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06
(DCS)
Objective:
1. Learn the basics and hardware components of DCS.
2. Understand the architecture of DCS.
Introduction:
In any process plant, the purpose of automation is to maintain product quality, and consistency,
reduce start-up time, and increase the speed of operation with human safety. Control system
whether it is a Programmable Logic Controller (PLC) or a Distributed Control System (DCS)
is required for the same purpose. The purpose of the Industrial automation laboratory is to
understand the theory and programming aspects of DCS.
Definition:
A Control system that is functionally as well as physically distributed is called a Distributed
Control System.
Evolution of DCS:
The control systems were developed along with the technology and the difficulties faced by
each technology were realized.
1. Open Loop: offline
In this technology, digital computers were applied for the acquisition and processing of plant
data/laboratory data, or test field data. At this time operator had to read this data and store them,
which was an offline process for the acquisition and processing of data—no optimization and
feedback control.
2. Closed Loop: offline
In this technology, set point values were calculated by computer but still manually set by the
plant operator. Thus offline closed-loop control was formed. This was only acceptable when
the timing condition of process control was not severe as manual intervention led to the
introduction of time delay in the control of the process.
Data Acquisition
Data Check
Plant Monitoring
Open and Closed-loop Control
Reporting
Production Dispatching
Inventory Control
Production Supervision
Production Re-Scheduling
Production Reporting
Working of DCS
The working of DCS can be divided into two parts
1. Hardware Flow
In any process the sensory organs of a process are sensors and /or transmitters through which
the status of the process is known. The flow of signal passes from sensors/ transmitters to a
local field junction box where number of wires comes. From field junction box through a multi
core cable it goes to the main junction box. Again from main junction box it comes to a
marshalling cabinet where the wires enter into the control panel. In the control panel, controller
and I/O cards are placed. After signal entering the panel, the signal wire with or without a relay
card goes into the input card connected to the controller. Controller thereby processes the data
according to the logic created and gives output to the Final Control Element through output
cards, following the same route.
3. Software
There is a scan cycle which needs to be completed for the execution of an instruction needed
to control the process. The scan period is set by the user while configuring DCS and the
following steps occur for each scan period:
Firstly the status of inputs from the process through the input cards are checked.
Then the values are updated in the program and according to the logic prepared by the
programmer output values are decided.
These outputs then go to the field through output cards.
Moreover the status is updated in the SCADA as well as the changes are stored for
future reference in the historian. Any alarms i.e. deviations in the process are there, then
they are also noted and stored.
Functions of DCS
I/O signal characterization
Signal filtering
Alarming I/O modules
Ranging and engineering units
Control logic
Control interlocks
Sequencing
Batch control
Passing on trending information
Passing on report information
Internals of DCS
DCS can be divided into two parts for understanding purposes.
To view and control the process using mimic, same as the real process (SCADA).
Programming environment wherein logic can be created.
A hierarchical view of the whole system
Advance Control Strategy Schemes
Configuration Suite to configure the hardware attached.
Diagnostic Suite
Alarm Module
History Module
Trends Module
Database management module
Advantages:
System implementation can be carried out in a modular fashion due to which system
growth can be easily achieved as each processor has a clearly defined set of functions;
if carefully designed.
System overloading is less in the case of DCS.
In case of failure of a part, DCS doesn't affect the whole system/ process.
Backup i.e. redundancy feature possible in DCS.
The reliability of DCS is more than that of Centralized Control.
Reduction of cost of interfacing to computer due to reduction in wire usage for control
purposes.
DCS is more flexible in terms of altering configurations within a specified range so as
to confirm to the change requirements if any.
Duplicate storage of critical data can be done easily.
Independent or standalone processors communicate with each other which make
management of computers easy.
Minimization of data loss as well as errors due to placement of controllers in the nearby
vicinity in DCS.
Advanced control strategies are easy to implement in DCS.
Limitations:
Cost is high when compared with PLC/PC Combination.
Specialized support from engineering personnel is required.
DCSs require a clean control room environment compared to a PLC/ PC environment.
Selection Procedure
There are several considerations for selecting a proper automation tool for a particular
application For multiple product manufacturing, varied recipe parameters, multiple procedures,
often changes required in recipes, and complex batch processes with several regulatory
loops, DCS is preferred. If the operator's interaction is required to keep the process to fulfill
target performance, observing the process with faceplates, and critical trends, to respond
effectively during plant upsets, DCS is preferred. DCS gives adjustable scan time, online
configuration changes, simple to advanced PID control, and advanced process control
strategies.
Test:
Conclusion: