MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

SUMMER – 2023 EXAMINATION

-
Subject Name: Distributed Control System Subject Code:
22645
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model
answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to
assess the understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance
(Not applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the
figure. The figures drawn by candidate and model answer may vary. The examiner may give
credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant
values may vary and there may be some difference in the candidate‟s answers and model
answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant
answer based on candidate‟s understanding.
7) For programming language papers, credit may be given to any other program based on
equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and
Bilingual (English + Marathi) medium is introduced at first year of AICTE diploma
Programme from academic year 2021-2022. Hence if the students write answers in Marathi or
bilingual language (English +Marathi), the Examiner shall consider the same and assess the
answer based on matching of concepts with model answer.

Q. Sub Answer Marking

No Q.No Scheme
1. Attempt any FIVE of the following: 10M

a) Elaborate the term SCADA. 2M

Ans SCADA stands for Supervisory Control and Data Acquisition is a system that 2M
aims to monitor and control field devices at your remote sites.. SCADA is a
centralized system that monitor and control the entire area.

b) List the different types of programs used for programming a process 2M

control application.

Ans Different types of programs used for programming a process control application (1 mark
are- each for
1. Operating system / Executive Program any 2
2. Application Program points)
3. System support software Program
c) List any two user designed displays used in DCS. 2M
Ans User Defined Displays can be classified as- (1 mark
• Plant Mimic Diagrams each for
• Area Mimic Diagrams any 2
• Group Mimic Diagrams points)
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

d) Enlist features of Experion DCS (any four). 2M

Ans • Mid-size DCS (1/2M each

• Up to 15 workstations for any 4
points)
• Up to 10,000 process I/OS-50,000 SCADA I/Os
• HART, Foundation Fieldbus and PROFIBUS I/O Support
• Redundant power supplies
• Optional redundant controllers and I/O
• It offers advanced alarm management functions such as „alarm shelving,
paging and dynamic suppression.‟

e) Enlist any two features of MODBUS. 2M

Ans 1. Bus Access Method used- Master Slave Principle. MODBUS Protocol (1M each
provides one for any 2
master and upto 247 slaves. points)
2. Transmission Modes- Data can be exchanged in two transmission modes-
a) ASCII- readable, used for testing activity
b) RTU- compact, faster used for normal operation
3. Transmission Rate- 0.6 to 19.2 Kbit/s
4. Length- 15 m for RS-232C, 1200m for RS-422

f) Give comparison between MAP and TOP protocol. 2M

Ans MAP TOP (1M each

for any 2
Manufacturing Automation Technical Office Protocol Points)
Protocol

MAP was defined in 1983 by Defined by Boeing for use in a

General Motors to allow open data Technical/ Scientific and Office
exchange between all the Automation environment.
automation equipment the
company used

Only Token passing method of CSMA/CD and Token Passing

Bus access is supported method

It specifies communication Emphasis on the exchange of

between- Computer, Robot documentation. TOP is used for both
Controllers, PLC, CNC and DNC CAD/CAM documentation and
office documentation such as text
and graphics.

g) What is PLC? Give its applications. 2M

Ans PLC stands for programmable logic controller or programmable controller. 1M for

Page No: 2/ 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

A Programmable Logic Controller (PLC) is a special form of microprocessor Definition

based controller that uses a programmable memory to store instructions and to
& 1/2M
implement functions such as logic, sequencing, timing, counting and arithmetic
each for
to control machines and processes. any 2
Applications of PLC are:- Applicati
 Process automation ons
 Automatic operation and control of the air compressor system
 Bottle and liquid filling industry
 Automatic temperature control
 Belt conveyor system
 Energy monitoring system
 Production line control
 Raw material handling
 controlling elevators
 traffic lights
 batch control,
 robotics processes.
2. Attempt any THREE of the following: 12M

