MODULE 4

Distributed Digital Control

• 4.1 Introduction
• 4.2 History
• 4.3 Functional Requirements of Distributed Process
Control System
• 4.4 System Architecture
• 4.5 Distributed Control Systems
• 4.6 Configuration
• 4.7 Some popular Distributed Control Systems
• 4.8 Fieldbus Systems
 Introduction
• 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

• DCS (Distributed Control System) is a computerized control system

used to control the production line in the industry controlled by one or
more controllers.

• DCS is a very broad term used in a variety of industries, to monitor and

control distributed equipment.
APPLICATION AREA
Electrical power grids and electrical generation plants
Environmental control systems
Traffic signals
Radio signals
Water management systems
Oil refining plants
Metallurgical process plants
Chemical plants
Pharmaceutical manufacturing
Sensor networks
Dry cargo and bulk oil carrier ships
 HISTORY
• The DCS was introduced in 1975. Honeywell and Japanese electrical
engineering firm Yokogawa introduced their own independently
produced .

• In 1978 Metso(known as Valmet in 1978) introduced their own DCS

system called Damatic (latest generation named Metso DNA[4]).

• In 1980, Bailey (now part of ABB[5]) introduced the NETWORK 90

system.

• In 1980, Fischer & Porter Company (now also part of ABB[6])

introduced DCI-4000 (DCI stands for Distributed Control
Instrumentation).
Dedicated Computer Concept
Dedicated Computers have wider applications
• Experiment automation in laboratory, test field etc.

• Small plant automation

• Partial plant automation

• Signal and image processing

• The small dedicated computers are relatively costly.

• A centralized single computer automation structure was

introduced containing a middle scale or large scale process
control computer as its central part .

• The essential functions of Centralized Computer

• Process monitoring
• Data acquisition
• Alarming and logging
• Data processing
• Data archiving
• Process control
Centralized Computer Control System
Centralized Control System
• In centralized a single large computer was used to acquire
data from one or a number of processes and control a
large number of process loops.

• The cost of interfacing the computer to one or more

processes was high.

• In such centralised computer process control systems it

was necessary to bring all the cables back to the central
control room.
Advantages

It is possible to achieve overall co-ordination and

optimization of the process.

Large amount of process data can be stored on associated

peripherals, such as hard discs and analysed to improve
the process performance.
Disadvantages

• Reliability i.e. any computer used for controlling

processes must be highly reliable.

• A highly reliable system can only be developed by using

a standby computer system and use it for process control
purposes in the event of breakdown of the main unit.

• Cost – mainframe and large minicomputers used for

centralised process control are expensive.
Distributed Control System
• A new automation structure was introduced which would
be more
(a) reliable
(b) easier and less costly to install
(c) more transparent w.rt to data structure and automation
functions.

So a hierarchical automation system structure was

introduced containing some elements of the distributed
computer system popularly known as Decentralised
computer system
Decentralized Computer Control Concept
Functional Requirements of (Distributed) Process Control
System
• Have a consistent and uniform system approach.
• Fulfil and perform all operational, process and control
functions.
• Automatically control the process and plant in normal
operation within the specified limit and tolerances but also
permit manual operation.
• Provide at any time, the operating personnel with full
information on the status of plant and process for control
and maintenance purpose, fault detection and localization.
• Be so designed that future expansions can be easily and
economically implemented.
• Enable highly economical plant operation.
In any plant following persons interact directly with the
systems.
• 1) Plant operator
• 2) Maintenance Engineer
• 3) Design and Development Engineer
• 4) Manger and Supervisor
•
Plant operator’s Requirements
• Easy handling of the system
• Auto/manual system provision
• Instantaneous access to any area of the process
• Continuous monitoring of the process dynamics
• Provision for accurate and reliable data
• High speed graphics facility with updated dynamic data
• Provision for tuning a control algorithm parameter
Maintenance Engineers Requirements
• Modular design
• Use of identical hardware components in various sub
systems
• Provision for repairs without shutdown of complete
process.
• Easy availability of spare parts and components.
• High MTBF – mean time between failures
• Low MTTR – Mean time to repair
Design/development Engineers Requirement
• Provision of the direct interaction of the process
• Provision for using modulating control, sequential control
or only data acquisition
• Provision for building display diagrams.
• Facility of the PROM burner
• Possibility of testing application programs with real time
data.
• Provision for initiating, implementing and activating the
functioning of various sub-systems.

