AN INTERNSHIP REPORT

Submitted in the partial fulfillment of the requirements for the Award of Degree
of

BACHELOR OF TECHNOLOGY

In

ELECTRONICS AND COMMUNICATION

ENGINEERING

DISTRIBUTED CONTROL SYSTEM

In

(IFFCO,PHULPUR,PRAYAGRAJ)

SUBMITTED BY: SHUBHAM KANOUJIA

(ROLL NO. 1900910310163)

DEPARTMENT OF ELECTRONICS AND COMMUNICATION

ENGINEERING

JSS ACADEMY OF TECHNICAL EDUCATION

 C-20/1 SECTOR-62,NOIDA

DECLARATION
I hereby declare that the internship work entitled “DISTRIBUTED CONTROL SYSTEM”
submitted to the JSS COLLAGE OF TECHNICAL EDUCATION NOIDA, is a record of
an original work done by me under the guidance of Dr. RITESH KUMAR JAISWAL and
this project work is submitted In the partial fulfillment of the requirements for the award of
the degree of Bachelor of technology in Electronics and Communication Engineering. The
results embodied in this report have not been submitted to any other University or Institute
for the award of any degree or diploma.

i
 ACKNOWLEDGEMENT

First I would like to thank Dr. Amarjeet Singh, Principal of Jss academy of technical
education Noida for giving me the opportunity to do an internship within National
Instruments. I also would like to thank all the people that worked along with me with their
patience and openness they created an enjoyable working environment. It is indeed with a
great sense of pleasure and immense sense of gratitude that I acknowledge the help of these
individuals. I would like to thank my Head of the Department, Dr. Arun Kumar G for his
constructive criticism throughout my internship. I would like to thank internship coordinator
Dr. Ritesh Kumar Jaiswal for his support and advices to get and complete internship. I am
extremely great full to my department staff members and friends who helped me in successful
completion of this internship.

SHUBHAM KUMAR KANOUJIA

(1900910310163)

ii
CERTIFICATE

iii
 ABSTRACT

The increasing application of flexible and powerful real-time distributed control systems is
presently characterizing the industrial automation field. Such systems involve three main
disciplines: control systems, real-time systems, and communication systems. Control
systems, due their stringent timing constraints, demand real-time computing technology. In
addition, communication systems are needed for the data messaging between field devices.
We propose an integrated approach to the design and implementation of such systems. We
show that by a separate control design and its posterior distributed implementation, the
system performance may suffer degradation. That is, when control loops are closed over
communication networks, timing problems, as communication induced varying delays, can
appear, decreasing the control system performance, and even leading the system to
instability. However, we show that by an adequate integrated approach, that takes advantage
of control theory, real-time communication properties, an adequate timing analysis, and an
appropriate distribution of the control functions, the system performance increases
dramatically.

iv
 LIST OF FIGURES

FIGURE 1
1

FIGURE 2
2

FIGURE 3
3

FIGURE 4
4

FIGURE 5
6

FIGURE 6
7

FIGURE 7
9

FIGURE 8
11

FIGURE 9
12

FIGURE 10
13

FIGURE 11
14

v
FIGURE 12
15

FIGURE 13
15

FIGURE 14
16

FIGURE 15
17

FIGURE 16
19

v
 TABLE OF CONTENTS

ACKNOWLEDGEMENT i

INTERNSHIP CERTIFICATE i
i

ABSTRACT iii

LIST OF FIGURES
vi

CHAPTER 1 INTRODUCTION 1-7

CHAPTER 1 INTRODUCTION
1-7
1.1 About Control System 1
1.2 PID Control 4
1.3 Fuzzy Logic 6

CHAPTER 2 TYPES OF CONTROL SYSTEM 8-12

2.1 Open Loop Control System 8
2.2 Closed Loop Control System 10

2.3 Feedback Control 11

CHAPTER 3 DISTRIBUTED CONTROL SYSTEM 13-26

6

3.1 Advantages of DCS

3.2 Applications of DCS

vi
CHAPTER 4 (CONCLUSIONS)

CHAPTER 2 TYPES OF CONTROL 7

SYSTEM

CHAPTER 3 DISTRIBUTED CONTROL SYSTEM 11

CONCLUSION 23
 Chapter 1

INTRODUCTION

1.1 About Control System

A control system manages, commands, directs, or

regulates the behavior of other devices or systems
using control loops. It can range from a single home
heating controller using a thermostat controlling a
domestic boiler to large industrial control systems which
are used for controlling processes or machines. The
control systems are designed via control
engineering process.

