the LCU rather than over the
shared communication facilities. These functions include:
• Allowing the plant operator to select control set points and
controller modes.
• Allowing the plant operator to override automatic equipment and
control the process manually in case of a controller hardware failure
of other system malfunction.
• Allowing the plant instrumentation engineer to Configure control
system logic and later tune control system parameters.
Security Design Issues for LCU
Security Requirements
• The first priority of the user of any process control system is to keep the
process running under safe operating conditions.
• One way of designing a highly reliable control system is to manufacture it using
only the highest quality of components, conduct extensive burn-in testing of
the hardware, and implement other quality control measures in the
production process.
SECURITY hierarchy

• Maximize availability of automatic control functions of the system. Failure of a

single control system element does not shut all automatic control functions.
• Automatic control to manual control, if a portion of the control system failure
happens.
• If critical (both automatic and manual function) failure, operator can shut
down the process in an orderly and safe manner.
 Overview of Security Design Approaches
• There are three basic categories of security approaches currently in use.
i) Manual backup only.
ii) Hot standby redundant controller.
iii) Multiple active controller.
 i) Provide manual backup only:

Manual Backup
• each LCU is designed to
Approach implement only one or two
control loops, and the operator
take over manual control in case
of a failure of the LCU.

• The control output is fed back to

the manual backup station and to
the computation section of the
controller so that inactive element
can synchronize its output with
the active element.
 ii) Provide a standby
redundant controller
• LCU is backed up by another
Hot Standby Redundancy LCU that takes over if the
Approach primary controller fails.

• In this way, full automatic

control is maintained even
under failure conditions.

• The control output is fed back

to both controllers to allow
bump less transfer to be
accomplished.
 iii) Provide multiple active controllers :
• several LCUs are active at the same
time in reading process inputs,
calculating control algorithms, and
producing control outputs to the
process.

• Since only one output can be used at

a time, voting circuitry selects the
valid outputs.

• Failure of one of the controllers does

Multiple Active Redundant not affect the automatic control
Controllers function.

• The selected control output is fed

back so that each controller can
Secure Control Output Design
Techniques to improve security of the control output circuitry

• Minimum output in D/A converters.

• Safe level when LCU fails (both analog and digital).

• Independent power supply for control output and rest of LCU.

• Actual value of output to be read back by rest of the LCUs.

• Minimum number of components and electrical connections between control output

hardware and field terminating point.
Multiplexed Control Output
Configuration
• a single D/A converter is used to produce several control outputs by including
an analog multiplexer in the circuitry.
• To generate each output, the microprocessor writes the proper values to the
output register
• the D/A converter generates a corresponding analog voltage.
• At effectively the same time, the processor instructs the multiplexer to switch
the output of the D/A converter to the proper hold circuit.
• This hold circuit is an analog memory that stores the output value and causes
the current driver to generate the appropriate output current
• Then the processor writes the next output value into the register and directs
the D/A converter output to the next hold circuit through the MUX.
• This process occurs on a cyclic basis at least several times per second
Secure control output configuration
• the D/A converter is dedicated to generating a single control output.
• provision is made to allow the processor to “read back” the value of
the control output.
• This is done by means of a current-to-voltage converter and an A/D
converter.
• The processor uses this capability to verify that the control output
has been generated correctly
• The processor can then take into account and correct any errors that
occur in the process of reading the A/D converter output and
generating the control output values to the D/A converter.
Pulsed Control Output Configuration
• the LCU processor is directly involved in the output generation process
by generating raise and lower command to an up/down counter in the
output channel.
• This counter responds the commands by incrementing or decrementing a
digital value in memory.
• This value is fed to the D/A converter, which generates a control output
through the current driver.
• The processor keeps track of the output through the current-to-voltage
converter and A/D converter circuitry shown and manipulates the raise
and lower commands until the output reaches the desired value.
Secure Digital Output Configuration
• An output read back capability also can be added to this
configuration if desired.
• The fail safe output selection section is much simpler in the digital
output case than in analog one.
• In the digital case, there are only two states (0 or 1) and selecting
and generating the safe state is a relatively straight forward process.
Redundant Controller Designs
Guidelines to follow designing redundant control system.
1. Redundant architecture should be simple as possible. At some point more
hardware reduces system reliability.
2. The architecture must minimize potential single points of failure. The
redundant hardware elements must be as independent as possible so that
the failure of any one does not bring the rest down as well.
3. The redundant nature of the controller configuration should be
transparent to the user; that is, the user should be able to deal with the
redundant system in the same way as a non-redundant one.
4. The process should not be bumped when failure occurs.
5. After a control element has failed, the system should not rely on control
element till replacement.
6. Hot spare replacement; replace failed elements without shut down.
Several approaches to designing a redundant LCU architecture:
i) CPU redundancy
ii) One-on-one redundancy
iii) One-on-many redundancy
iv) Multiple active redundancy
CPU Redundancy configuration
• only the CPU portion of the LCU is redundant, while the I/O circuitry is not redundant.

