Distributed Control

System
The Next Era of Factory Automation

[ Narrendar.R.C 12MMT0007 ]
[ G.N.Abhilash 12MMT0026 ]

Current Issues faced in Automation

Integration and Long time Support
System Upgrades
Factory Support
Enterprise Integration

Highlights of PLC
1. Low cost
2. Easy Design
3. Well Documented
4. Well supported by Industry
5. Faster Implementation

Why Does PLC Lag Behind..?

It doesnt support the following characteristics:
Peer to peer
Single Database
Security
Alarms
Advanced Math Functions
Proprietary HMI
Open Protocols

Inherent Features of DCS

1.Peer to Peer:
This benefit is seen by reduced wiring costs between controllers and with a
reduction in engineering time based on simplified mapping.

2. Single Database:
The accuracy of the initial build and the maintenance of the system are
made far easier with the single database. Transcription errors are minimized
and changing tags in control schemes is much simpler.

3.Security:

Most PLC packages don't include Security Management in the package. It

must be purchased and configured separately.

4. Alarms:
Most PLC packages don't include Alarm Management as part of the
database which will add extra time and complexity to the project.

5. Advanced Math Functions:

6.

PID calculations are done in the CPU of the PLC so multiple and complex
calculations will slow down the process time. Additional costs may be
required to do advanced math with add on cards.

Proprietary HMIs:
Many PLC vendors use their own HMI which makes interface to other
devices difficult and training more expensive.

7. Open Protocols:

Some PLC vendors use proprietary protocols at the control level which
makes communication difficult.

PLC Architecture

DCS
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 controlled by one or more controllers.
The entire system of controllers is connected by networks
for communication and monitoring.
DCS is a very broad term used in a variety of industries,
to monitor and control distributed equipment

Components of DCS
1. Introduction
2. Architecture
3. CPU
4. Analog Input Module
5. Digital Input Module
6. Analog Output Module
7. Digital Output Module
8. Communication System
9. Human Interface system (HIS)

DCS Architecture

The CPU

Model is chosen based on software to

be used.
The main memory is ensured of high
reliability by error correction code
(ECC).
Addition of the new error detection and
protection functions.
Other newly added functions include
the memory management unit (MMU)
and write protection which ensure data
integrity, the parity check of addresses
and data, the ECC memory, and a two
wire signal self checker.

Analog I/O Module

To input an analog voltage the

continuous voltage value must
be sampled and then converted
to a numerical value by an A/D
converter.

The data value sampled will be

somewhere
between
the
voltage at the start and end of
the sample.

The maximum (Vmax) and

minimum (Vmin) voltages are a
function
of
the
control
hardware. These are often
specified
when
purchasing
hardware

Digital I/O Module

The digital I/O module is

configured by the card unit and
either the terminal unit or
connector unit.

It inputs and outputs 16 or 32

signal
points
and
converts
signals.

Since the types or I/O signals are

software-set, no control switch or
knob is found on this module.

Communication
Systems

The
communication
cards are used to realize
the
general-purpose
communication of field
control
station
and
subsystems via serial
links,
so
that
the
subsystem
may
be
controlled or monitored.

Human Interface Station

The
human
interface
system
programmed for a project/plan is
designed in such a way that it would
be easy for the operator to
understand
all
the
operations
occurred in the plant.

HIS and Monitoring Windows

Nuclear Reactor Control Unit

SCADA Based Interface

Applications
1. Electrical power grids and electrical generation plants.
2. Environmental control systems.
3. Traffic signals.
4. Radio signals.
5. Water management systems.
6. Oil refining plants.
7. Metallurgical process plants.
8. Chemical plants.
9. Pharmaceutical manufacturing.
10.Sensor networks.
11.Dry cargo and bulk oil carrier ships

Whats Next..?