a) 4M
Explain in brief the functions of all levels of hierarchical control in
automation with respect to DCS.
Ans Function of all levels of Hierarchical control in automation with respect to DCS: 1M each
Level 1A and 1B To provide a tight control of each operating unit of the point
plant, and ensures maximum efficiency of using raw material and energy.
 Reacts directly to any emergencies that occur in its own unit.
Level 2 and 3:
 A supervisory and coordinating system that determines and set the local
production level of all units working together between inventory location
and optimizes their operation.
 This system assures that no unit exceeds the general area level, no unit uses
excess energy or raw material.
 This responds to emergencies in any unit under its control to shut down or
Systematically reduce the output in related units.
Level 4: An overall production control system capable of carrying out the
scheduling function for the plant based on customer orders or management
decisions so as to produce the required product at the optimum combination of
time,energy, and raw materials.
Overall function of all layers: Assuring the overall reliability and availability
of the total control system through fault detection, fault tolerance, redundancy
and other techniques.

b) Describe the functions of controller module and power supply module w.r.t. 4M

Page No: 3/ 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

DCS with neat sketches.

Ans Function of Controller Module: 2M

2M

The controller module is connected to field devices via analog, digital or

combined analog/digital buses. Controller executes sequential and regulatory
logic and directly scans I/Os. While scanning of the I/O, it update the input
register and based upon regulatory logic generates the control compound which
is useful for controlling field output devices.
Function of Power Supply:

Power Supply is a part of DCS system which is used to supply required amount
of power to CPU, Input module and Output module. PLC has two types of
Power supplies 1. Internal power Supply: This powers the processor module.
2. External Power supply: This gives AC or DC power supply to I/O modules.

c) Explain operating system configuration w.r.t. DCS. 4M

Ans Following steps are followed in DCS system Configuration: 1M each

 Initial preparation work: Before entering the system configuration, first (any four
determine the measuring point list , control calculation plan , system in brief)

Page No: 4/ 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

hardware configuration , including the scale of the system, the

configuration of each station IO unit and the distribution of measuring
points, and also propose the flow chart, report form,
historical database and design requirements.
 Create target project :Before the configuration of the application project
is formally carried out, a project name must be defined for the application
project.
 System configuration equipment :The hardware configuration of the
application system is completed through the system configuration
configuration software. Using graphics display , each device connected to
the system network corresponds to a basic graphics display . The
corresponding project must be created in the database master control
before the system equipment configuration.
 Database configuration :Database configuration is to define and edit the
point information of each station of the system, which is the basis for
forming the entire application system .
 Control algorithm configuration :After completing the database
configuration, you can configure the control algorithm.
 Graphics, report configuration :Graphical configuration
includes background definitions (static point) and dynamic point
definition. Static point means the display/point which will not change all
the time such as, picture of tank, pipe, etc.
 Compile and generate :The system binding function is connected to form
a system library, which becomes the basis of the online operating software
on the operator station and on-site control station.
 System download : After the application system is generated, the system
library, graphics and report files of the application system are downloaded
to the server and operator station through the network.
d) Explain the procedure to maintain DCS system. 4M

Ans  Maintenance Procedure of DCS system: DCS Maintenance could be 1M each

defined as: “All actions that are necessary to keep the DCS stay
operational in its full functional state as main objective.”
 There are 4 types of DCS maintenance:
 Breakdown maintenance: This is the most inefficient way of
maintenance: a part get repaired when it breaks or fails.
 Preventive maintenance: With preventive maintenance, regular activity is
performed in order to keep the functional condition. During this activity
there will be cleaning, replacing before failing, et cetera. This preventive
maintenance can be approached on two different ways: periodic
maintenance and predictive maintenance. Periodic maintenance follows a
predefined time schedule while predictive maintenance is based on
working conditions like: 2500 hours running at 85% of load)
Page No: 5/ 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