• The CPU is redundant because its failure affects all of the control outputs.
• Only one of the CPUs is active in reading inputs, performing control computations,
and generating control outputs at any one time.
• The user designates the primary CPU through the priority arbitrator circuitry, using a
switch setting or other mechanism.
• The arbitrator monitors the operation of the primary CPU, if it detects a failure in the
primary, the arbitrator transfers priority to the backup.
• During operation, the backup CPU periodically updates its internal memory by
reading the state of the primary CPU the arbitrator.
• While both CPUs are connected to the plant communication system, only the primary
is active in transmitting and receiving messages over this link.
• The main operator and engineering interface in this system is the high-level human
interface.
• A CRT-based video display unit that interfaces with the LCU as if it were non-
redundant.
• Only the primary CPU will accept control commands or configuration and tuning
changes transmitted by the VDU.
One to One Back Up Redundancy
• The remaining three redundancy approaches provide for redundancy in
the control output circuitry as well as in the CPU hardware.
• Most of these architectures do not provide a low-level operator interface
for manual backup purposes.
• The approach provides a total backup LCU to the primary LCU. The control
output circuitry is duplicated in this case; an output switching block must
be included to transfer the outputs when the controller fails.
• In this configuration, the arbitrator has the additional responsibility of
sending a command to the output switching circuitry, if the primary LCU
fails, causing the backup LCU to generate the control outputs.
• Communication with the high-level human interface are handled in the
same way as in the CPU redundant configuration.
• The main advantages of the one-on-one configuration, compared to the
previous CPU redundant approach, are that no manual backup is needed.
It eliminates any questions that may arise with a partial redundancy
approach.
One on Many Back up Redundancy
• More cost effective approach to redundancy.
• Single LCU is used as a hot standby to back up any one of several primary LCUs.
• In other configurations, an arbitrator is required to monitor the status of the
primaries and switch in the backup when a failure occurs.
• In this case, there is no way of knowing ahead of time which primary controller
the backup would have to replace.
• A general switching matrix is necessary to transfer the I/O from the failed
controller to the backup.
• This configuration is loaded into the backup LCU from the primary LCU only
after the primary has failed.
• A better approach would be to store a copy of each primary LCU’s control
configuration in the arbitrator.
• When an LCU failure occurs, the arbitrator could then load the proper
configuration into the backup LCU.
Multiple Active Redundancy
• Three or more redundant LCUs are used to perform the same control
functions performed by one in the non-redundant configuration.
• In this one all of the redundant controllers are active at the same time in
reading process inputs, computing the control calculation, and generating
control outputs to the process.
• Each LCU has access to all of the process inputs needed to implement the
control configuration.
• An output voting device selects one of the valid control outputs from the
controllers and transmits it to the control process.
• When a controller fails, it is designed to generate an output outside the
normal range.
• The output voting device will then discard this output as an invalid one.
• The voting device is designed to select the signal generated by at least two
out of the three controllers.
• The main advantage of this approach is that, as long as the output voting
device is designed for high reliability, it significantly increases the reliability
of the control system.
Process Input / Output Design Issues
Input / Output Requirements
• large variety of input/output signals .
• providing cost effective I/O hardware

• Common and normal mode voltage rejection.

• Voltage isolation between terminal and system elements.
• Input impedance requirements.
• Ability to drive loads.
• The third dimension to the I/O problem is the varying degree of I/O “hardening” required in different applications.
• No hardening is required- application requires low-cost hardware.
• Application is in a hazardous environment- I/O hardware must be designed to be explosion proof.
• Field mounted equipment is subject to lightening strikes or large induced voltage spikes- I/O hardware must be
designed to withstand high level voltage surges.
• Field mounted equipment is subject to Radio frequency Interference (RFI)- I/O hardware must be shielded, filtered or
isolated from RFI environment to minimize or eliminate errors due to this type of noise.