• Facility for retrieving and analysing the historical data.

• On-line expansion of the system.
Manager/supervisor Requiremnts

• Provision of overall plant operation display with facility of

selecting a particular area of the plant

• Provision for accurate and reliable data

• Facility for sending and receiving error-free messages.
• Availability of historical data and other reports.
• Quick reporting of abnormal conditions.
• Easy system operation.
• Easy and fast maintenance.
• High reliability of the system.
• Fast and error-free communication with other units of the plant.
• Fast response time of the system even with worst loading
conditions.
• Cost effective system.
Distributed Control systems Evolution
These software packages have the following common software functions:
• Input signal conditioning
• Validity check
• Engineering unit conversion
• Linearization
• Digital filtering and smoothing
• Averaging and extrapolation
• Peak-value search and tracing/
• Pulse and digital signal evaluation and processing
• Trend check and monitoring
• Open and closed-loop control
• Logging
•
Some of the 50 modern Distributed computer control systems in the market today
such as,
 CP-80 (AEG-Telefunken)
 DCI 4000 (Fisher and Porter)
 MAX (Leads and Northup)
 MICON (VDO)
 PROCONTROL (Brown Boveri)
 MOD III (Taylor and ABB)
 MV 8000 (Beckmann)
 PCS 8000 (Philips)
 PLS 80 (J.C. Echardt)
 P 4000 (Kent)
 PMS (Ferranti)
 PRO VOX (Fisher Controls)
 TDC 3000 (Honeywell)
 TELEPERM-M (Siemens)
 TOSDIC (Toshiba)
 TPS system (Honeywell)
 Lonwork system (Echelon), and so on.
SYSTEM ARCHITECTURE - Characteristics

 Be of functional and topographical distributed design and

have a hierarchical structure.
 Distribute the functions among devices and stations in
accordance with the hierarchy and modularity of the
automation tasks and suit the individual requirements
involved.
 have devices which perform all the automation functions .
 have central operator stations for comprehensive process
monitoring and interaction.
DCS Hierarchy

• Level 1- Field Level

• Level 2- Area Control Level
• Level 3 – Plant Control Level
• Level 4 – Plant Management Level
Hierarchy for Distributed Control System
Level1FieldLevel

Level2(AreaControlLevel)

• Dedicated microprocessor-based systems.

• Detection of any emergency conditions and shutdown, and to provide a manual
backup if all other layers fail.

Functions of this layer are (microcomputers)

• Process Data collection( Temp, flow, Pressure etc),message and alarm signals
processing.
• Open and Closed loop control
• Hardware test
Level 3 (Plant Control Level –Medium scale
computers)
• Optimal control
• Adaptive control
• Self tuning control

Level 4 (Plant Management Level-

Large scale computers)
• Production planning, resource scheduling and other
management functions.
DCs
• A typical DCS is represented based on AEG-Telefunken
Logistat CP80 Automation structure for industrial Control.
Hierarchy levels
• Level 1-Process Level
• Level 2 – Unit Control Level
• Level 3- Group Control Level
• Level 4- Process control Level
• Level 5 – Operation control Level
DCS
Process Level
• Conventional plant instrumentation for
interlocking ,alarming, manual back-up control etc.

Unit control Level (individual sensors actuators)

• Data collection and supervision
• Data check and alarming
• Data logging
• Open and closed loop control
• Group Control Level
• Individual field stations are grouped and attached to the
relevant group control stations.