For continuously modulated control, a feedback

controller is used to automatically control a process or
operation. The control system compares the value or
status of the process variable (PV) being controlled with
the desired value or setpoint (SP), and applies the
difference as a control signal to bring the process
variable output of the plant to the same value as the
setpoint.

For sequential and combinational logic, software logic,

such as in a programmable logic controller, is used.

1
 FIGURE :1:CONTROL SYSTEM BLOCK DIAGRAM

1.1a Proportional Control

Proportional control is a type of linear feedback control system in which a correction is

applied to the controlled variable which is proportional to the difference between the desired
value (SP) and the measured value (PV). Two classic mechanical examples are the toilet
bowl float proportioning valve and the fly-ball governor.

The proportional control system is more complex than an on–off control system, but simpler
than a proportional-integral-derivative (PID) control system used, for instance, in an
automobile cruise control. On–off control will work for systems that do not require high
accuracy or responsiveness, but is not effective for rapid and timely corrections and
responses. Proportional control overcomes this by modulating the manipulated variable
(MV), such as a control valve, at a gain level that avoids instability, but applies correction as
fast as practicable by applying the optimum quantity of proportional correction.

A drawback of proportional control is that it cannot eliminate the residual SP–PV error, as it
requires an error to generate a proportional output. A PI controller can be used to overcome
this. The PI controller uses a proportional term (P) to remove the gross error, and an integral
term (I) to eliminate the residual offset error by integrating the error over time.

2
In some systems, there are practical limits to the range of the MV. For example, a heater has
a limit to how much heat it can produce and a valve can open only so far. Adjustments to the
gain simultaneously alter the range of error values over which the MV is between these
limits. The width of this range, in units of the error variable and therefore of the PV, is called
the proportional band (PB).

FIGURE:2:PROPORTIONAL CONTROLLER BLOCK DIAGRAM

Furnace example

When controlling the temperature of an industrial furnace, it is usually better to control the
opening of the fuel valve in proportion to the current needs of the furnace. This helps avoid
thermal shocks and applies heat more effectively.

At low gains, only a small corrective action is applied when errors are detected. The system
may be safe and stable, but may be sluggish in response to changing conditions. Errors will
remain uncorrected for relatively long periods of time and the system is overdamped. If the
proportional gain is increased, such systems become more responsive and errors are dealt
with more quickly. There is an optimal value for the gain setting when the overall system is
said to be critically damped. Increases in loop gain beyond this point lead to oscillations in

3
the PV and such a system is underdamped. Adjusting gain to achieve critically damped
behavior is known as tuning the control system.

In the underdamped case, the furnace heats quickly. Once the setpoint is reached, stored heat
within the heater sub-system and in the walls of the furnace will keep the measured
temperature rising beyond what is required. After rising above the setpoint, the temperature
falls back and eventually heat is applied again. Any delay in reheating the heater sub-system
allows the furnace temperature to fall further below setpoint and the cycle repeats. The
temperature oscillations that an underdamped furnace control system produces are
undesirable.

In a critically damped system, as the temperature approaches the setpoint, the heat input
begins to be reduced, the rate of heating of the furnace has time to slow and the system
avoids overshoot. Overshoot is also avoided in an overdamped system but an overdamped
system is unnecessarily slow to initially reach setpoint respond to external changes to the
system, e.g. opening the furnace door.

1.2 PID Control

Pure proportional controllers must operate with residual error in the system. Though PI
controllers eliminate this error they can still be sluggish or produce oscillations. The PID
controller addresses these final shortcomings by introducing a derivative (D) action to retain
stability while responsiveness is improved.

4
 FIGURE:3:PID CONTROLLER BLOCK DIAGRAM

Derivative action

The derivative is concerned with the rate-of-change of the error with time: If the measured
variable approaches the setpoint rapidly, then the actuator is backed off early to allow it to
coast to the required level; conversely, if the measured value begins to move rapidly away
from the setpoint, extra effort is applied—in proportion to that rapidity to help move it back.

On control systems involving motion control of a heavy item like a gun or camera on a
moving vehicle, the derivative action of a well-tuned PID controller can allow it to reach and
maintain a setpoint better than most skilled human operators. If a derivative action is over-
applied, it can, however, lead to oscillations.

Integral action

The integral term magnifies the effect of long-term steady-state errors, applying an ever-
increasing effort until the error is removed. In the example of the furnace above working at
various temperatures, if the heat being applied does not bring the furnace up to setpoint, for
whatever reason, integral action increasingly moves the proportional band relative to the
setpoint until the PV error is reduced to zero and the setpoint is achieved.

5
 FIGURE:4:GRAPH

Ramp up % per minute

Some controllers include the option to limit the "ramp up % per minute". This option can be
very helpful in stabilizing small boilers (3 MBTUH), especially during the summer, during
light loads. A utility boiler "unit may be required to change load at a rate of as much as 5%
per minute (IEA Coal Online - 2, 2007)".

Other techniques

It is possible to filter the PV or error signal. Doing so can help reduce instability or

oscillations by reducing the response of the system to undesirable frequencies. Many systems
have a resonant frequency. By filtering out that frequency, stronger overall feedback can be
applied before oscillation occurs, making the system more responsive without shaking itself
apart.

Feedback systems can be combined. In cascade control, one control loop applies control
algorithms to a measured variable against a setpoint but then provides a varying setpoint to
another control loop rather than affecting process variables directly. If a system has several
different measured variables to be controlled, separate control systems will be present for
each of them.

6
Control engineering in many applications produces control systems that are more complex
than PID control. Examples of such field applications include fly-by-wire aircraft control
systems, chemical plants, and oil refineries. Model predictive control systems are designed
using specialized computer-aided-design software and empirical mathematical models of the
system to be controlled.

1.3 FUZZY LOGIC

Fuzzy logic is an attempt to apply the easy design of logic controllers to the control of
complex continuously varying systems. Basically, a measurement in a fuzzy logic system can
be partly true.

The rules of the system are written in natural language and translated into fuzzy logic. For
example, the design for a furnace would start with: "If the temperature is too high, reduce the
fuel to the furnace. If the temperature is too low, increase the fuel to the furnace."

FIGURE:5:FUZZY LOGIC BLOCK DIAGRAM

Measurements from the real world (such as the temperature of a furnace) are fuzzified and
logic is calculated arithmetic, as opposed to Boolean logic, and the outputs are de-fuzzified to
control equipment.

7
When a robust fuzzy design is reduced to a single, quick calculation, it begins to resemble a
conventional feedback loop solution and it might appear that the fuzzy design was
unnecessary. However, the fuzzy logic paradigm may provide scalability for large control
systems where conventional methods become unwieldy or costly to derive.

Fuzzy electronics is an electronic technology that uses fuzzy logic instead of the two-value
logic more commonly used in digital electronics.

CH
APTER 2

TYPES OF
CONTROL SYSTEM

2.1 Open Loop Control System

If in a physical system there is no automatic correction of the variation in its output, it is

called an open loop control system. That is, in this type of system, sensing of the actual
output and comparing of this output (through feedback) with the desired input does not take
place. The system on its own is not in a position to give the desired output and it cannot take
into account the disturbances. In these systems, the changes in output can be corrected only
by changing the input manually.

8
 FIGURE:6:OPEN LOOP CONTROL SYSTEM

2.1.a APPLICATIONS

An open-loop controller is often used in simple processes because of its simplicity and low
cost, especially in systems where feedback is not critical. A typical example would be an
older model domestic clothes dryer, for which the length of time is entirely dependent on the
judgement of the human operator, with no automatic feedback of the dryness of the clothes.

