➢Objective of the Lecture

• This class will develop students’ knowledge on the

Distributed Control Systems software and its structure.

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 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

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DCS Software
• The software is the language in which the system understands the
system components and also the user requirements.
• The software is classified into two categories:
• System software
• Applications software

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System software
• It implements the configuration, compilation, and runtime system for
one or several application specific programming languages.
• System software details the method of interconnections and the
optimum hardware utility for many functions.
• System software support the following features:
• Standard templates: the system software provides standard
templates of process, systems, and maintenance functions. Also,
standard templates for operator viewing capabilities, report, and
history requirements are generated.

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• Information transfer: The system software provides tools for
expanding the system online. The system also defines the method of
transfer of information between I/O devices and human interface.
• Utility Tools: the software for graphic generation tools, print
functions, remote maintenance of system components and
diagnostics are included. Application software is mainly the utility tool
for the people who utilize the system for operator functions and
engineering function. It has the following characteristics.
• User friendliness: Application software makes sure that software is
easy to use, gives answers to all queries.

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• Support for reuse: Application software supports techniques like
libraries and inheritance by which the standard solutions can be used.
• Use of internet technology: web servers are used as a standard
platform for hosting applications ( also for embedded systems).
Application software also support the use of standards for
communication and information exchange based on XML (eXtensible
Markup Language).

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DCS Structure

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• In a DCS, actual command and data topology of the system can be
partitioned into either hierarchical structures or heterarchical
structures.
• Hierarchical structures have distinct command and data paths such
that each element receives command from the level above it and
sends information back tothat level on the basis of information
received from the elements at the same level.
• High level control may, for example, be more concerned with the
overall performance strategy of the plant rather than immediate
control of the plant environment.

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• The most commonly used DCS structure with hierarchical levels is
shown in figure. At the first place, there are transducers and
controllers installed in close proximity to the process.
• The I/O parameters are communicated to the next level of controllers
(which are usually computers) placed in the control room.
• Further monitoring is done by the supervisory control, which is at the
next level in the hierarchy.
• Finally the management level is at the highest level in the hierarchy; it
manages and coordinates the entire system for the smooth
functioning of the same.
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• The detailed function of each level is listed below:
• LEVEL 0: (Basic Control) control of basic parameters using PID type of regulatory control.
• LEVEL 1: (Advanced Control) dynamic computer control using certain advanced control
techniques such as product quality control, feedforward control, adaptive gain control, local
optimization, etc.
• LEVEL 2 : (real time supervisory systems)Real time data reconciliation, optimization of process
units, computation of performance indicators, control of product movement, optimization of set
points with minimization /maximization of suitably defined objective functions while ensuring
quality and quantity of production.

• LEVEL 3: (Decision support system for production management) Scheduling, maintenance

management, overall mass balance, product movement management, and spare scheduling.

• LEVEL 4: (Production and distribution corporate management) operations research techniques for
planning, database management systems, accounting facilities, staff management.

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 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

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 • 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

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Architecture of a simple DCS

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Functional components of DCS

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 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.

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 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

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 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.
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 PLC vs DCS
https://realpars.com 2020 1980(expensive), 2020(cheaper)

1980

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 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.

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 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

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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.

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 ➢Outcome of the Lecture

• Having listened to this lecture you should be able to

Describe the software of Distributed Control Systems
and its structure.

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 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.

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