Chapter10 DCS FF July 08 v3 1 Oct

EAB4223/EEB5223
Industrial Automation and Control System
• PART 3:
DCS and Fieldbus
Assoc Prof Dr Nordin Saad

Department of Electrical & Electronics Engineering
Universiti Teknologi PETRONAS
23.03.005
Email: nordiss@petronas.com.my
Tel: 05-368 7835
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-
3- 1
This topic covers the key and base areas of automation in the process industries.
Synopsis
Synopsis Learning
Learning Outcomes
Outcomes
This
Thiscourse
coursecover
covertopics
topicsrelated
relatedto
tomeasurements
measurements
(PLTF)
(PLTF) and automation in the processindustry.
and automation in the process industry.These
These that
thatstudents
studentsare
areexpected
expectedtotoachieved
achievedafter
after
include
include a study on industrial sensors andactuators,
a study on industrial sensors and actuators,industrial
industrial successfully completing the course
successfully completing the course
controllers
controllers such as computer-based control, PLC, DCSand
such as computer-based control, PLC, DCS and
FF.
FF.
Process
Process,,Industrial
Industrial Instr.&
Instr.& Meas.
Instr.& Meas. Automation
Automation DCS
DCSand
andFoundation
Foundation Fieldbus
Fieldbus
The learning outcomes related to The learning outcomes related to The learning outcomes related to
Industrial instruments and Automation and the implementation of DCS and Foundation Fieldbus use
Measurements Programmable logic controller in process industries.
• Have knowledge and
understanding of the various
• Have knowledge and • Have knowledge and
process industry instruments,
understanding of the PLC understanding of a DCS and its
concept of measurements,
architecture and its importance in use in process industries, and
calibration and configuration
automation. the features and architecture of a
requirements and their applications.
Foundation Fieldbus system, and
• Be able to develop a PLC program
• Be able to design and develop a its improvement over the
to perform sequential, and batch
control loop consisting the process conventional DCS.
control.
instruments, based on a prescribed
requirement.

3- 2
CONTENTS
qDCS
• Overview of DCS (also SCADA)
• DCS Definition and Configuration
• DCS Architecture
• Advanced Control Development
qFieldbus
• What is Fieldbus? Features
• Why Fieldbus? Advantages
• Fieldbus – Function blocks, DD, Configurations,
Implementations
• Issues: Device Descriptions, Interoperability

3- 3
3- 4
Block Diagram of Process Control Loop
Block diagram of a process control loop

SETPOINT
SP +
- PV
OP CONTROL
CONTROLLED
MANIPULATED VARIABLE
VARIABLE
MEASUREMENT
PROCESS
FINAL CONTROL
ELEMENT

3- 5
Principle of Controller
Block diagram of a controller
SETPOINT
SP
PID
CONTROLLED
VARIABLE
PV A
MANUAL
ADJUSTMENT
M
OP
A AUTO M MANUAL

3- 6
Analog vs Digital in Field Signals
Analog Digital
Signal Signal
Time Time
Discrete signal with only
Continous variable two possible values or
position

3- 7
Use of Computer in Process Control
- Data Logging
Monitor
Printer
CPU Computer used to store data for

reviewing the data.
SP
PV OP
LT
Process

3- 8
- Set Point/Supervisory Control
Monitor
Printer
Computer used to perform

CPU
adjustments of loop setpoints
besides keeping records of
Set Point process parameters. The
computer using specified
equations, calculates the setpoint
Process Variable based on the measured variable
Output
LT
Process

3- 9
- Direct Digital/Centralized Control
Monitor
Controller Printer
PV4
Out4
PV3
Out3 The function of controllers were
PV2 Out2
CPU superseded by the computer. A
PV1 Out1 central computer monitor and
control all the process variables.
PV OP
LT
Process

3- 10
- Distributed Control
Monitor Printer
Network
IOP
Control Control Control

Station 1 Station 2 Station 3
PV OP
Process
LT

3- 11
History and Development of DCS:
• In the 1940s…
o Mechanical and pneumatic controllers for
controlling a few process variables: T,P,F.
o Coordinated process unit control system was
not possible.
o Conservatively for stability rather than
economic performance.