For example, an irrigation sprinkler system, programmed to turn on at set times could be an

example of an open-loop system if it does not measure soil moisture as a form of feedback.
Even if rain is pouring down on the lawn, the sprinkler system would activate on schedule,
wasting water.

Another example is a stepper motor used for control of position. Sending it a stream of

electrical pulses causes it to rotate by exactly that many steps, hence the name. If the motor
was always assumed to perform each movement correctly, without positional feedback, it
would be open-loop control. However, if there is a position encoder, or sensors to indicate the
start or finish positions, then that is closed-loop control, such as in many inkjet printers. The
drawback of open-loop control of steppers is that if the machine load is too high, or the motor
attempts to move too quickly, then steps may be skipped. The controller has no means of
detecting this and so the machine continues to run slightly out of adjustment until reset. For
this reason, more complex robots and machine tools instead use servomotors rather than
stepper motors, which incorporate encoders and closed-loop controllers.

However, open-loop control is very useful and economic for well-defined systems where the
relationship between input and the resultant state can be reliably modeled by a mathematical
formula. For example, determining the voltage to be fed to an electric motor that drives a

9
constant load, in order to achieve a desired speed would be a good application. But if the load
were not predictable and became excessive, the motor's speed might vary as a function of the
load not just the voltage, and an open-loop controller would be insufficient to ensure
repeatable control of the velocity.

An example of this is a conveyor system that is required to travel at a constant speed. For a
constant voltage, the conveyor will move at a different speed depending on the load on the
motor (represented here by the weight of objects on the conveyor). In order for the conveyor
to run at a constant speed, the voltage of the motor must be adjusted depending on the load.
In this case, a closed-loop control system would be necessary.

Thus there are many open-loop controls, such as switching valves, lights, motors or heaters
on and off, where the result is known to be approximately sufficient without the need for
feedback.

2.2 Closed Loop Control System

A closed loop control system is a system where the output has an effect upon the input
quantity in such a manner as to maintain the desired output value.

In a closed loop control system, the controlled variable (output) of the system is sensed at
every instant of time, feedback and compared with the desired input resulting in an error
signal. This error signal directs the control elements in the system to do the necessary
corrective action such that the output of the system is obtained as desired.

The feedback control system takes into account the disturbances also and makes the
corrective action. These control systems are accurate, stable and less affected by noise. But
these control systems are sophisticated and hence costly. They are also complicated to design

10
for stability, give oscillatory response and feedback brings down the overall gain of the
control system.

FIGURE:7:CLOSED LOOP CONTROL SYSTEM

2.2a APPLICATIONS

There are different kinds of electronic devices that use a closed-loop control system. So
the applications of closed-loop control systems include the following.

In servo voltage stabilizer, the voltage stabilization can be attained by giving output voltage
feedback to the system

 In the water level controller, the level of water can be decided by the input water

 The temperature in the AC can be adjusted depending on the temperature of the room.

11
 The motor speed can be controlled using a tachometer or current sensor, where the sensor
detects the motor speed and sends feedback to the control system to change its speed.

 Some more examples of these systems include thermostat heater, solar system. missile
launcher, auto engine, automatic toaster, water control system using a turbine.

 Automatic electric iron can be controlled automatically by the heating element’s

temperature in the iron.

2.3 FEEDBACK CONTROL

A feed back control system, such as a PID controller, can be improved by combining
the feedback (or closed-loop) control of a PID controller with feed-forward (or open-loop)
control. Knowledge about the system (such as the desired acceleration and inertia) can be fed
forward and combined with the PID output to improve the overall system performance. The
feed-forward value alone can often provide the major portion of the controller output. The
PID controller primarily has to compensate whatever difference or error remains between the
setpoint (SP) and the system response to the open-loop control. Since the feed-forward output
is not affected by the process feedback, it can never cause the control system to oscillate, thus
improving the system response without affecting stability. Feed forward can be based on the
set point and on extra measured disturbances. Setpoint weighting is a simple form of feed
forward.

