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DCS L1

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45 views15 pages

DCS L1

Uploaded by

B. V.SAHRUDHY
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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➢Objective of the Lecture

• This class will develop students’ knowledge on the


Concept of Distributed Control Systems.

4/30/2023 O. Anjaneyulu 1
What is a DCS?
• The classic DCS originated from an overall system
approach
• A DCS is a complete tightly integrated package from a
single vendor consisting of
• Hardware
• Process Controllers, including redundant
controllers & IO and other certified safety systems
• Networking - wired, fibre-optic, wireless, mesh,
redundant
• Server & PC hardware, including industrial PCs,
redundant drive systems, multi-monitor systems

4/30/2023 O. Anjaneyulu 2
What is a DCS?
• Software
• Engineering and Configuration Environment with
in-built Change Tracking and Audit Trails
• Single Data Model – One data owner – System-
wide Tag.
• Example : Tag defined in Process Controller
with HMI Alarming, History Logging is
immediately available with HMI and Historian
• Visualization
• Batch Support at Controller-level
• Process Database
• System-wide Modelling and Simulation

4/30/2023 O. Anjaneyulu 3
• Multiple Process Controllers autonomously control large
sections of the plant and they can inherently communicate with
each other.
• The entire system is tested, certified and guaranteed to handle
high-speed data communications between the nodes
• Coordination, synchronization and integrity of process data over
a high-performance and deterministic network are at the core of
the DCS architecture
• 20-30 year Vendor guarantee for entire system support

4/30/2023 O. Anjaneyulu 4
Architecture of a simple DCS

4/30/2023 O. Anjaneyulu 5
Functional components of DCS

4/30/2023 O. Anjaneyulu 6
The major advantages of functional distribution of
hardware and software characteristic of DCS are:

• Flexibility in system design

• Ease of expansion

• Reliability

• Ease of maintenance.

4/30/2023 O. Anjaneyulu 7
PLC vs DCS
• Historically the DCS was designed for

• integrated control of entire scope of large process plants with


millions of IO points
• Guaranteed network performance for communication between the
distributed Process Controllers and also with the HMI, Historian,
etc..
• Redundancy and high availability
• Large Number of Analog Control Loops – programmed with
Function Blocks
• Standard Function Blocks (PID, etc), Fuzzy Logic, Advanced
Algorithms and Visualization Templates(Refining Column, etc)
are available out-of-the-box in the DCS software
• New Function blocks can be created and reused
• Of-course Digital IO is also supported!
• Configured and maintained by Trained Engineers
• Guaranteed fixed interval scan. Example : @0.1s @1s @5s

4/30/2023 O. Anjaneyulu 8
PLC vs DCS
• Historically the PLC was designed for

• Local control with a few 100 IO points


• Stand-alone operation
• Low Cost and Simplicity
• Relay logic Replacement – programmed with Ladder Logic
• Initial emphasis on simplicity to enable even electricians to
understand
• Ladder Logic is continuously executed cyclically
• Fast response guaranteed below the Scan Watchdog Time (say
0.1 ms )
• Fast but non-deterministic scan scheduling interval –
sometimes say every 50ns, other times 52 ns…

• Many machines ship with built-in PLCs for their control and may be
installed in a plant that is controlled by a DCS. The DCS may
communicate with these PLCs using IO or a field-bus.
4/30/2023 O. Anjaneyulu 9
PLC vs DCS
https://realpars.com 2020 1980(expensive), 2020(cheaper)

1980

4/30/2023 O. Anjaneyulu 10
PLC vs DCS
Today – PLCs come close.. but..
• PLCs today support

• Networking using standard Field Buses (but through-put and reliability


may not be guaranteed for your system configuration)
• Function Block Programming
• Redundancy (but at cost comparable to a DCS)
• Configurable Scan Intervals
• PLC Tag data-base integrated with SCADA of the same vendor (or uploaded
to SCADA for a different vendor – here syncing changes could be an issue)
• Using PLCs, SCADA, Historian… a system comparable to a DCS could be built
• But… using networked PLCs+SCADA as a DCS … is very much a “do-it-yourself”
(DIY) approach with plenty of technical risk as well as added costs that are not
always immediately obvious.

4/30/2023 O. Anjaneyulu 11
PLC vs DCS
Today – PLCs come close.. but..
• Today due to significant price reduction in DCS systems…it still makes good
Engineering and Economic sense to use a DCS than attempt to “club together”
your own system using networked-PLCs and SCADA

• For distributed systems with large IO counts

• DCS applications – refineries, chemical processes


• Where long support guarantees are required for the system – and individual
PLC and SCADA vendors may not provide 20-30 year support guarantees
• Several DCS Systems of today actually use PLC hardware and SCADA software
with some tweaking. However here the integration is done by the equipment
manufacturer and a pre-packaged system tested and certified for the IO Counts
and data-transfer rates is supplied. Example Siemens PCS7 DCS that uses S7-400
PLCs and WinCC HMI, Rockwell’s ProcesLogix

4/30/2023 O. Anjaneyulu 12
RESEARCH PAPERS
• 1. Application of Active Disturbance Rejection Control technology in distributed
Control System of coal-fired power generation
Abstract:
Distributed Control System plays a role of “brain” and control center for coal-fired power generation
unit. Super critical (SC) and Ultra-super critical (USC) power generation units with large capacity,
high parameters, high efficiency have been the key units of coal fired power industry. Reliability and
stability of these units are preconditions for safety of large grid. And the automatic control system
and control strategy with good performance are the basis for safety and stability of power plant. SC
and USC are multi-inputs, multi-outputs system with strong coupling and nonlinearity. Good
performance couldn't be achieved by employing conventional PID control technology. This paper
first introduces how embedded Active Disturbance Rejection Control algorithm is implemented in
DCS. Then, the ADRC coordinated control scheme for Super critical one-through power generation
unit is presented. The simulation results obtained from the DCS show that the proposed control
scheme can effectively solve problems of strong nonlinearity, uncertainty, coupling, large time delay.
And it can improve greatly the control performance of coordinated control system for SC units.

4/30/2023 O. Anjaneyulu 13
➢Outcome of the Lecture

• Having listened to this lecture you should be able to


Describe the Concept of Distributed Control Systems.

4/30/2023 O. Anjaneyulu 14
Self Evaluation:
• Explain the way a DCS performs transmission
of process information and commands.
• Explain reason how DCS has evolved with the
main intention of avoiding failure of a
process/plant or part of it due to failure of a
single controller.

4/30/2023 O. Anjaneyulu 15

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