 Corrective maintenance: With corrective maintenance, we try to detect

and improve weaknesses that might result in failures or breakdowns.
 Maintenance prevention (Predictive maintenance): Maintenance
prevention means performing actions like design actions, to reduce
maintenance requirements, based on the experience and analysis of the past
with similar equipment.
3. Attempt any THREE of the following: 12M

a) 4M
Explain fault tolerance in distributed system and its difference with
redundancy.
Ans  Fault tolerance is defined as the ability of DCS system 4M
(Workstations, controllers, I/O system etc.) to continue correct and safe
operations in spite of hardware failures.
 Fault tolerance is a major part of DCS, because it ensures the continuity and
functionality of a system at a point where there is a fault or failure.
 Normally each operator station is a stand-alone device with no
interconnection between operator stations and no sharing of microprocessor,
memory, power supplies etc. This ensures that a fault in one operator station
cannot cause another operator station to malfunction.
 The DCS controllers normally utilize redundant power supplies. Similarly in
DCS system communication sub-systems, data highways, highway
gateways, highway interface to each device are also redundant with both
auto and manual switchover capability.
 DCS multi-loop controllers also have redundant CPU, highway interface,
analog input and analog output cards.
 All of these fault tolerance techniques are employed by DCS manufacturers
to make DCS system highly reliable and available system.
 Redundancy is an important requirement for any critical process control
application using DCS system.
 In DCS processors, Network cables and even I/O channels are equipped with
„hot standby‟ duplicates which are ready to assume functionality in the event
the primary component fails.
 Redundancy increases MTBF of a system.
 Difference between Fault Tolerance and Redundancy-Redundancy is
technique to achieve fault tolerance in DCS. Most DCS system employ
redundancy at practically every level to achieve a very high degree of fault
tolerance.

b) Describe with neat sketch the functions of workstation. 4M

Page No: 6/ 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

Ans 2M
diagram
1M each
for
function
of each
workstati
ons

OR

diagram shows Components of DCS Architecture .

DCS Architecture consists of two Workstations:-a) Engineering Workstation
and b)Operator Workstation.
The functions of the Workstations are listed below:-
A) Engineering Workstation :-
1. Development of projects

Page No: 7/ 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

2. Configuration of graphics
3. Configuration of alarms, logic and trends for entire projects
4. Process plant security
5. Documentation
B)Operator Workstation:-
1. It provides operator interface
2. Includes color graphics, faceplate, alarm, data logging, trends etc
3. Diagnostic and trouble shooting of process problem
4. View and control of process plant.
c) Compare PLC and DCS on any four points. 4M
Ans Parameters PLC DCS Each
point 1M
Full form PLC is an acronym for DCS is an acronym for
Programmable Logic Distributed Control System.
Controller.

Definition A PLC is a controller A DCS is a computerized control

designed to control and system consists of multiple
automate the processes in controllers that are distributed
industries. throughout the system for control
and automation of a plant.

Type of control PLC involves discrete DCS involves regulatory control.

control.

Programming For PLCs, various high level For DCS, the existing function
programming languages are blocks are used to create custom
available for creating custom logic.
logic.

Redundancy additional hardware are used DCS has redundancy as its default
to make PLCs redundant feature
which makes them costlier.

Architecture PLC has comparatively The architecture of a DCS system

simple and flexible is relatively complex and less
architecture. flexible.

IO (Input - The IO handling capacity of The IO handling capacity of a

Output) a PLC is less than DCS. It is DCS is more than that of a PLC. It
capacity around few hundred IOs. is around thousands of IOs.

Scan Time Scan time of the PLC is Scan time of the DCS is
lower comparatively higher

Page No: 8/ 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

d) Explain sequential flow chart (SFC). 4M

Ans Sequential Function Chart (SFC) Diagram
Sequential Function Chart (SFC) is the graphical language used in 1M
programming of PLC.
Explanati
SFC represents the functions of a sequential automated system as a sequence of on 3M
– „Steps and Transitions‟.

 Step- each step indicates the state of the process. Step is represented by a
rectangular box. The initial step in a program is represented differently to
other steps .A step can be active or inactive. The flow of control passes from
one step to the next through a conditional transition.
 Transitions- It is conditional/logical statement it can be true or false. Each
connecting line between states has a horizontal bar representing the
transition condition that has to be realized before the system can move from
one state to the next.
 When the transfer conditions to the next state are realized then the next
state or step in the program occurs. The process thus continues from one
state to the next until the complete machine cycle is completed.
 Outputs/actions at any state are represented by horizontally linked boxes and
occur when that state has been realized.
 Example-As an illustration of the principles of SFC, consider the situation
with, say, part of the washing cycle of a domestic washing machine where the
drum is to be filled with water and then when full a heater has to be switched
on and remain on until the temperature reaches the required level. Then the
drum is to be rotated for a specified time. We have a sequence of states which
can be represented in the manner shown in Figure-
Fig. SFC for part of the washing cycle of a domestic washing
machine.

Page No: 9/ 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

4. Attempt any THREE of the following: 12M

a) Explain group display with neat sketches. 4M

Ans The group display shows the operating parameters of eight, twelve, or sixteen 2 marks
control loops, arranged in rows so that they look like the faces of instruments on diagram
an instrument panel. 2 marks
Following Fig. shows an eight-unit group display. Each of the control loops is explanati
represented by a rectangle with bar graphs to indicate the values of the process on
variable and the output signal

Page No: 10/ 21

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

A moving index positioned beside the process variable bar shows the set point
value. Engineering values for process variable, set point, and output percent are
printed in or below the rectangular area .The process variable value range may
be
printed on the left or right side of the bar graph. Several lines of text permit a tag
number and a service description to be shown. The rectangle may change color
(usually to red) if an alarm condition occurs
b) Describe bus access method for fieldbus. 4M

Ans In Fieldbus systems, the bus access method refers to the way in which devices 4 marks
connected to the bus access and transmit data. Commonly used bus access
method known as & quot; Token Passing & quot; in Fieldbus systems.
Token Passing: Token passing is a bus access method that ensures fair and
controlled access to the Fieldbus network. In this method, devices connected to
the bus take turns transmitting data by passing a special control token.
1. Token Generation: The token is initially generated by a designated device
on the network, typically a master or controller device. The token represents the
permission to transmit data onto the bus.
2. Token Circulation: Once the token is generated, it is circulated among the
devices connected to the Fieldbus network in a predetermined order. Only the
device that possesses the token has the right to transmit data onto the bus.
3. Data Transmission: When a device acquires the token, it can use the bus to
send its data. The device can transmit the data directly or exchange it with other
devices on the network through request-response communication.
4. Token Release: After a device completes its data transmission or
communication cycle, it releases the token, making it available for the next
device in line. The token then continues to circulate, allowing each device to
take turns accessing the bus.
5. Token Priority and Collision Detection: In some implementations, token
passing methods may have additional features such as token priority and
collision detection. Token priority allows certain devices to have higher priority
to acquire the token, ensuring time-critical data can be transmitted promptly.
Collision detection mechanisms detect and resolve conflicts if multiple devices
attempt to access the bus simultaneously. Token passing provides controlled
access to the Fieldbus network, ensuring that devices have fair and orderly
opportunities to communicate. It helps prevent data collisions and allows for
deterministic communication, where the timing and order of data transmission
can be precisely controlled.
Also note while token passing is a commonly used bus access method, other
methods like Master/Slave and Time Division Multiple Access (TDMA) can
also be used in Fieldbus systems depending on the specific protocol and
requirements of the application.

Page No: 11/ 21

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

c) Describe alarm processing method followed in DCS. 4M

Ans In a Distributed Control System (DCS), alarm processing refers to the 4 marks
systematic handling and management of alarms generated by various process
variables within a control system. The alarm processing method in a DCS
typically involves the following steps:
1. Alarm Generation: Process variables, such as temperature, pressure, or
level, are continuously monitored by sensors or instruments. If a variable
exceeds predefined limits or deviates from the desired set point, an alarm
condition is generated.
2. Alarm Prioritization: Once an alarm condition is detected, alarms are
prioritized based on their severity or impact on the process. The severity can
be categorized as high, medium, or low, depending on the potential
consequences of the alarm. This prioritization helps operators to focus on
critical alarms and take appropriate actions promptly.
3. Alarm Filtering and Suppression: To avoid overwhelming of operators
with a flood of alarms, alarm filtering techniques are applied. Some alarms
may be filtered out based on predefined criteria, such as alarm duration,
acknowledgment status, or alarm type. Similarly, alarms that occur within a
short time span and have the same cause may be suppressed, and only the
first alarm is presented to the operator.
4. Alarm Presentation: Once alarms are prioritized and filtered, they are
presented to the operator through Human-Machine Interface (HMI) displays.
The alarms are typically displayed in a dedicated alarm summary window or
alarm list, which provides information such as alarm tag, description,
timestamp, and current status (active or cleared). The most critical alarms are
usually highlighted or color-coded for quick identification.
5. Alarm Acknowledgment: When an operator acknowledges an alarm, it
signifies that they have noticed the alarm and are taking responsibility for
addressing it. The acknowledgment process helps in preventing alarm
overload and ensures that alarms are not ignored or missed.
6. Alarm Escalation: In situations where alarms are not resolved within a
specified time or if the severity increases, the alarm may be escalated to
higher-level operators or
supervisors. This escalation ensures that critical alarms receive attention and
appropriate actions are taken promptly.
7. Alarm Management and Documentation: The DCS maintains a log or
database of
alarms, including their timestamps, status changes, acknowledgments, and
resolutions. This information serves as a historical record for analysis,
troubleshooting, and improvement of the system performance. The alarms
can be archived for future reference and can also be used for generating
reports or statistics.

Page No: 12/ 21

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

By following these steps, the alarm processing method in a DCS helps operator
effectively monitor and respond to alarms, ensuring the safety, efficiency, and
reliability of the controlled process.
d) Explain backup systems and fault tolerant system with respect to DCS 4M
maintenance.

Ans Backup 2 marks

“Backup” is protecting the critical data from damage or loss and retaining it for each
as long as you may need it. Damage and loss can occur from technical
problems, such as a damaged hard drive, more likely, from human action -
either accidental or malicious.
In modern DCS system, when the data is exposed to internet, it is more
susceptible to the virus attack, malware attack or hacking. Hence it is necessary
to have a backup of the critical data which will be available as and when
primary data is damaged.
Fault tolerance refers to the ability of a DCS system (workstations, I/o network,
controllers, etc.) to continue operating without interruption when one or more of
its components fail. The objective of creating a fault-tolerant system is to
prevent disturbance arising from a point of failure, ensuring the high availability
of a system.
Fault-tolerant systems use backup components that automatically take the place
of failed components, ensuring no loss of operation. The fault tolerant in the
system includes –
• Hardware System :-In this, the important parts of the system are backed
up by identical or equivalent system. For example – a specific server
computer can be made fault-tolerant by using an identical server running in
parallel, with all operation mirrored to the backup server.
• Software System :-In this, the software systems are backed up by other
software which is identical. For example – a database with process
parameter information can be continuously replicated to another machine.
If the primary database goes down, operation can be automatically
redirected to the second database.
• Power Sources:- In this, the power sources are made fault tolerant using
alternative sources. For example – specific section or area of a plant can
have power generators that can take over in case main line electricity fails.
e) Describe with sketches different types of logs and reports generated in 4M
DCS.

Ans DCS logs are the collection and recording of information and data from around 2 marks
the production process. The information is usually collected automatically, but
there may also be the need for manual input points where staff can input
information or add relevant comments to explain the reason for downtime,
faults, or change of operator.
Data History used in Logs or reports:
13
Page No: / 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

Within any production line there are large quantities of information that can be
logged. This data is collected automatically by sensors or transducers within the
production line that are set to monitor the production process. This collected
data or information is then recorded (logged) in DCS system. This logged data
can then be-

 Types of Logs: There are three types of logs:

1. Event / Activity Log:The Event or Activity log records information about
various types of system activities or events such as, Tag writes, Occurrence
of predefined event, System messages, occurrence of system errors and
communication errors etc.To set up activity logging, activity log setup editor
is used in DCS system.
2. Alarm Log: The alarm log records alarm incidents, such as, when tag goes
into alarm, when tag goes out of alarm, when an alarm is acknowledged.
The name of the user (Operator) who acknowledges the alarm is also
logged. To setup, an Alarm log setup editor is used in DCS system.
3. Data Log: The data log records, specifies tag values, or data, under certain
conditions. These conditions are defined by a data log model. To setup,
data log setup editor is used in DCS system.
DCS Reports

Page No: 14/ 21

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

A DCS report is a document that presents the logged (or recorded) process
information
in an organized format for a specific operator and purpose. Although summaries
of these reports may be delivered orally, complete reports are almost always in
the form of written documents. Similar to logs the reports are of three types:
Event/ activity report, Alarm report, and data report
5. Attempt any TWO of the following: 12M
a) Draw feedback control algorithm for level control. Explain it. 6M

Ans Feedback control for Level control: Diagram

3M
Diagram:
Explanati
on 3M

Explanation: An “algorithm” is a mathematical relationship between the

process variable and set point inputs of a controller, and the output (manipulated
variable). Control algorithms determine how the manipulated variable quantity
is deduced from PV and SP inputs, and range from the elementary to the very
complex. In the most common form of control algorithm, the so-called “PID”
algorithm, calculus is used to determine the proper final control element action
for any combination of input signals.
As shown in figure above, feedback control system employed in tank liquid
level control system uses the measurement system, controller and final control
element.
b) Explain plant mimic display with neat sketch. Give its importance. 6M

Ans  Plant Mimic Diagram:

These diagrams represent the most appropriate means for a detailed survey
of an instantaneous situation within the plant and intervention, if necessary.
Even in a conventional, central control room, the plant mimic diagrams have
been applied for total plant representation, including the representation of
control instrumentation used. This has in a great deal simplified the central
plant monitoring. Today the plant mimic diagrams, combined with the 1M
appertaining functional key boards, cursers or light pens, can be applied for Diagram
operation on the process in straightforward manner.

15
Page No: / 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

2M
Explanati
on

2M
(Note: Any other suitable diagram can be also be considered )
Importan
Similar to the classification of standard displays, discussed in earlier section, ce
the user
defined displays can be classified as:
 Group mimic diagram:
In this diagram the whole plant is represented by a single, continuous mimic
diagram stored in a computer. In this the total plant is mimic diagram mimic
diagram has to be imagined as a large single drawing on a computer screen,
can be rolled for displaying the selected portion by operator. The rolling
will be operated by the use of a key board or mouse etc.
 Area mimic diagram:
In this diagram the total Plant Mimic diagram is split into a series of small
or partial (area) mimic diagram. Usually a paging technique is applied for
selection of the required plant area.

c) Explain bus access method for PROFIBUS. Give its features and 6M
applications.

Ans The Bus Access Method used for Profibus is Master Slave with Token 3M
Passing.
Master Slave method:

Page No: 16/ 21

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

3M

Page No: 17/ 21

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

6 Attempt any TWO of the following: 12M

a) Compare foundation fieldbus and MODBUS on any six points 6M

Ans Foundation Fieldbus Modbus 1 mark

Communication It is a digital, multi-drop, Modbus is a simple, aster- each
Protocol serial communication slave, serial mmunication
protocol that is based on the protocol that operates on a
OSI model. It uses a token- request-response model. It
passing mechanism for is commonly used for
communication and supports connecting field devices
peer-to-peer communication to programmable logic
between devices. controllers (PLCs) or
other devices.
Network It supports a multi-drop bus Modbus can be
Topology topology, allowing multiple implemented in various
devices to be connected in a network topologies,
single bus segment. It including point-to-point
typically uses twisted-pair connections and multi
wiring with power provided drop configurations. It is
by the commonly used over RS-
network itself. 485 or Ethernet networks.
Data Types It supports complex data Modbus supports basic
and Addressing types and provides data types such as
standardized object-oriented integers, floats, and coils.
addressing. Each device in a It uses a simple address
Foundation scheme where each device
Fieldbus network has a has a unique address and
unique address and can can be accessed using
expose multiple variables function codes.
with specific attributes.
Functionality Foundation Fieldbus Modbus: Modbus is a
and provides advanced straightforward protocol
Features functionality such as process primarily focused on
control, asset reading and writing data.
management, and device It lacks advanced features
diagnostics. It supports like diagnostics and asset
distributed control management. It is
capabilities and allows commonly used for
devices to communicate data acquisition and basic
with each other directly. control tasks.