For example, in most motion control systems, in order to accelerate a mechanical load under
control, more force is required from the actuator. If a velocity loop PID controller is being
used to control the speed of the load and command the force being applied by the actuator,
then it is beneficial to take the desired instantaneous acceleration, scale that value
appropriately and add it to the output of the PID velocity loop controller. This means that
whenever the load is being accelerated or decelerated, a proportional amount of force is
commanded from the actuator regardless of the feedback value. The PID loop in this situation
uses the feedback information to change the combined output to reduce the remaining
difference between the process setpoint and the feedback value. Working together, the

12
combined open-loop feed-forward controller and closed-loop PID controller can provide a
more responsive control system in some situations.

CH
APTER 3

Distribut
ed Control System

A distributed control system (DCS) is a computerised control system for a process or plant

usually with many control loops, in which autonomous controllers are distributed throughout
the system, but there is no central operator supervisory control. This is in contrast to systems

13
that use centralized controllers; either discrete controllers located at a central control room or
within a central computer. The DCS concept increases reliability and reduces installation
costs by localising control functions near the process plant, with remote monitoring and
supervision.

FIGURE:8:DCS ARCHITECTURE

Distributed control systems first emerged in large, high value, safety critical process
industries, and were attractive because the DCS manufacturer would supply both the local
control level and central supervisory equipment as an integrated package, thus reducing
design integration risk. Today the functionality of Supervisory control and data acquisition
(SCADA) and DCS systems are very similar, but DCS tends to be used on large continuous
process plants where high reliability and security is important, and the control room is not
geographically remote.

3.1 Working and Operation

In a DCS system, the sensors are operated to receive data and process the information, and
transfers the data to the local input/output modules where the actuators are also connected to
these I/O modules. With this connection, the process parameters are exactly managed. From
here, the received data is collected and sent to the process controlling section through a field
bus. In the case of smart field appliances, the sensed data will get directly transmitted to the

14
process controlling section, and the gathered data is again processed, evaluated, and generates
the result depending on the control logic that is executed in the controller

.These results are now transmitted to the actuator devices through the field bus. The
distributed control system alignment, authorization, and execution of control logic function at
the engineering level. And the operator has the ability to look at and transmit the control
actions at the functional locations.

FIGURE:9:WORKING AND OPERATION

3.2 Structure and Architecture of Distributed Control System

In the DCS structure, the control processing unit is distributed all across the nodes present in
the system and the entire system has enhanced reliability and reduces the failure of a single
processor.  When a single processor gets failed the entire process will get impacted by this
when there is a failure in the centralized computer unit. The dissemination of the computing
power ability for the I/O field connected racks even makes sure for quick controller

15
functionality by eliminating the probable central and network operating delays. The structure
of a DCS can be clearly explained at each level.

F
IGURE:10:STRUCTURE OF DCS

Level 0 – This level is included with field equipment like final control components like
control valves, temperature sensors, and flow elements.

Level 1 – This level includes technologically advanced I/O modules and their related
distributed type of electronic processors.

Level 2 – Here, regulatory computers assist in collecting data from the processor nodes
present in the system and then offer the operator managed screens.

Level 3 – This is termed as the production-managed phase where it is not directly related in
controlling the process but involved in examining production and monitoring targets.

Level 4 – This is termed the production scheduling phase.

16
Level 1 and Level 2 are considered as the operational phases of the general type of DCS
where all the components come under integrated systems of a single manufacturing person.
Whereas level 3 and level 4 manages to control and scheduling activities.

Whereas in the architecture of distributed control system, it has mainly three crucial
characteristics which are:

 The automation of industrial procedure by assimilation of high-end control

approaches.
 Arrangement of entire things as the whole system
 Multiple control functions are distributed as small sub-systems that are
semiautonomous in nature. They are interrelated using high-speed communication bus
and the operations consist of data management, process control, data addressing,
process examination, data reporting, accumulation, and data retrieval.

F
IGURE:11:DCS SYSTEM

17
The above three attributes are clearly observed in the architectural diagram of the distributed
control system. Here, the 4 basic elements of distributed control system are:

3.2.1Engineering Workspace

For the DCS, these elements function as the supervisory controller. This can be a computer
device or any personal computer which has consistent engineering software like the ABB
freelance type of DCS for control builder F engineering workspace. This element provides
controlling configuration tools that permit the user to operate engineering activities like the
development of new loops, forming multiple I/O points, altering control and sequential
logics, the configuration of multiple devices, and formulating documentation for every I/O
component and many others.

