A Seminar on

Distributed Control System

Under Guidance Of:

Presented by: Prof. R.G. Jamkar
S.R.Shiledar
Instrumentation Engineering
S.G.G.S. I.E & T. Nanded
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Contents:
1. Automation overview
2. Tools of Automation
3. DCS
- History
- Concept
- Different DCS available in market
- General Architecture
- Advantages of DCS
- DCS Versus PLC
4. Honeywell DCS (EPKS)
5. Conclusion
6. References

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Automation Overview

 Automation is one of the rising fields and it has become the

backbone of the process and manufacturing industries.

Industrial automation has taken a giant step to control industrial

machineries and industrial processes by replacing human operator.

In recent days device used for automation is PLC (Programmable

Logic Controller) and DCS (Distributed control system).

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Tools of Automation

Automation

Microcontroller PLC DCS

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Microcontroller

• Microcontroller based automation is applied for small

applications.
• Example vending machine is one of the microcontroller based
application.
• commonly used microcontrollers are ATMEL
89C51,PHILIPS 89V51 etc.
• Microcontroller preferred when application is low cost, small
in size.

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Programmable Logic Controller

• A Programmable Logic Controller is a digital electronic

device that uses a programmable memory to store instructions
and to implement specific functions such as logic, sequencing,
timing, counting, and arithmetic to control machines and
processes.
• PLC were develop to replace relay based control.
• It is used for automation of small plants.
• It is used for application containing digital I/O and limited
analog.

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PLC Manufacturers

• Allen Bradley
• ABB
• Mitsubishi
• Messung
• Siemens
• Omron
• GE-fanuc

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Types of Control Architecture

Centralized

Decentralized

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Centralized Control Architecture
Central Computer
(Mainframe)

Group Group Group

PLCs
Control Control Control

Sensors, Actors plant

• Classical, hierarchical, centralized architecture.

• The central computer only monitors and forwards commands to the PLCs
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Decentralized Control System (DCS)

peer-to-peer (horizontal communication)

hierarchical
(vertical
communication) engineering operator
data logger
workstation workstation

plant bus

controller controller controller controller

field bus

plant

• All controllers can communicate as peers (without going

through a central master), restricted only by throughput and
modularity
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Centralized and Decentralized

Centralized(simple) Decentralized(Complex)

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Distributed Control System(DCS)

• Distributed Control System refers to a control system usually

of a manufacturing System, process in which the controller
elements are not central in location but are distributed
throughout the system with each component sub-system
controlled by one or more controllers.

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DCS-History

• DCS was introduced in 1975 by:

» Honeywell-TDC 2000
» Yokogawa – Centum
• Today Centum is Having around 14,000 installations around
the world.
• Advances in centum: CS1000 and CS3000
• Advances in Honeywell: TDC-3000, TPS & at present EPKS

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DCS Available in Market

• Yokogawa-Centum CS3000
• Emerson-Delta V
• Siemens
• Bailey
• Foxboro
• Fisher-Rosemount
• Honeywell-EPKS

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DCS-Concept

 It distributes information and control functions that previously

required central computer.
 A DCS typically uses computer(usually custom designed
processor) as a controller and proprietary interconnection and
protocols for communication.
 It is not concentrated in a specific geographic location or
around a single center computer.

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DCS General Architecture

Supervisory (host)
Computer

Operator Main Operator Archival

Control Control Control Data
Panel Computer Panel Storage

Data highway
To other Processes To other Processes

Local data acquisition and Local Local Local

control computers Computer Computer Computer
Local Display Local Display

PROCESS

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DCS Elements

• Data Acquisition Unit: Digital (discrete) and analog I/O can

be handle.
• Batch Sequencing Unit: This unit controls a timing
counters, arbitrary function generators, and internal logic.
• Local Display: This device provides analog display stations,
and video display for readout.
• Bulk Memory Unit: This unit is used to store and recall
process data.

