5.

7 DCS Architecture
 5.7 DCS architecture

Introduction
• Distributed Control System is a tightly integrated
control system where in all the components
used to communicate with the field process
could be distributed around the plant.
• The data from all these distributed systems are
put together to control the entire process
industries like the oil and gas refineries, the
power generation plant etc..
• The following architecture would explain it better.
 5.7 DCS architecture
General Architecture of DCS system
 5.7 DCS architecture

Concept of Distributed Control System:

• DCS refers to a control system usually of a
manufacturing system, process or any kind
of dynamic system.
• In DCS controllers are not central in
location, but which are distributed
throughout the system with each
component sub-system controlled by one or
more controllers
 5.7 DCS architecture

Concept of Distributed Control System

• The entire system is connected by communication network to
control and monitor the system.
The basic architecture of the distributed control system, as shown:
• The DCS consists of an
 operator station,
 a control station, and
 a communication system.
• The operator station collects data relating to the process
operation and can display and manipulate those data.
• The control station contains control functions such as for the
DDC.
 5.7 DCS architecture

Components of DCS:
• The distributed control system (DCS) consists of the four
interfaces.
• The process interface is the interface between the distributed
control system and the plant (i.e., measurement sensors and final
control elements).
• Field Control Station:
• The control stations receive measurement signals from sensors
such as for temperature, pressure, and flow rate, and perform
control calculations in accordance with the deviations from the
setpoint values.
• Output signals are then sent to the final control element to perform
compensatory actions.
 5.7 DCS architecture
Components of DCS:
Human Machine Interface station:
• The man-machine interface is the interface between the distributed control system
and the operator.
• It does central monitoring of the plant and permits the operator to perform
operations.
• The operator console is composed of a powerful microprocessor, CRT, and keyboard.
Many different operations can be carried out by switching displays on the CRT.
Control sub-interface:
• The control sub-system interface connects the distributed control system to other
types of instruments such as the PLC (programmable logic controller) or a
composition analyzer to integrate plant operation.
Communication Bus:
• Communication buses are used to communicate between HMI station and control
interface.
•  It permits system build-up and software maintenance in the distributed control
system.
 5.7 DCS architecture

Basic architecture of the distributed control system

 5.7 DCS architecture

Structure of DCS
• As DCS contains the distribution of the control processing around
nodes in the system, the complete system is reliable and
mitigates a single processor failure.
• It will affect one section of the plant process; if a processor fails
and the whole process will be affected when the central computer
fails.
• This distribution of computing power to the field Input / Output
(I/O) field connection racks also ensures fast controller
processing times by removing possible network and central
processing delays.
• The below diagram showcases the functional manufacturing
levels using computerized control:
 5.7 DCS architecture
Structure of DCS
 5.7 DCS architecture
Structure of DCS
Level 0
• Level 0 is the field device level.
• All the field devices such as control valves, transducers,
transmitters etc, are at this level.
• Input devices (transmitters etc.) and output devices (control
valves, etc.) are connected to input/output units (I/O units).
• I/O units convert the 4-20mA or digital signals to specially
coded signals for the Fieldbus.
• And also converts the coded signal to 4-20mA.
DCS and PLC concept and applications
https://www.youtube.com/watch?v=a2YX1oyjXdQ
 5.7 DCS architecture

Structure of DCS
Level 1
• This is the control level.
• The microcontroller takes data from the Fieldbus to control individual
control loops.
• At a time more than one can be controlled.
• All control actions are to be done with this level.
• The data on the Fieldbus contains all the information for each loop input
and output.
• The CP, using only milliseconds of time, controls each in turn.
• The PID of each is separately programmed.
• To the operator, it looks as if all the loops are controlled at the same time.
 5.7 DCS architecture

Structure of DCS
Level 2
• This is the plant supervisory unit. All the
information about the control loop is displayed in
this unit using Video display unit (VDU).
• Large control systems may have many
workstations which display the distributed control
units around the plant.
• From this unit, an operator can adjust the setpoint
or he can change from manual to automatic etc.
 5.7 DCS architecture