FIGURE:12:ENGINEERING WORSPACE

3.2.2 HMI or Operating Workspace

This element is employed for functionality, monitoring, and managing plant parameters. This
can also be any monitoring equipment or personal computer which has a distinct software
tool where the user can look at process factor values and correspondingly performs
functionality.  These HMI units can be of multiple or single units where single units are
responsible for performing activities like alarming value and trend displays. Whereas

18
multiple units are responsible for performing a few PC display factors, data acquisition and
logging, and for trend records.

FIGURE:13:OPERATING WORKSPACE

3.2.3 Process Controlling Unit

In a distributed control system, this element is termed the local controlling unit, processing
unit, or distribution controller. A DCS might have one or more PC units that can be expanded
using multiple kinds of I/O units. The process control unit is included with a potent CPU
section, a communication unit having extended field bus ability, and remotely connected
I/Os. The field equipment such as actuators and sensors are connected to I/O components for
this unit. Few of the field equipment can have a direct connection to the field bus without
connecting to the I/O module. The device which has this type of connection is called a smart
field device.

19
 FIGURE:14:PROCESS CONTROLLING UNIT

The input for the PC unit is received from multiple sensors through the input section,
examine and handle the received input depending on the control logic that is executed, and
transmits the output through the output section in order to have regulation on relays and
actuators.

3.2.4 Communication Media

The communication media acts as a crucial role in the DCS. This connects the engineering
workspace, process unit, operating section, and smart devices. This transmits the data across
the stations. The common type of communication protocols that are utilized in the DCS
consists of Profibus, DeviceNet, Ethernet, Foundation Field Bus, and others.

This is not much required to implement only one protocol for the whole DCS, few levels use
only one network whereas few other levels use various networks. For example, assume that
field equipment, processing station, and distributed input and output devices are
interconnected using Profibus and the communication across HMI unit, processing station
and engineering workspace is carried using Ethernet which is shown as follows:

20
 FIGURE:15:COMMUNICATION MEDIA

The added benefit of DCS is the redundancy of few or entire levels of the controlling
location. In many of the situations, complex processes are embedded with the redundant
types of controllers and redundant communication networks like the issue in the major
processing line show not show impact the observation and controlling activities due to the
redundant processing unit.

These are the 4 fundamental elements in the distributed control system.

3.3 TECHNICAL POINTS

The processor nodes and operator graphical displays are connected over proprietary or

industry standard networks, and network reliability is increased by dual redundancy cabling

21
over diverse routes. This distributed topology also reduces the amount of field cabling by
siting the I/O modules and their associated processors close to the process plant.

The processors receive information from input modules, process the information and decide
control actions to be signalled by the output modules. The field inputs and outputs can
be analog signals e.g. 4–20 mA DC current loop or two-state signals that switch either "on"
or "off", such as relay contacts or a semiconductor switch.

DCSs are connected to sensors and actuators and use setpoint control to control the flow of
material through the plant. A typical application is a PID controller fed by a flow meter and
using a control valve as the final control element. The DCS sends the setpoint required by the
process to the controller which instructs a valve to operate so that the process reaches and
stays at the desired setpoint. (see 4–20 mA schematic for example).

Large oil refineries and chemical plants have several thousand I/O points and employ very
large DCS. Processes are not limited to fluidic flow through pipes, however, and can also
include things like paper machines and their associated quality controls, variable speed
drives and motor control centers, cement kilns, mining operations, ore processing facilities,
and many others.

DCSs in very high reliability applications can have dual redundant processors with "hot"
switch over on fault, to enhance the reliability of the control system.

Although 4–20 mA has been the main field signalling standard, modern DCS systems can
also support fieldbus digital protocols, such as Foundation Fieldbus, profibus,
HART, modbus, PC Link, etc.

Modern DCSs also support neural networks and fuzzy logic applications. Recent research

focuses on the synthesis of optimal distributed controllers, which optimizes a certain H-
infinity or the H 2 control criterion

3.3a SOME IMPORTANT FEATURES Of DCS

The main features of the distributed control system are:

22
  Management of complicated processes
 System redundancy
 Numerous pre-defined functional blocks – DCS provides various algorithms, many
standard application libraries, pre-defined and pre-tested activities to handle huge
systems
 More advanced HMI design allows to manage and monitor complex systems and also
this functions as a centralized system of the entire DCS.
 Enhanced scalability – The DCS structure allows more flexibility which can be used
for any range of server systems
 System protectionComparison between DCS and PLC

3.4 Programmable Logic Controller(PLC)

A programmable logic controller(PLC)  is an industrial computer that has

been ruggedized and adapted for the control of manufacturing processes, such as assembly
lines, machines, robotic devices, or any activity that requires high reliability, ease of
programming, and process fault diagnosis. Dick Morley is considered as the father of PLC as
he had invented the first PLC, the Modicon 084, for General Motors in 1968.

PLCs can range from small modular devices with tens of inputs and outputs (I/O), in a
housing integral with the processor, to large rack-mounted modular devices with thousands of
I/O, and which are often networked to other PLC and SCADA systems.

They can be designed for many arrangements of digital and analog I/O, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to
control machine operation are typically stored in battery-backed-up or non-volatile memory.

PLCs were first developed in the automobile manufacturing industry to provide flexible,
rugged and easily programmable controllers to replace hard-wired relay logic systems. Since
then, they have been widely adopted as high-reliability automation controllers suitable for
harsh environments.

A PLC is an example of a hard real-time system since output results must be produced in

response to input conditions within a limited time, otherwise unintended operation will result.

23
 FIGURE:16:PLC

3.4a To know clearly on DCS, one has to know how DCS is varied from
PLC.

DCS PLC

24
 To create custom logic, a high
With the prevailing function blocks,
level of programming languages
custom logics are created
are used

There is more probability of system Redundancy is not that much

redundancy required

There must be provisions for the

The whole system acts as one complete
integration of functions into one
solution
single architecture

Most of the algorithms are complicated

and there will be no variation across the This requires customized routines
applications

It has simple to advanced PID and even

PLC has simple PID only
sophisticated process controlling

3.5 Advantages of DCS

The one basic quality of DCS 20 is to distribute its functions into relatively small sets of
semiautonomous subsystems, and they are connected using a high-speed communication
network. The distribution of functions has several advantages over more classical process
computer architectures, including:

 Lower exposure to component or subsystem failure and better isolation to facilitate

maintenance and upgrades
 Better partitioning of application requirements for different process areas
 Improved modularity for application development

25
Facilitation of geographical distribution, which reduces installation costs (reduced wiring)
and provides more localized operational supervision while offering global access to
information and control capabilities

The DCS automate the process by integrating advanced regulatory control, logic and
sequential control. The “control” aspect of the modern DCS has expanded to include
information that is capable of supporting such manufacturing enterprise applications as:

 activity-based cost accounting

 production scheduling and dispatching
 preventative or predictive maintenance scheduling
 validation of employee job certification and readiness
 information exchange with business, logistics, and transportation applications

The systems aspect of a DCS organizes the command structure and information flow between
its constituent parts to act as a single automation system that unifies the various subsystems,
including:

 process signal input and conditioning

 process actuator signal output
 regulatory, combinatorial, and sequence logic and procedural and supervisory control
 human readable process displays of current values, alarms, trends, and calculations
 human actions including setpoint changes, manual overrides and alarm handling
 application subsystems such as process optimization and manufacturing support
 information-storage subsystems
 communications subsystems

3.6 Applications of Distributed Control System

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Distributed control systems (DCS) are dedicated systems used in manufacturing processes
that are continuous or batch-oriented.

Processes where a DCS might be used include:

 Chemical plants
 Petrochemical (oil) and refineries
 Pulp and paper mills (see also: quality control system
QCS)
 Boiler controls and power plant systems
 Nuclear power plants
 Environmental control systems
 Water management systems
 Water treatment plants
 Sewage treatment plants
 Food and food processing
 Agrochemical and fertilizer
 Metal and mines
 Automobile manufacturing
 Metallurgical process plants
 Pharmaceutical manufacturing
 Sugar refining plants
 Agriculture applications

CHAPTER 4

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 CONCLUSION

In the recent years, the emerging process industries are merely operated by advanced
automation technologies such as distributed control systems (DCS). These systems are used
as an extension of traditional controllers across diversified range of industries. The main
concept of DCS application is derived by the idea of decentralizing the control unit and
establishing a common network between the engineering stations. In addition, integrating
DCS with process plants enables it to control, report, and monitor the components
individually, while providing flexibility and simplicity to the plant operation. DCS uses a set
of configuration tools to manage the database, graphics, control logic, and system security.
Moreover, it supports modification, upgrade, and integration to the existing architecture of
any industry.

The emerging process industries are merely operated by advanced automation technologies
such as distributed control systems (DCS). These systems are used as an extension of
traditional controllers across diversified range of industries. The main concept of DCS
application is derived by the idea of decentralizing the control unit and establishing a
common network between the engineering stations. In addition, integrating DCS with process
plants enables it to control, report, and monitor the components individually, while providing
flexibility and simplicity to the plant operation. DCS uses a set of configuration tools to
manage the database, graphics, control logic, and system security. Moreover, it supports
modification, upgrade, and integration to the existing architecture of any industry

Factors such as increasing demand in power and energy sectors, emergence of open source
DCS solutions, and cost and time effectiveness are expected to fuel the DCS market growth.
However, sluggish industrial growth in developed economies are expected to hinder the
market growth. Furthermore, developing industrial infrastructure in emerging markets and
growing inclination towards public or private cloud are expected to offer lucrative
opportunities for the market globally.

The report highlights Porter’s five forces analysis of the global distributed control systems
market, which encompasses the impact of suppliers, industry rivals, substitute products, and
buyers of the market. Large number of suppliers paired with technological expertise lead to

28
moderate bargaining power among suppliers. On the other hand, availability of substitutes
and low threat of backward integration lead to moderate bargaining power among buyers.

The leading players profiled in the distributed control systems market report are Siemens AG,
ABB Ltd., Honeywell International, Inc., Yokogawa Electric Corporation, General Electric
Company, Rockwell Automation, Inc, Emerson Electric Co., Metso Corporation, Schneider
Electric SA and NovaTech Process Solutions LLC. These companies have adopted strategies,
such as expansion, product launch, and research & development, to increase their DCS
market share and expand its geographical presence.

Segment Overview:

The DCS market size is segmented on the basis of component type, industry vertical and
geography. The segmentation done under component type is hardware, software and services.
In 2015, software contributed the highest revenue in the market globally.

Based on industry verticals the market is segmented into chemical, oil and gas,
pharmaceutical, petrochemical, food and beverage, power generation and others
(manufacturing, metal & mining, paper & pulp and automation). Among the industry
verticals segments, oil & gas dominated the market in terms of spending in 2015 and is
projected to continue its dominance throughout the forecast period.

The geographical regions considered in the report are North America, Europe, Asia-Pacific,
and LAMEA. Asia-Pacific contributes the highest revenue among other regions.

REFERNCES

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 "Feedback and control systems" - JJ Di Steffano, AR Stubberud, IJ Williams.
Schaums outline series, McGraw-Hill 1967
 Wayand, Ben (20 March 2020). "What is a PLC?". www.mroelectric.com. MRO
Electric. Retrieved 11 May 2021.
 "PLC Programming Basics Part I". Control Systems & Automation. 2019-07-23.
Retrieved 2020-02-23.
 Kuo, Benjamin C. (1991). Automatic Control Systems (6th ed.). New Jersey: Prentice
Hall. ISBN 0-13-051046-7.
 Ziny Flikop (2004). "Bounded-Input Bounded-Predefined-Control Bounded-Output"
(http://arXiv.org/pdf/cs/0411015)
 https://www.alliedmarketresearch.com/distributed-control-system-DCS-market

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