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DCS Elements

• General Purpose Computer : This unit is programmed by a

customer or third party to perform optimization, advance
control, expert system, etc
• Central Operator Display: This unit typically contain
several consoles for operator communication with the system,
and multiple video color graphics display units
• Data Highway : A serial digital data transmission link
connecting all other components in the system. It allow for
redundant data highway to reduce the risk of data loss
• Local area Network (LAN)

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Advantages of DCS:

 Access a large amount of current information from the

data highway.
 Monitoring trends of past process conditions.
 Readily install new on-line measurements together with
local computers.
 Alternate quickly among standard control strategies and
readjust controller parameters in software.
 A sight full engineer can use the flexibility of the
framework to implement his latest controller design
ideas on the host computer.

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PLC V/S DCS
Sr. No. Functions and Features PLC DCS
1 System Design designed for mainly designed for mainly
digital I/O control. analog I/O control.
2 Redundancy required to be in built
engineered.

3 Control Algorithms Engineered Built in

Configurable
Complex
Algorithms
4 PID Function Blocks Limited Loops with Multiple loops with
limited enhanced
functionality functionality
5 Self tuning Supported No Yes
6 Software Signal Filters Not Supported Supported
7 Discrete logic Execution Fast(10-100ms) Slow(250ms-1sec)
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PLC V/S DCS
8 Networking Engineered Normally all
Networking as per Components
requirement tightly Integrated
on the network

9 Modularity Modular Less Modular

10 Distribution Of Functionality Limited Distributed
architecture.

11 I/O variety Large Collection Limited Variety

of I/O

12 Ruggedness & Reliability of Rugged and Relatively lower

hardware reliable reliability and
ruggedness

13 Third party Connectivity yes Limited

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Honeywell-DCS(EPKS)
Introducing Experion Process Knowledge System
 Experion PKS is sophisticated management and control
application that:
• Displays system data in manner that you can easily
understand.
• Allows you to control your system by sending appropriate
commands.
• Automatically performs schedule tasks.
• Notifies you of system activities, including alarms and system
events.
• Produces comprehensive report.

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Simplified Experion PKS

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Basics

• Is well suited for both small and large system.

• It provide power and flexibility required to handle the full
spectrum of process control applications.
• It interfaces with foundation Fieldbus, Profibus, DeviceNet,
HART, LON, ControlNet and interbus.
• Robustness, security, compliance, control, safety and
reliability are plant-wide.

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Features

• Sophisticated human-machine interface.

• Tightly integrated database, engineering tools, and control
applications.
• Open deterministic, high-speed control network
communication system for predictable and repeatable control
linking servers, controllers, and remote I/O.
• A configurable Control Execution Environment(CEE)
provides deterministic, consistent, and reliable control
application execution.

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Architecture

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Basic control system Topology

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Basic control system Topology

• In basic Experion PKS system topology, the server and C200

process controllers share a global database, so you only need
to enter data ones.
• EPKS can be segmented into basic sites of hardware
component platforms:
– Supervisory Platform
– C200 Controller
– Integrated Controller
– Third Party Controllers
– Communication Platform

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Configuration Studio

• Configuration Studio Provides a Central location from which

you can configure your EPKS system.
• The individual tools required to configure parts of your system
are launched from configuration studio.
• Tools in Configuration studio are as follows:-
– Enterprise Model Builder
– Quick Builder
– System display
– Control Builder
– HMI Web Display Builder

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Configuration Studio

• Enterprise Model Builder:

– It is graphical tool for building asset model
• Quick builder:
– It is graphical tool for building hardware items such as Flex Stations
,Printers, Controllers, and standard(non C200) points in the system.
• System Display:
– Displays that are used to configure items such as reports, groups
display, trends, station setting and console station.
• Control Builder:
– A graphical tool for building your control strategy for process
controllers.
• HMI Web display builder
– It is graphical tool for creating your own displays using web based
features.
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Control Builder Introduction
• About Control Builder
– The Experion PKS Process Engineering Tool is Control Builder.
– Control Builder is a Windows-based application and offers the
latest in control building functions and strategies.
– It is a graphical, object-oriented configuration environment that
reduces the effort required to design, implement and document
control applications.

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Control Builder Introduction

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Control Builder Introduction
Tabs appear at the bottom of each tree window:
– Project -- Displays your CPM, IOMs, CMs and SCMs in the
current project.
– Monitoring -- Displays all objects that have been loaded to the
Control Processor Module (CPM). Permits active modules to
be viewed and controlled during process.
– Library -- Displays all available System CMs and
Function Blocks grouped into type categories.