Page No: 18/ 21

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

Scalability Foundation Fieldbus Modbus is typically used

supports larger-scale systems in smaller-scale systems
with a high number of with fewer devices. It is
well-suited for
devices and Complex control
applications where
architectures. It allows for simplicity and cost-
seamless integration of effectiveness are key
various devices and provides factors.
robust networking
capabilities.
Industry Foundation Fieldbus is Modbus: Modbus is
Adoption commonly used in process widely used across
industries such as oil and various industries,
gas, including building
chemical, and automation,
pharmaceutical manufacturing,
industries. It is known for its and energy management.
robustness and advanced Its simplicity and wide
control capabilities. availability make it
popular for many
applications
b) Explain Rack bus in detail with its advantages. 6M

Ans 1 Rackbus" typically refers to a communication bus or backplane used 1 mark

to interconnect various modules or cards within a DCS rack or cabinet. It each
provides a means for communication and data exchange between the
modules, enabling the integration and coordination of different functions
within the system. Here's a detailed explanation of Rack bus in DCS
and its advantages:
2 Communication Backbone: The Rack bus serves as the primary
communication backbone within the DCS rack. It allows modules such as
input/output (I/O) cards, controllers, power supplies, communication
interfaces, and other components to communicate with each other and share
data seamlessly. High-Speed Data Transfer: Rack bus is designed to provide
high-speed data transfer capabilities, enabling rapid exchange of information
between modules. This allows for real-time control, monitoring, and data
acquisition within the DCS system.
3 Reduced Wiring Complexity: By utilizing Rack bus for internal
communication, the need for extensive point-to-point wiring between
modules is minimized. Instead, modules can be plugged directly into the
rack, and the Rack bus handles the data exchange between them. This
reduces wiring complexity, simplifies installation, and reduces the potential
for wiring errors.
4 Improved System Flexibility and Modularity: Rack bus provides a
modular approach to DCS design. Modules can be easily added, removed, or
replaced within the rack without significant disruption to the system. This
19
Page No: / 21
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

modularity allows for flexible system configuration and scalability as the

DCS requirements evolve or change over time.
5 Enhanced System Integrity and Reliability: Rack bus provides a reliable
and robust communication infrastructure within the DCS rack. Its design
incorporates fault-tolerant features such as redundancy, error checking, and
error recovery mechanisms,ensuring the integrity and reliability of data
transmission between modules.
6 Centralized System Management: With Rack bus, the DCS system can be
centrally managed and controlled. Configuration, monitoring, and
diagnostics can be performed through a centralized control interface,
simplifying system administration and troubleshooting processes.
7 Streamlined Maintenance and Upgrades: Rack bus facilitates easier
maintenance and upgrades of DCS modules. Faulty or outdated modules
can be easily identified and replaced, minimizing downtime and system
disruptions. Upgrades or enhancements to the DCS system can be
implemented by simply adding or swapping modules on the Rack bus.
c) Define algorithm. Draw feed forward control algorithm for flow control 6M
loop.

Ans Definition: An algorithm is a well-defined sequence of instructions or a set of 2 marks

rules that can be followed to solve a specific problem or perform a particular definition
task. It is a step-by-step procedure that outlines a series of actions or
4 marks
calculations to be executed in a specific order. A feed-forward control algorithm
explanati
for a flow control loop is a control strategy that aims to regulate the flow rate of on
a system based on predefined set points and measured process variables.

Feed forward Control:

• Feed forward control looks at load changes, anticipates their effect on
the process and compensates for these effects before they have evolved.
• Feed forward improves control by inserting a function into the control loop
that closely duplicate of the process response & load changes and
final control element position.
• Corrections if applied too early, will interfere introduce too much anticipation,
resulting in over control and oscillation. Process models must be expressed in
the form of transfer functions or differential equations because of the dynamic
functions. Exact duplication of analog feed forward on the central computer
would require integration, imposing a severe load on computer time. This

Page No: 20/ 21

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)

Subject Name: Distributed Control System Subject Code: 22645

makes it desirable to device an approximation method that will adequately

describe the process but will not overload the computer.
The response of chemical process systems to a step I/P can be
approximated by one of the following transfer functions:

Where, K is the process gain constant, TDT is its dead time, and T, T1 and
T2 are the time constants of the process

Page No: 21/ 21