3- 12
• In the 1950s…
o Electronic controllers introduced.
o Centrally located in the control room
and wired into the measuring devices
and actuators in the plant
o Provide feedforward dynamic models.
o Small pneumatic instruments were also
used.
3- 13
• In the 1960s…
o Process computers made their debut.
o Assembly of distributed, mutually
independent and dedicated controllers.
Smaller instruments (electronic)
Digital computer

3- 14
History and Development of DCS
These dedicated controllers/computers had

wider applications in:
• Decentralised (not distributed) control operation of
process plant
• Monitoring and control by local operators
• Small plant automation
• Partial plant automation
• Automation in the laboratory, etc.

3- 15
• In the 1970s…
o Introduction of analog system architecture, specialized
computer interface devices and computers with higher
capacity and speed of processing
o A centralized control structure was introduced. It
contained process control computer as its central.
Management Information System
•Distributed
control system
Operator Supervisory Programmable
Interface Computer Logic Controller
System Interface Interface
•CRT
Controller and
Data
Foreign Device
Communication
operation
Interface
Acquisition System
(Analyzer etc.)
System
A general DCS component

3- 16
• Additional features in 1970s…
o Production planning and plant management
functions were added, so that the central computer
truly became a concentrator of most important
process and plant data.
This centralized control, was called Direct Digital
Control (DDC) - used control signals to directly
operate the control devices.

3- 17
Evolution Man-machine
interface
Mechanical Mechanical + Pneumatic + Electronic + Distributed

instruments pneumatic electronic process control system
[Field operation] controllers controllers computers [CRT Operation]
[Signal [Signal [Digital computer]
transmission] transmission]
1900 1930’s 1940’s 1950’s 1960’s 1970’s - now

3- 18
Industrial
Industrial Control
Control SystemSystem
Evolution Evolution
DISCRETE MECHANCIAL
DISCRETE
ANALOGANALOG
DEVICES
DEVICES
DIRECT PNEUMATIC
PNEUMATIC TRANSMISSION
ELECTRIC ANALOG CONTROL
RELAYS
DISCRETE
DISCRETE
SWITCHING
SWITCHING
DEVICES ELECTRONIC LOGIC
DEVICES
PROGRAMMABLE LOGIC
CENTRALIZED DCS FIELDBUS

CENTRALIZED
INTEGRATED
INTEGRATED
SYSTEM
SYSTEM DIRECT DIGITAL CONTROL
SUPERVISORY CONTROL
1930 1940 1950 1960 1970 1980

1990 2000
• Timeline of computer control of industrial processes:

Ø Ferranti Argus 200
Ø Microprocessor
Ø SCADA - (I/Os of 1000 or less)
Ø Distributed Control System (DCS) - (I/Os of more than 1000)
Ø Communication protocol -Fieldbus/Profibus
3- 19
PROCESS CONTROL
EVOLUTION
TDC is Introduced by Honeywell
Open System
Architecture
PROVOX by Fisher
Return on Investment
RS3 by Rosemount
ROI
IA by Foxboro
DCS
Another dramatic change is required to
create an acceleration of value from the
current DCS offering.
Analog Control
1975 1985 1995

3- 20
SCADA System
Indirect control is its main limitation
Collect
information
Softw a re Hardware
(Monitor, (PLC or
Screen/ a n a lysis,
Transfer to
central com m ercial Plant
D isplay control) computer hardware)
Supervisory
control
Indirect control:
• For monitoring and indirect control based on certain set-points.
• Changes to a process would have to go through various levels
before being implemented – takes time and cannot be done
immediately.
3- 21
SCADA System
Host control functions
are restricted to basic
overriding or
supervisory level
intervention.
The SCADA system
allows operators to
change the set points
for CVs, and enable
alarm conditions, such
as loss of flow and
high temperature, to
be displayed and
recorded.
The feedback control
PLCs control the
loop passes through
CVs of an the RTU or PLC, while
industrial process. the SCADA system
monitors the overall
performance of the
loop.

3- 22
Development of DCS
Centralized control
The following essential functions were

concentrated in the central computer:
Ø Process Monitoring
Ø Data Acquisition
Ø Alarming and Logging
Ø Data Processing
Ø Process Control

3- 23
Development of DCS
The main concerns and disadvantages of a
centralized system are:
o Reliability: Very depended on proper functioning of the
central computer. System breakdown results in
disruption of production and complete shutdown -
prove to be extremely expensive.
o Programming effort and cost: Tailored to the
uniqueness of each process and its control system.
o Cost of a centralized computer process control system:
Mainframe and large minicomputers are very expensive.

3- 24
Development of DCS
This created the need of future systems

development.
The system should be such that data should be

stored where they have been created and where
they will be needed. Similar principles hold for
the functions also. Only the data required
for”other purposes” within the automation
system will be distributed.