Input / Output Design Approaches

• » Separate unit DI/DO
• » Augment in LCU
Communication Facilities

Conventional Point-to-Point
Wiring
• Conventional Point-to-Point Wiring: In conventional non-distributed control
systems, the connections that allow communication between the various system
elements. This system consists of a combination of continues controllers,
sequential controllers, data acquisition hardware, panel borad instrumentation,
and a computer system. The controllers communicate with each other by means of
point- to-point wiring. This approach to interconnecting system elements has
proven to be expensive to design and check out, difficult to change, burdensome to
document, and subject to errors.
• • Advantage:
• – In conventional system communication between system elements travels at the
speed of light with zero delay.
• – No overloading a channel.

• • Disadvantage:
• – Expensive to design.
• – Difficult to change.
• – Subject to errors.
Advantage:
– Cost of plant wiring is reduced because 1000 of
wires are replaced by the few cables or buses used t
implement shared communication system.
– Flexibility of marking changes increases because
it is software configuration.
– Less time to implement large system since the
wiring
labor is nearly eliminated, Configuration error
reduced.
– Control is more reliable due to reduction in
physical connection. So failure is easily identified.

• Disadvantage:
– Delay occurs between communication systems.
Communication System Requirements
Communication System Requirements
• Minimize delay and maximize security transmission.
• Transmission of process variables, control variables, and Alarm status
information from LCU to HLHI, and LLHI in the system.
• Communication of special commands, operating modes, control variables from
the HLHI to LCU for the purpose of supervisory control.
• Down loading of control system configuration, tuning parameters and user
programs from HLHI to LCUs.
• Transmission of information from data input/output unit to high level
computing devices for the purpose of data acquisition.
• Transfer of large block of data (data base) / programs from one high level
computing devices to another high level computing devices or low level
computing devices.
• Synchronization of real time among all of the elements in the DCS
Communication System Performance Requirements
• Maximum size of the system.
– Distance; number of devices.
• Maximum delay time through the system.
• Interaction between LCU architecture and communication facility.
• Rate of undetected errors occurring in the system.
• Sensitivity to traffic loading.
• System scalability.
• System fault tolerance.
• Interfacing requirements.
• Ease of application and maintenance.
• Environment specification.
• Architectures Issues
• whether to choose a parallel or serial link as the communication medium.

• Parallel: Multiple conductors or wire to carry a combination of data and

handshaking signal. It provides a higher message throughput rate than does
the serial approach.
• Disadvantages:
• – More cost.
• – Arrive data at different time if distance between nodes become large (IEEE 488 BUS).

• Serial: Uses only a single coaxial cable, fibre optic link, or pair of wires.
• Advantages:
Cable cost is less.
Long distance.
Use baseband signal.
 Levels of Subnetworks
• Sub network is defined to be a self-contained communication system:
• It has own address structure.
• Allows communications among elements connected to it using a specific protocol.
• Allows communication between elements directly connected to it and elements in
other sub networks through an interface device that “translates” the message
addresses and protocols of the two subnetworks.
• Local subnetwork- Located in central control room. Allow high level devices to
intercommunicate.
• Plant level subnetwork –Interconnect the control room elements with the distributed
elements in process.
Communication system Partioning-
Communication system Partioning-
example 2
Communication System Standards
• CAMAC-Computer Automated Measurement And Control.
• IEEE 488 BUS
• PROWAY-PROcess data highWAY.
• IEEE 802 Network
STAR TOPOLOGY
• Simple and les expensive
• An active switching device routes the message from one device to the other
• A failure of this device cause the entire subnet to stop functioning
• Adding redundant switching device increase complexity
BUS TOPOLOGY
• Similar to star topology
• However the switching device is passive, that each element in the subnet has
to get control over the network
• As each element has to transmit the message directly to the receiving device
MESH TOPOLOGY
• Multiple active switching circuits
• If any active switching circuit fails , redundant active switching circuit takes
over the task of routing
• This topology is complex and expensive also results in delays as the switching
device stores and forwards the message
RING or LOOP PROTOCOL
• Special case of mesh topology which provides connection only between
adjacent switching devices.
• Message is usually permitted to travel only in one direction around the ring
• Switching devices are simple and inexpensive
 Other communication issues
• Communication protocol
• Rules or conventions that govern the transmission of data in system
• Selecting protocol is as critical as selecting the physical architecture
4-20mA Protocol
• Industries have been using 4-20mA current loops are primarily for
two purposes:
1) To report an industrial process variable such as temperature,
pressure, or flow from a remotely- located sensor to a control station.
2) To transmit control signals from a control station out to a remote
device such as a valve, actuator, or heater.
• The transmitter converts the sensor output to a 4-20mA signal which
corresponds to the full scale of the sensor.
• 4mA represents minimum scale, while 20mA represents maximum
scale.
• It then sends this current signal, usually over a long distance, to a
receiver that converts the signal back to a voltage.
• A simple receiver would consist of a resistor that would convert this
current back to a voltage simply by Ohm Law. A typical value for this
resistor is 250ohm, resulting in a final voltage of 1-5V
HART Protocol
• HART is a master-slave communication protocol, which means that during
normal operation, each slave (field device) communication is initiated by a
master communication device. Two masters can connect to each HART loop.

• The primary master is generally a distributed control system (DCS),

programmable logic controller (PLC), or a personal computer (PC).

• The secondary master can be a handheld terminal or another PC. Slave

devices include transmitters, actuators and controllers that respond to
commands from the primary or secondary master

• The HART Protocol communicates at 1200 bps without interrupting the

4-20mA signal and allows a host application (master) to get two or more
digital updates per second from a smart field device. As the digital FSK signal
is phase continuous, there is no interference with the 4-20mA signal
Foundation Fieldbus Protocol
• Fieldbus allows many input and output variables to be transmitted
on the same medium such as, a pair of metallic wires, optical fibre or
even radio, using standard digital communication technologies such
as baseband time-division multiplexing or frequency division
multiplexing.
• Thus sensors transmit the measured signal values as well as other
diagnostic information; the controllers compute the control signals
based on these and transmit them to actuators.
• Further, advanced features such as process monitoring can be
carried out leading to increased fault
• tolerance. Online process auto-tuning can be performed leading to
optimized performance of control loops.
•
Future Trends in DCS
• More intelligent I/O
• DCS suppliers are working to reduce both the cost and the complexity of
their I/O by incorporating more intelligence and programmability into the
devices.
• Shift in I/O type
• There is a growing trend towards adding more wireless I/O and associated
field devices, particularly for process and equipment monitoring applications
• Virtualisation
• Use of virtual servers in some parts of DCS
• Cyber security
• network firewalls and strategically placed switches are required to help
prevent the propagation of external viruses and intrusions
• Internal threats from disgruntled employees or other internal access points
must be addressed with such things as USB locks and software to monitor
internal automation system network activity.
• Need for network consulting services
• End users now often rely on the expertise of suppliers for consulting to set up these
networks in a safe and secure manner.
• Mobility
• DCS suppliers now use tablet technology for roving operators and use of smartphones
for alerts and condition monitoring. This trend towards increasing mobility will grow in
importance in the coming years
• Cloud computing
• To move selected DCS applications ‘to the cloud’, a reference to moving applications to
remote, Internet (public) or intranet (private) based servers. However, the control
automation industry is very conservative by nature, and for the time being this is just
talk.
• Modular skid-mounted DCS
• More process units these days are being built and delivered on skids (engineered to
order and ready to plug into the process flow), rather than built in situ.
Important features of DCS
• To handle complex processes
• DCS is preferred for complex control applications with more number of I/O’s with
dedicated controllers.
• System redundancy
• DCS facilitates system availability when needed by redundant feature at every level.
• Lot of Predefined function blocks
• DCS offers many algorithms, more standard application libraries, pre-tested and pre-
defined functions to deal with large complex systems. This makes programming to
control various applications being easy and consuming less time to program and control.
• 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 also 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
• 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.
Industrial Automation
• Industrial automation is defined as a set of technologies that results
in operations of industrial machines and systems without significant
human intervention and achieve performance superior to manual
operation.
The Automation Pyramid Industrial automation systems are
organized hierarchically as shown
in the following figure
• Sensors and Actuators Layer: Level 0
• This layer is closest to the processes and machines, used to translate signals so that signals can be
derived from processes for analysis and decisions and hence control signals can be applied to the
processes. This forms the base layer of the pyramid also called ‘level 0’ layer.
• Automatic Control Layer: Level 1
• This layer consists of automatic control and monitoring systems, which drive the actuators using the
process information given by sensors. This is called as ‘level 1’ layer
• Supervisory Control Layer: Level 2
• This layer drives the automatic control system by setting target/goal to the controller. Supervisory
Control looks after the equipment, which may consist of several control loops. This is called as ‘level
2’ layer
• Production Control Layer: Level 3
• This solves the decision problems like production targets, resource allocation, task allocation to
machines, maintenance management etc. This is called ‘level 3’ layer
• Enterprise control layer: Level 4
• This deals less technical and more commercial activities like supply, demand, cash flow,
product marketing etc. This is called as the ‘level 4’ layer
• The spatial scale increases as the level is increased
• e.g. at lowest level a sensor works in a single loop, but there exists many
sensors in an automation system which will be visible as the level is increased.
The lowest level is faster in the time scale and the higher levels are slower.
• The aggregation of information over some time interval is taken at higher
levels.
• All the above layers are connected by various types of communication
systems.
• For example the sensors and actuators may be connected to the automatic
controllers using a point-to-point digital communication, while the automatic
controllers themselves may be connected with the supervisory and
production control systems using computer networks.
• The automation pyramid helps to classify the engineering devices,
engineering needs, maintenance requirement.
• Thus it makes the entire system management easy
• Since the automation pyramid clearly distinguish the levels of
operation of process it is easy for the operators ,engineers or the
managing team to maintain and r
• Level 0 contains the field devices such as flow and temperature sensors, and final
control elements, such as control valves
• Level 1 contains the industrialised Input/Output (I/O) modules, and their associated
distributed electronic processors.
• Level 2 contains the supervisory computers, which collect information from
processor nodes on the system, and provide the operator control screens.
• Level 3 is the production control level, which does not directly control the process,
but is concerned with monitoring production and monitoring targets
• Level 4 is the production scheduling level.
Levels 1 and 2 are the functional levels of a traditional DCS, in which all
equipment are part of an integrated system from a single manufacturer.
Levels 3 and 4 are not strictly process control in the traditional sense, but
where production control and scheduling takes place.
EMERSON DELTA V ARCHITECTURE LEVELS ABOVE LEVEL 2
IS ASSOCIATED WITH
GENERAL PURPOSE
COMPUTER
DCS support to Enterprise Resources Planning
• Enterprise resource planning (ERP) is the integrated management of core
business processes, often in real-time and mediated by software and
technology.
• Enterprise resource planning (ERP) is a method of using computer technology
to link various functions—such as accounting, inventory control, and human
resources—across an entire company.
• Modern distributed control systems (DCS) are modular and hence more
effective. They are designed to achieve specified levels of repeatability,
reliability and repair ability.
• They consist of a number of linked components, such as smart transmitters,
distributed control modules, plant historians, analysis tools, and model-based
decision support systems. They work together as an integrated system
• The approach to "plant control" has evolved.
• Functions such as local control, inter-area control, and data analysis
are clearly distinguished and architected appropriately.
• No attempt is made to do all things in one system or in a group of
modules.
• There is focus.
• The result is an "integrated system" with components that do a
number of tasks well.
performance criteria for DCS and other automation tools
• Return on Assets (ROA)
• process automation offers the potential to deliver significant higher return on
assets (ROA) during the life cycle of a process plant.
• The absence of a return on investment (ROI) feedback mechanism and a
common basis for measuring performance between business and manufacturing
systems further complicates the issue.
• Effectiveness, Agility, and Visualization
• Effectiveness, agility, and performance visualization are keys to operational
excellence.
• Effectiveness and agility support the principle of flawless operation. Research
shows that, on average, most process plants operate at less than Four Sigma
performance levels.
• Automate and Empower
• By automating everything that should be automated, it should be ensured that manual
tasks will always be executed based on best practices.
• Automation also frees up time for worker empowerment, providing these knowledge
workers with the opportunity to perform more value-adding functions.
• Automation Asset Management
• Must support a mixed supplier environment, with each application having its own
configuration and system management facility.
• Traditionally, each DCS/PAS employed a proprietary system and configuration
management environment.
• DCS or any automation system must provide open platform and a mixed supplier
environment. In this environment, each application retains its own system and
configuration management, but a unified automation asset management facility for
configuration management and system health addresses the issue of multiple system
and configuration facilities.
• Configuration management includes an audit trail, priority access, and failsafe
configurations for all applications and devices in the system.
• Data Certainty and Traceability
• it is important for this data to have associated quality tags.
• Dependent variable data should also have quality tags.
• The regulated industries require that product constituents can traced
through their processes