Industrial

Automation
 Lecture Three
Distributed Control Systems (DCS)
❑ A Distributed Control System (DCS) refers to 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
The Programmable Logic Controller abbreviated by PLC is a special
component sub-systemmicroprocessor based controlled system. Also, it is a special type of computer
❑ DCS is a computerized capable of withstanding vibration, high temperature, and high humidity and
control system used to control the production line in the industry
optimized for control tasks in the industrial environment rather than the
controlled by one or more controllers.
calculations and display tasks assigned to the normal computer.

❑ DCS is a very broad term used in a variety of industries, to monitor and control distributed
equipment.
❑ Examples where DCS might be used are given below:
Architecture of an Advanced DCS
✓ Chemical plants
✓ Petrochemical plants (oil) and refineries
✓ Pulp and Paper Mills
✓ Boiler controls and power plant systems
✓ Nuclear power plants
✓ Environmental control systems
The Programmable Logic Controller abbreviated by PLC is a special
✓ Water management systems
microprocessor based controlled system. Also, it is a special type of computer

✓ Metallurgical processcapable
plants of withstanding vibration, high temperature, and high humidity and
optimized for control tasks in the industrial environment rather than the
✓ Pharmaceutical manufacturing plants
calculations and display tasks assigned to the normal computer.

✓ Sugar refining plants

✓ Dry cargo and bulk oil carrier ships
✓ Formation control of multi-agent systems
3.1 Basic Concepts of Distributed Computed

DCS has three essential qualities:

1. Distribute (Process functions into smaller sub-systems)

2. Compute (for automating the process) and set up a
The Programmable Logic Controller abbreviated by PLC is a special
3. System (to make it appear as an
microprocessor integrated
based system
controlled system. Also, it isof process
a special monitoring and control)
type of computer
capable of withstanding vibration, high temperature, and high humidity and
optimized for control tasks in the industrial environment rather than the
❑ In DCS, the process plant’s monitoring and control functions are distributed into relatively
calculations and display tasks assigned to the normal computer.

small sets of semi-autonomous subsystems. These subsystems are interconnected via a

high speed communications network.
❑ These functions include data collection, process control, presentation of information,
process analysis and supervision, storage and retrieval of archived information, and the
presentation and reporting of information.
(DCS)

The Programmable Logic Controller abbreviated by PLC is a special

microprocessor based controlled system. Also, it is a special type of computer
capable of withstanding vibration, high temperature, and high humidity and
optimized for control tasks in the industrial environment rather than the
calculations and display tasks assigned to the normal computer.
3.2 PLC and DCS

❑ When PLCs were invented, they were really good at handling single processes and were
primarily used for repetitive, discrete control.
❑ The advent of the DCS was for controlling many autonomous controllers that handled
many continuous operations, mainly using analog control.
❑ PLCs, traditionally, were used for single batch or high-speed control, have a relatively
simple, low-cost design, and are the core of the system. Their design is flexible and generic
but completely customizable.
❑ A DCS is used for continuous, complex controls, have an integrated control center much
like a SCADA, which is the core of the system versus the processors in a PLC system.
❑ DCS also have a claim that when safety is a top priority, it is the most reliable system.
3.3 Basic Components of a Typical DCS Network

1. Operator Station

❑ A typical plant starts with a centralized operator control center typically called Operator
Stations.
❑ Operator Stations, in a DCS, are the heart of the system.
❑ This is where the operator can observe the operations of the plant, view process warnings
and alarms, monitor production, and more.
2. Servers, Archiving and Engineering Computer

❑ Communications with the Operator Station level is typically Industrial Ethernet.

❑ Servers are used for the collection of data at the processor level. They are responsible for
the data that moves between the Operator Station and the processors on the plant floor.
❑ Archiving computers are used for storing historical data that may be used for trends or
compliance.
❑ Engineering Stations are used for creating the projects on which the processes run. This
includes:
▪ Hardware configurations
▪ Logic for tasks
▪ Graphical displays for operator interaction
▪ Administration of all of those tasks through installed software packages.
❑ This is the station that is used to download the projects to the processors and the graphical
display
3. DCS Controllers

❑ A DCS controller is a high-performance device capable of handling hundreds of discrete or

regulatory control loops per second. The control performance capability of a DCS
controller varies from manufacturer to manufacturer. But a user can customize his control
configuration to meet the application requirements.
❑ These controllers are also responsible for providing the data to the servers, which in turn,
supply the data for the graphical interface.
❑ Industrial Ethernet is typically used for communication with the previous level. Fiber
Optic may be used here when Ethernet cabling runs would be too long.
❑ At this level, the processor executes the logic and does what it needs to do in order to
control the process.
4. Field Devices

❑ Communications between this level and the processor level can be nearly any type that may
be compatible with the components.
❑ Those include Industrial Ethernet, Profibus, Fiber Optic, or other proprietary
communication protocols.
❑ Components at this level would be devices such as transmitters, switches, valves, motors,
remote or distributed I/O, etc.
▪ Fieldbus is consisting of two terms, Field and Bus. The meaning of Field, as defined in industrial world, is
a geographical or contextual limited area. From the industry point of view the Field is an abstraction of the
plant levels. As for the term Bus is a well-known word in computer science as a set of common line that
electrically (or even optically) connects various units (circuits) in order to transfer the data among them.
▪ The origin of the fieldbus was to replace any point-to-point links between the field devices (Field Devices
are simply the Sensors and Actuators of the plant) and their controllers ( PLC's) by a digital single link on
which all the information is transmitted serially and multiplexed in time.
▪ Process Field Bus (PROFIBUS) is a one type of a fieldbus.
Advantages of DCS

❑ Complex structures: Access a large amount of current information from the data highway.
❑ System redundancy: If a processor fails, the redundancy provided in the DCS ensures that
only one section of the plant's processes is interrupted.
❑ Scalability: More control or process units can be added whenever needed. Adding more I/O
modules to a controller also extends I/Os.
❑ Security: Security and cybersecurity capabilities are enabled at the engineer and operator
levels.
❑ Some downsides of the technology include situations where failure of one controller affects
more than one loop. DCSs can also increase software development costs, and diagnosing
problems can be a complex process.
❑ Monitoring trends of past process conditions.
❑ Alternate quickly among standard control strategies and readjust controller parameters in
software.