3- 25
Development of DCS
These lead to the following data and functions

requirements:
• Local control and supervision of plant should be located
next to the plant instrumentation.
• Processing of data for higher purposes (optimization, set
point value calculation, etc.) should be allocated in central
control room.
• Production planning and plant management should be
situated closer to the relevant plant management staff.

3- 26
Development of DCS
A Distributed Control System (DCS)
o Hierarchical automation system structure was introduced popularly
known as Distributed Control System.
o The operators console in the control room, is connected through a
shared communication facility to several distributed local control
units. Local
Central Control Process
Room (several Control
computers) Units
Shared
Communication
Facility
Local Local Local

Process Process Process
Control Control Control
Units Units Units

3- 27
3- 28
DCS Definition and Configuration
The definition of DCS has changed

dramatically over its history. The information
processing role of DCS has expanded fast, adding
Advanced Process Control, Information
Analysis tools, Intelligent Systems and
Business System Integration capabilities.

3- 29
DCS has three (3) essential qualities:
o DCS distributes its functions into smaller sets of
semi-autonomous subsystems covering specific
process or geographic areas of the plant complex.
The functions generally are:
• Process Analysis and Supervision
• Data Collection
• Process Control
• Storage and Retrieval of Information
• Presentation of Information and Reports

3- 30
DCS has three (3) essential qualities (cont…):
o To automate the manufacturing process by integrating
advanced regulatory control logic and procedural
languages with advanced application packages, expert
systems, including information to support such
manufacturing enterprise application as:
Ø Production scheduling and dispatching

Ø Preventive and predictive maintenance scheduling
Ø Information exchanges with business and logistics application

3- 31
DCS has three (3) essential qualities (cont…):
o The third characteristic is the system aspect of the
DCS, which organizes information flow between
the constituent parts so as to have a single
automation system unifying the semi-autonomous
subsystems.

3- 32
Basic DCS function
Input Output
Monitoring Input
Control Loop
Primary & Control Alarms ( PV & SP )
Elements Trend , Log & Report
Execute Special
Programmed Logic.

3- 33
Conventional Controller Vs DCS
Conventional Vs DCS
100%
200 ton/hr 75%
MAN
50%
25%
AUTO
0%
FIC21765
KLB/HR
FLOW 21
SP 42.9
PV 31.3
OP% CAS52.8
C O
0 100
HPM/APM
AI AO
I I
P P

3- 34
In DCS, the functions of control system are distributed into
different work areas of a process plant:
o Central control room: Operator operation and monitoring
functions
o Distributed control stations: Distributed at various plant
locations throughout the process facility, perform the
following functions at each location-
ü Generation of input signals based on analog
variables and discrete inputs
ü Generation of output signals to control the actuators
to change the process conditions.
o Communication system interfacing – the information is
communicated between the central control room and
remote control stations.

3- 35
DCS System Component
Supervisory Programmable
Operator Computer Logic Controller
Interface System Interface Interface
Controller and Foreign Device

Communication
Data Acquisition Interface
System
System (Analyzer etc.)
A General DCS Component

3- 36
DCS System Configuration
o DCS Configuration comprises of:
o Operator Interface system: consists of one or more operator
consoles for monitoring and controlling process parameters and
performing other process related functions.
o Supervisory Computer system: Provide supervisory level plant
control, plant and unit optimization and computer based plant
management capabilities.
o PLC Interface – Plant start-up and safety shutdowns are
performed by separate PLC. PLC interface shall communicate
with the PLCs.
o Controller and Data Acquisition System – It is the main field
interface system and is capable of data acquisition, processing
and control function.
o Foreign device interface- Interfaces with foreign device such as Gas
Chromatograph, Analyzer system etc.

3- 37
DCS System Configuration
o DCS Configuration comprises of (cont…):
o Communication system – Interconnects various systems over which

they can communicate with each other to meet all function
requirements. Performs the function of transmitting and receiving of
digital information from all the systems. consists of one or more
operator consoles for monitoring and controlling process parameters
and performing other process related functions.
o Management Information System: Interconnects various other

systems to extract plant-wide management information without
affecting or disturbing plant operations.

3- 38
3- 39
DCS Architecture
A physical arrangement of the hardware modules and the

selection of software options to satisfy system requirements.
The complexity of a DCS can vary. In the simplest form it
could only be a CRT display and keyboard in the control
room and a local control unit in the process area connected by
communication cables.

