Distributed control system

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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 controlled by one or more controllers. The
entire system of controllers are connected by networks for communication and
monitoring.

DCS is a very broad term used in a variety of industries, to monitor and control
distributed equipment.

Electrical power grids and electrical generation plants

Environmental control systems
Traffic signals
Water management systems
Oil refining plants
Chemical plants
Pharmaceutical manufacturing
Sensor networks
Dry cargo and bulk oil carrier ships

[edit] Applications

Distributed Control Systems (DCSs) are dedicated systems used to control manufacturing
processes that are continuous or batch-oriented, such as oil refining, petrochemicals,
central station power generation, pharmaceuticals, food & beverage manufacturing,
cement production, steelmaking, and papermaking. DCSs are connected to sensors and
actuators and use setpoint control to control the flow of material through the plant. The
most common example is a setpoint control loop consisting of a pressure sensor,
controller, and control valve. Pressure or flow measurements are transmitted to the
controller, usually through the aid of a signal conditioning Input/Output (I/O) device.
When the measured variable reaches a certain point, the controller instructs a valve or
actuation device to open or close until the fluidic flow process reaches the desired
setpoint. Large oil refineries have many thousands of I/O points and employ very large
DCSs. Processes are not limited to fluidic flow through pipes, however, and can also
include things like paper machines and their associated variable speed drives and motor
control centers, cement kilns, mining operations, ore processing facilities, and many
others.
 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. Todays controllers have extensive computational
capabilities and, in addition to proportional, integral, and derivative (PID) control, can
generally perform logic and sequential control.

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.

CHAPTER 1 Process control system

Introduction
1.1 Conventional control panel
1.2 Control panel with a PLC controller
1.3 Systematic approach to designing a process control system

Introduction

Generally speaking, process control system is made up of a group of electronic devices and equipment that
provide stability, accuracy and eliminate harmful transition statuses in production processes. Operating system
can have different form and implementation, from energy supply units to machines. As a result of fast progress
in technology, many complex operational tasks have been solved by connecting programmable logic controllers
and possibly a central computer. Beside connections with instruments like operating panels, motors, sensors,
switches, valves and such, possibilities for communication among instruments are so great that they allow high
level of exploitation and process coordination, as well as greater flexibility in realizing an process control
system. Each component of an process control system plays an important role, regardless of its size. For
example, without a sensor, PLC wouldnt know what exactly goes on in the process. In automated system, PLC
controller is usually the central part of an process control system. With execution of a program stored in
program memory, PLC continuously monitors status of the system through signals from input devices. Based on
the logic implemented in the program, PLC determines which actions need to be executed with output
instruments. To run more complex processes it is possible to connect more PLC controllers to a central
computer. A real system could look like the one pictured below:
1.1 Conventional control panel

At the outset of industrial revolution, especially during sixties and seventies, relays were used to operate
automated machines, and these were interconnected using wires inside the control panel. In some cases a
control panel covered an entire wall. To discover an error in the system much time was needed especially with
more complex process control systems. On top of everything, a lifetime of relay contacts was limited, so some
relays had to be replaced. If replacement was required, machine had to be stopped and production too. Also, it
could happen that there was not enough room for necessary changes. control panel was used only for one
particular process, and it wasnt easy to adapt to the requirements of a new system. As far as maintenance,
electricians had to be very skillful in finding errors. In short, conventional control panels proved to be very
inflexible. Typical example of conventional control panel is given in the following picture.
In this photo you can notice a large number of electrical wires, time relays, timers and other elements of
automation typical for that period. Pictured control panel is not one of the more complicated ones, so you can
imagine what complex ones looked like.

Most frequently mentioned disadvantages of a classic control panel are:

- Too much work required in connecting wires

- Difficulty with changes or replacements
- Difficulty in finding errors; requiring skillful work force
- When a problem occurs, hold-up time is indefinite, usually long.

1.2 Control panel with a PLC controller

With invention of programmable controllers, much has changed in how an process control system is designed.
Many advantages appeared. Typical example of control panel with a PLC controller is given in the following
picture.

Advantages of control panel that is based on a PLC controller can be presented in few basic points:

1. Compared to a conventional process control system, number of wires needed for connections is reduced by
80%
2. Consumption is greatly reduced because a PLC consumes less than a bunch of relays
3. Diagnostic functions of a PLC controller allow for fast and easy error detection.
4. Change in operating sequence or application of a PLC controller to a different operating process can easily be
accomplished by replacing a program through a console or using a PC software (not requiring changes in wiring,
unless addition of some input or output device is required).
5. Needs fewer spare parts
6. It is much cheaper compared to a conventional system, especially in cases where a large number of I/O
instruments are needed and when operational functions are complex.
7. Reliability of a PLC is greater than that of an electro-mechanical relay or a timer.