Structure of DCS
Level 3
• This is the Production control level.
• The application processors takes some values from the
micro processor and send to Central Control Room (CCR).
• Normally, you cannot change control operations from this
level.
• It can only display information for management overview.
• The Applications Processor (AP) takes some of the signals
from the CP and puts them into a digital code (protocol) so
that they can be sent over a higher level data highway.
 5.7 DCS architecture

Structure of DCS
Level 4
• This is the production scheduling or Group management level.
• The group management level.
• Some signals for the AP are converted so that they can be
sent (by microwave link, satellite, etc.) to a distant
headquarters
• The workstation at headquarters can not make changes at
plant level.
• However, the workstation displays up to date information on
production operations for planning purposes.
 5.7 DCS architecture

Architecture of DCS:
Distribution Control Systems (DCS) consists of three major qualities.
1) Various control functions can be distributed into small sets of subsystems
that are of semiautonomous.
• These are interconnected by a high-speed communication bus and their
functions include data presentation, data acquisition, process control, process
supervision, reporting information, storing and retrieval of information.
2) The second characteristic is the automation of manufacturing process by
integrating advanced control strategies.
3) The third characteristic is arranging the things as a system.
• The organizing of the entire control structure as a single automation system
can be done with DCS as it unites sub-systems through a proper command
structure and information flow.
• DCS is included with basic elements such as engineering workstation,
operating station or HMI, process control unit, smart devices, and
communication system.
 5.7 DCS architecture

Benefits of DCS:
•    It requires minimal troubleshooting
•    It contains HMI graphics and faceplates
Alarms
•    Lends itself to better organization and
consistency than a PLC/HMI combo
•    Batch management is possible
•    OPC server
•    Reduced engineering time
•    Redundant operator system servers
 5.7 DCS architecture

How is DCS different from PLC?

• To perform advanced regulatory control on a plant-wide
scale, DCSs contain the built-in infrastructure.
• Slower processes typically require coordination across
various production units.
• Superior speed makes PLCs a better choice for applications
involving fast production startup using discrete I/O.
• They also offer range in I/O granularity and maintainability.
• At the same time, the DCS is hybridized to incorporate
PLCs and PCs to control certain functions and to provide
reporting services.
What is the Difference Between PLC and DCS?
https://www.youtube.com/watch?v=iF99iKlDpxA
 5.7 DCS architecture

Differences between DCS & PLC

 5.7 DCS architecture

Difference between PLC & DCS: (PLC vs. DCS)

To differentiate between PLC & DCS, there are five key factors to consider:
They are:
1) Response Time:
• PLCs are fast, which make the PLC an ideal controller for real-time actions
such as a safety shutdown or firing control.
• A DCS takes much longer time to process data, which made it not the right
solution when response times are critical.
2) Scalability:
• A few thousand I/O points can be handled by a PLC whereas DCS can handle
many thousands of I/O points and accommodate new equipment, process
enhancements, and data integration.
• DCS can be preferred when advanced process control is required and contain
a large facility that’s spread out over a wide geographic area with thousands
of I/O points.
 5.7 DCS architecture
Difference between PLC & DCS: (PLC vs. DCS)
3) Complexity
• The advanced process control capabilities of the DCS are required to carry
out the complex nature of many continuous production processes such as
oil and gas, water treatment and chemical processing.
4) Frequent process changes
• PLCs are used for processes that will not change often. And, a DCS is the
better solutions when the process is complex and requires frequent
adjustments or must analyze a large amount of data.
5) Vendor support
• To provide integration services and implement process changes, DCS
vendors require users to employ them.
• System integrators perform similar functions for PLC-based systems. It
has also become common for PLC vendors to offer support services
through their network of system integrator partners.
• Overall, DCS tends to be used in large continuous process plants where
high reliability and security is important, and the control room is not
geographically remote.