3- 40
DCS Architecture
Various configurations are possible Man-machine Interface
OPERATOR
CPU – Central Operation and

monitoring
functions
Processing Unit
Allows DAQ and control Display and
functions to be performed via operation

functions
LCUs Operator
Station Man-machine
data-base
Interface to other systems
Engineering Interface
OTHER ENGINEER
Communication system
LCU- Local Control Unit
SYSTEMS System
Gate-
Communication configuration,
way
between other System
systems maintenance
Usually dedicated to specific Control data- Control data-

unit operations of a process. Control Station base base
Control Control
If CPU or communication function function
systems fails, LCU can keep

controls of the plant.
LCU controller module Process Process
interfaces with field Process Interface
instruments EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

3- 41
Control loop diagram of DCS
Single control loop diagram
FIELD JUNCTION BOX TERMINAL PT FTA(DCS CABINET) DCS (CONSOLE)
J21
WTT161
FTA-ID APM 1
WT301 WT301 TE61+1A1
+ 1 1 MU-TAIH02 NETWORK NO 01
WT302 WT302 TE61-1A1
- 2 2 01 TB2 03
NODE NO
TE61 01 TB3 MODULE NO 01
SLOT NO 01 DCS TAG NO
I/O SLOT NO 06 WTTIC61

REGCLNIM
NODE NO 03
SLOT NO 04
CTLACN-REVERSE
J22
WTTV61
APM 1
FTA-ID
WT307 WT307 TCV61+1A0 NETWORK NO 01
3 3 MU-TAOX02
WT308 WT308 TCV61-1A0
4 01 TB1 NODE NO 03
4
02 TB1 MODULE NO 02
TCV61 SLOT NO 01
I/O SLOT NO 07

3- 42
Function of DCS
- Point Trend Display with Four Trace
EU High R-AXIS 20 MIN HM HM HM % High

150.00 100.00
150.00
100.00
200.00
EU Low
0.00
0.00
0.00
% Low
0.00
0.00
Add Scroll Scroll

Trace Back Fwrd
TIC 21741 TIC 21741 TIC 21741 FIC 21741
Parameter : SP PV OP PV
EU Desc : DEG. C DEG. C DEG. C KLB/HR
RT Value : 71.00 73.99 28.00 39.00

3- 43
Function of DCS
- Real Time Control
Enter Time Base (1 - 17)
Time Base Time Base
1 = 1 min
2 = 2 min EU High R-AXIS 20 MIN HM HM HM % High
3 = 5 min 150.00 100.00
4 = 10 min 150.00
5 = 20 min 100.00
6 = 1 hr
7 = 2 hr
8 = 8 hr
9 = 16 hr
10 = 24 hr
11 = 48 hr
12 = 96 hr EU Low
13 = hourly 0.00
14 = shift 0.00
15 = daily 0.00 % Low
16 = mnthly
0.00
17 = user
Add Scroll Scroll
Trace Back Fwrd
TIC 21741 TIC 21741 TIC 21741
Parameter : SP PV OP
EU Desc : DEG. C DEG. C DEG. C
RT Value : 71.00 73.99 28.00

3- 44
DCS General Architecture
User
6 Interface
Printer
Control
Station 2
Data Control
5 Highway Station 3
Control 2 I/O Bus

Link
Station 1
Comm.
1 I/O Module 4
Module
Controller
3 Module
LT

3- 45
Example of DCS Architecture
-Yokogawa DCS Architecture
PF(K)SB's DCS system is segregated into 4

domains as shown below :
PF(K)SB
Domain 1 Domain 2 Domain 3 Domain 4

Urea,Urea
Amonia and Utility Granulation and Urea Export
Methanol Section formaldehyde Terminal(located at
Plant plant Butterworth)

3- 46
Point, Unit, Area and US
Relationship
CCU
Plant
Amonia Urea Utilities Manager's
Office
Terminal GUS GUS GUS GUS GUS GUS GUS GUS GUS
1 2 3 4 5 6 7 8 9
Area 1 - Amonia Area 2 - Urea Area 3 - Area 4

Area Utilities
Unit Unit Unit Unit Unit Unit Unit Unit Unit

A1 A2 A3 U1 U2 U3 B1 B2
Points
FT 21442 TCV 21242 TT 21242
FCV 21442

3- 47
DCS Architecture
In a large process facility, a DCS is used for much wider integration
of control and comprises of:
o Central Control Station Hardware-CPU for process integration,
I/O blocks
o Local Control Station Hardware-specific local control and DAQ
o PLCs- emergency shutdown, start-up functions
o Other intelligent systems- smart valves, analyser packages etc.
o Interfaces and Communication
o Maintenance and Diagnostics services workstation
o Software – Process Optimisation, Control Modules, Interface
Software, Communication Protocols