Process Control Level

• This is the highest control level .
• Necessary Software will be stored to complete
• ** Plant supervision
• ** Archiving and logging of data
• ** Optimal Plant Control
• ** Central Plant monitoring , alarming etc.
Operational Control Level
• Production planning
• Plant Management
• Order Booking
• Personal Management
• Machine Management
Local Field station
• Smallest intelligent unit of a DCS.
• Honeywell TDC field station- controller file
• Siemens TELEPREM field stations – automation sub
system.
• It usually contains
• -- Microcomputer (32 to 64 KB RAM,16 to 32 analog
I/P,8 to 16 analog output,48 digital I/O,serial and parallel
bus)
• -- Hard copy output terminal
• -- Local Display Terminal
Presentation and monitoring device
• For efficient process monitoring and control ,efficient
communication is necessary b/w process operator and the
process to be automated.
• On display screen following are visually represented
--Current values of measuring data.
• --Position of actuators
• --History of individual signals
• --State of different plant parts,control loops etc.
TDC 3000 displays are used in three operating
modes:
 Normal conditions
 At time of process upset
 In the event of control equipment malfunction
Continuous process displays
Batch/sequence operation Displays
Batch Summary Display-summary of information
on each active batch.
Batch Display – status of process modules related
to a particular batch
Process Upset Displays
• Alarm Annunciator Display
• Area and Unit alarm Display
Alarm Annunciator Display
Communication Option in DCS
• Communication paths are an essential requirement of a
decentralized automation system.
• It provide the link for data flow between automation
equipment attached to the same or to different
automation levels.
• Level-1, usually the point-to-point connection will be
applied to connect individual sensors and actuators to
analog and digital inputs and outputs of the local field
station.
• For shorter distance, an instrumentation bus can be
applied, like the. IEEE 488-bus, or special buses like
K-110 bus of AEG-Telefunken.
• Level-2 and Level-3 systems long-distance buses
extendable up to 5 or 10 km.
• PDV-bus, PROWAY, IEEE 488-bus, etc. Long distance
buses are usually serial buses.
Configuration
The configuration of distributed control system is performed
in two steps.
• Step 1—Configuration of operating system
The operating system is configured to define the following:
•• Composition of groups and overviews displays
•• Period for Trend Displays
•• Hiway Station Priorities
•• Message Tables
Step 2—Configuration of controller functions
• The configuration of controller functions is
done by using various software control modules
which are resident in memory.
• These software modules are known as
algorithms.
FIELDBUS SYSTEM
• Fieldbuses are special local area networks that are
dedicated to data acquisition and the control of sensors
and actuators.

Fieldbus Types
•FOUNDATION Fieldbus.

•WorldFIP (or WorldFIP Europe).

•Profibus.

•CAN
FOUNDATION Fieldbus.
• This was formed in 1994.
• The H1 standard has defined low-speed 31.25 kbps
transmission.
• The H2 standard (which is equivalent to WorldFIP)
operates at 1 Mbps.
• The Fieldbus foundation is an initiative of mainly
USA-based vendors.
• Its main aim is to standardize Fieldbus for the
petrochemical/chemical industries.
WorldFIP (or WorldFIP Europe).
• This standard has been incorporated into many
products and supports a 1 Mbps transmission rate.
Profibus. This has three main types:
FMS (Flexible Manufacturing Systems),
DP (Distributed Peripherals) and PA (Process
Automation).
FMS and DP use RS-485 signaling, whereas PA uses
the IEC physical layer at low speeds.
Other buses, such as the CAN bus,
The CAN protocol is an ISO-defined standard (ISO
11898) for serial data communication at bit rates up to
1 Mbps.
Fieldbus Topology
Fieldbus Layer
The FOUNDATION Fieldbus consists of two main layers:

• The communications layer and the user layer

• The user layer operates above the communications layer

and includes function blocks, resource blocks, transducer
blocks and alarm notifications.
Function Blocks (FB) :
• The user layer supports device configuration and uses
function blocks.
• A device can have any number of function blocks.
• These are used for control, diagnostic, safety and
production accounting purposes, status propagation,
trend collection mechanism, execution scheduling
mechanism, status of process variables, and rules for
propagation of status and behaviours in response to
status changes.
Resource blocks (RB).
• Each device also has an RB, which contains
parameters related to the physical device such as
manufacturer ID, type of device, revision, memory
usage and free space, computational time and
device state (on-line/off-line/standby/fault
condition, etc.).
Transducer blocks (TB).
• Each device has a TB, which stores the parameters
association with the sensor or actuator.
Alarm Notifications.
• Each block (functional, resource or transducer) can
produce an alarm notification for any problem which is
associated with that particular block
• process problems with function blocks, sensor/actuator
problems with transducer blocks, and overall device
problems with resource blocks.
WORLDFIP
•Physical layer
• The physical layer ensures the transfer of bits from one
device to another.
• In the main specification the transmission rate is 1
Mbps over Shielded Twisted-Pair (STP) or Optical
Fibre Cable (OFC).
• The three defined rates are S1(31.2 kbps), S2 (1 Mbps)
and S3 (2.5 Mbps), and there is an additional speed of
5 Mbps (fibre-optic).
•Data link layer
•The data link layer supports two types of service:
1. Exchanges of variables
2. Message transfers.
• These can be either cyclic or an explicit user request