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Control Builder
• Control Builder is an engineering tool offering the latest in control
strategy building going well beyond looking “pretty” on screen. Its
graphical, object-oriented design dramatically reduces the effort
required to design, implement and document control applications.

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Control Builder

• Function Blocks
• Control Modules
• Continuous Control Functions
• Logic Control Functions
• Sequential Control Functions
• Batch Control Functions
• Template and hierarchical build functions
• Version Control System
• -

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Servers and Stations

• Experion PKS’s supervisory infrastructure consists of one or

more servers and a number of client computers running the
Experion PKS’s user-interface application called Station.
• The client computers are usually referred to as “Stations”.
• These components provide the infrastructure for engineering
and operations software applications.

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Stations

• Flex Stations
• A Flex Station is the most common Station configuration.
• It typically runs on a standard PC and communicates with the server using
either of the following two connection types:
• Static: A permanent, dedicated connection. This is the recommended
connection type for Flex Stations used by operators.
• Rotary: An “as required” connection. This is the recommended connection
type for users who do not need full-time access to the server, or who need
remote access (typically through a modem). Rotary connections are
advantageous from a licensing viewpoint because the license specifies the
maximum number of simultaneous Station connections.

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Stations

• Console Stations:
• A Console Station is a Station that connects directly to a
Process Controller, FIM,IOLIM, or ACE node as well as to an
Experion PKS server.
• Console Stations are advisable in an environment where
continuity of view is paramount and where it is important to
minimize the impact of a server being unavailable. Because
Console Stations can directly access process data, alarms and
messages from sources, there is no loss of view of critical data
and alarms when the server fails and therefore an operator can
still control and monitor the process.

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Honeywell Icon console station

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Server

 Capability:
• Experion PKS server software runs under Windows 2000
Server.
• A server can support up to 64,000 points.
• The server contains supervisory control functions, the
Experion PKS Global Data infrastructure and optional
redundancy.
• The server hosts object-oriented graphical tools such as
Control Builder and HMIWeb Display Builder and acts as the
central repository for all system data.

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Process Control Hardware

• Basic components:
 The Experion PKS system uses a common hardware
infrastructure for both controller and chassis I/O
configurations. Common chassis, power supplies and
communication cards are employed across the basic system.
 Typical control hardware components include:

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• Control Processor Module (CPM):

 Is the Control module within the C200 Process Controller in

which Experion PKS control strategies execute. It
communicates with Input/output (I/O) Modules and peer
devices via the Integrated Control Protocol (ICP) backplane
and the connected ControlNet network. Together with an ICP
backplane and I/O devices, the CPM constitutes a controller. It
may also be referred to as the C200 controller, since C200
identifies the current version of the CPM.

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• I/O Modules:

 It provide the terminals and processing power to accept input

signals from transmitters, thermocouples, etc. and send output
signals to valves, motors, etc. A variety of I/O modules are
available for analog inputs/outputs and digital inputs/outputs.
Experion PKS also offers Serial Interface and Pulse Input
Modules.

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• ControlNet Interface module:
 Links the controller with remote I/O module chassis (up to 8
via the I/O Network and/or other system controllers and plant
networks via ControlNet.

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• Fault Tolerant Ethernet(FTE):
 can be optionally configured using a Fault Tolerant Ethernet
Bridge module for the FTE Supervisory Network connection
between the server and the Process Controller.

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• Redundancy Module(RM):
 with a Controller chassis provides automatic backup for the
primary Controller. It can also be used in chassis containing
Fieldbus Interface Modules to support redundant Fieldbus
operation.

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Conclusion

• DCS is one of the best tool to be used for Process Automation.

• Honeywell EPKS is the most cost effective solution providing
DCS for Process Industries.

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References

• Instrument Engineers Handbook, Vol II

– B. G. Liptak
• Process Control
– S.Bhanot
– Oxford Publication, 2003.
• Honeywell Experion PKS Manuals
• www.honeywell.com

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 Thank You

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