3- 48
DCS Architecture
§ Regulatory capabilities:
Normal DCS controller modules have the following basic
regulatory capabilities:
üP, PI, PD, PID
üPI plus Adaptive Gain
üPD plus Adaptive Gain
üPID plus Adaptive Gain
üAuto/manual with bias control
üRatio control
üCascade control

3- 49
DCS Architecture
§ Operator Interface:
ü Located in central control station

ü Console desk
ü Keyboard – special functions for graphic and other
displays, programming and command.
ü Displays on CRT – group displays showing a group of
control loops, in instrument panel like appearance.

3- 50
DCS Architecture
§ Input/Output Modules:
• Analog input modules:
o 4 – 20 mA DC
o 1 – 5 volt DC
o Some DCS accept low level input from
thermocouples/RTDs.
• Discrete input modules (sense switch inputs):
o 24 volt DC, 48 volt DC
• Analog output modules:
o 4 – 20 mA DC
• Digital inputs and outputs modules:
o 24 volt DC, or 120 volt AC

3- 51
DCS Architecture
What are the differences between a DCS system and a centralized system?
In a centralized control system structure, the main functions of

control and monitoring were concentrated in a central computer, eg.,
process monitoring, DAQ, alarm and logging, data processing and
process control.
In a DCS system architecture only the data required for ’other

programs’ within the automation system will be distributed. DCS
distributes its function into smaller sets of semi-autonomous
subsystems covering specific process or geographic area of the plant
complex.

3- 52
DCS Architecture
What are the advantages of a DCS system ?
ü Has the benefits of a centralized control system with
the additional enhancement in the ability of the system to
process information more rapidly, allowing more
advance function to be incorporated into the system.
üImprove/automate the manufacturing process and
integration of advanced regulatory control and
procedural language with advanced application
languages that support manufacturing enterprise
application.

3- 53
3- 54
Advanced Control Development
§ Hierarchy of a DCS
Level 4 Corporate Information System
Level 3
Process Model and Optimization
Level 2 Supervisory Control
Level 1
Regulatory Control
Level 0 Measuring Devices
PROCESS

3- 55
The system when specified along with a supervisory
computer, could also meet the following requirements in
addition the basic process control.
§ Advanced Control
§ Management information system and interface
to Enterprise resource planning (ERP).
Note: ERP creates an enterprise-wide transaction

backbone and integrate manufacturing financial,
and other systems.

3- 56
Advanced Process Control
DCSs and other types of digital control systems are

enabling technologies. They provide the infrastructure
that allows substantial improvements in plant
operations.
To realize these improvements, the multivariable
predictive control (MPC), and other model-based
advanced control technologies, and advanced
controllers are incorporated.

3- 57
and Interface to ERP
Whenever information network is specified, the system shall
meet any or all of the following requirements:
o Centralised information system
o Statistical process control/statistical quality control
o Plant optimisation
o Plant planning and scheduling
o Computer integrated manufacturing (CIM) – to achieve functions
like production and preventive maintenance, scheduling and plant
wide co-ordination, etc.

3- 58

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EAB4223/EEB5223

Industrial Automation and Control System

Assoc Prof Dr Nordin Saad

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

Block diagram of a process control loop

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

CPU Computer used to store data for

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

Computer used to perform

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

Control Control Control

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

Smaller instruments (electronic)

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

These dedicated controllers/computers had

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

A general DCS component

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

Mechanical Mechanical + Pneumatic + Electronic + Distributed

1900 1930’s 1940’s 1950’s 1960’s 1970’s - now

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

ELECTRIC ANALOG CONTROL

CENTRALIZED DCS FIELDBUS

1930 1940 1950 1960 1970 1980

• Timeline of computer control of industrial processes:

1975 1985 1995

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

The following essential functions were

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

This created the need of future systems

The system should be such that data should be

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

These lead to the following data and functions

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

Local Local Local

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

The definition of DCS has changed

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

Ø Production scheduling and dispatching

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

Controller and Foreign Device

A General DCS Component

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

o Communication system – Interconnects various systems over which

o Management Information System: Interconnects various other

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

A physical arrangement of the hardware modules and the

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 3-

CPU – Central Operation and

functions to be performed via operation