1

A 1LCnNICAL kLCk1 ICk SLMINAk

kLSLN1A1ICN
ON
"DISTRBUTED CONTROL SYSTEM"





resented by
GAUkAV kUMAk SINnA

A report subm|tted |n part|a| fu|f||ment of the requ|rement of Sem|nar resentat|on

ACADLM CI 1LCnNCLCG
ALDCCNAGAk nCCGnL712121



CERTIFICATE BY THE SUPERVISOR

rofPlranmoy Mondal
uepL Cf Applled LlecLronlcs and lnsLrumenLaLlon
Academy of 1echnology
AdlsapLagram
Pooghly711


1hls ls cerLlfled LhaL Lhe 1echnlcal 8eporL on #DIS1kI8U1LD CCN1kCL SS1LM ls a
record of work done by Lhe candldaLe Gaurav kumar S|nha as a requlremenL of Semlnar
resenLaLlon and lLs documenLaLlon aL Academy Cf 1echnology afflllaLed Lo WesL 8engal
unlverslLy of 1echnology


_________________
rof Plranmoy Mondal





STATEMENT BY THE CANDIDATE

Caurav kumar Slnha
4
Lh


year 81LCP 7
Lh


Sem
uepL of Applled LlecLronlcs and lnsLrumenLaLlon
Academy Cf 1echnology
AdlsapLagram


l hereby sLaLe LhaL 1echnlcal reporL enLlLled ulS18l8u1Lu CCn18CL S?S1LM" has been
prepared by me Caurav kumar Slnha Lo fulflll Lhe requlremenL of Semlnar resenLaLlon







(CAu8Av kuMA8 SlnPA)


4

ACKNOWLEDGEMENT
l would llke Lo Lhank my frlends back who have always been Lhere wlLh Lhelr ldeas and
suggesLlon for Lhe successful and Llmely compleLlon of Lhls reporL l would llke Lo Lhank all
Lhe faculLles aL AC1 for Lhe knowledge and ldeas wlLh whlch Lhey showered us so LhaL we
could undersLand and easlly compleLe Lhls reporL of ours l am also graLeful Lo my parenLs
for Lhelr flnanclal as well as moral supporL Lhey provlded me durlng Lhe compleLlon of Lhls
reporL
LasL buL noL Lhe leasL l would llke Lo Lhank 1he AlmlghLy for always belng Lhere Lo brlng
Lhe sense of confldence ln us and Lo gulde us Lhrough Lhls enLlre reporL


Gaurav Kumar 8inha








INDEX











Topics Page No.

INTRODUCTION 6

HARDWARE COMPONENTS OF DCS 7

DISTRIBUTED PROCESSING UNIT 8

FEATURES OF DPU 9

I/O SYSTEM 11

TYPES OF I/O SYSTEM 11

CONFIGARUTION OF I/O MODULES 12

CONCLUSION 13

BIBLIOGRAPHY 14


INTRODUCTION:

DEFINITION OF DISTRIBUTED CONTROL SYSTEM:
A type oI automated control system that is distributed throughout a machine to provide
instructions to diIIerent parts oI the machine. Instead oI having a centrally located device
controlling all machines each section oI a machine has its own computer that controls the
operation.
For instance, there may be one machine with a section that controls dry elements oI cake Irosting
and another section controlling the liquid elements, but each section is individually managed by a
DCS.
MEANING OF THE WORD:
The modern DCS, or distributed control system, could be described by taking each word oI the
acronym out and explaining it.
First, 'Distributed' implies that the Iunctions are all distributed. These Iunctions reIer to the data
collection, processing, controlling outputs, alarming, collecting historical data, etc. In a typical
DCS system, you will Iind physical boxes that handle each oI the above Iunctions (well, almost).
There is additionally an implication about geographical distribution, or that the Iunctions can be
distributed in diIIerent physical locations. This is a beneIit in that prevents Iailure in one part oI the
system Irom aIIecting another part.

The word 'Control' implies the ability oI the system to close the loop between an input
measurement and a manipulated handle in the process. This means that the DCS shall have the
capability Ior basic and advanced control algorithms.

The word 'System' implies that all oI the above is connected as one contiguous system i.e. in
simple words, one comprehensive system with systems and physical parts spread over potentially a
wide area carrying out monitoring and control Iunctions

APPLICATIONS:
Distributed control systems (DCSs) are dedicated systems used to control manuIacturing
processes that are continuous or batch-oriented, such as
O Oil reIining,
O Petrochemicals,
O Central station power generation,
O Fertilizers, pharmaceuticals,
O Food and beverage manuIacturing,
O Cement production,
O Steelmaking,
O And papermaking.
O Modern dcs support also neural networks and Iuzzy application.
WORKING PRINCIPLE OF A DCS:
DCSs are connected to sensors and actuators and use setpoint control to control the Ilow oI
material through the plant. The most common example is a setpoint control loop consisting oI
a pressure sensor, controller, and control valve. Pressure or Ilow measurements are
transmitted to the controller, usually through the aid oI a signal conditioning input/output
(I/O) device. When the measured variable reaches a certain point, the controller instructs a
7

valve or actuation device to open or close until the Iluidic Ilow process reaches the desired
setpoint. Large oil reIineries have many thousands oI I/O points and employ very large DCSs.
Processes are not limited to Iluidic Ilow through pipes, however, and can also include things
like paper machines and their associated quality controls (see quality control system QCS,
variable speed drives and motor control centers, cement kilns, mining operations, ore
processing Iacilities, and many others.

HARDWARE COMPONENT OF DCS:
Basically a power plant is continuously monitored Ior the proper Iunctioning oI each block without
any interruption. When automation is done Ior the monitoring purpose a closed loop system is
Iormed and some logic is set up.
The system consists oI the Iollowing components:
maxDPU, Distributed Processing Units providing control and data
Acquisition
maxPAC I/O Modules interIacing with the plant I/O
DISTRIBUTED PROCESSING UNIT( DPU)
INTRODUCTION:
DPU IS THE HARDWARE PROCESSNG ENGINE OF THE DCS.
Mounted in a single slot of the 8 pac rack.
Must be mounted in the leIt most position oI the maxpac rack to allow Ior best
airIlow. When using a second dpu , it must be mounted vertically beneath the
primary to allow Ior connection oI the backup cable
Operates in conjunction with the i/o modules.
Each dpu/dpu pair can control upto maximum oI 60 i/o modules & allows a i/o bus
length oI 30 Ieet.
Bus length can be extended to 2000m with bem modules &additional modules can
be supported.
On the maxnet each dpu/dpu pair is identiIied with a unique ethernet ip address.

DISTRIBUTED PROCESSING UNIT FUNCTIONS:
Execution oI control algorithms (conIiguration/database) Ior process control & data
acquisition.Upto 8500 Iunction blocks can be executed in three diIIerent time classes.
(10MS to 1/2S)
Continuous scanning oI i/o modules.
Logging oI soe at 1 ms resolution.


Acquisition oI trend inIormation.
Calculations & alarming.
Scans and processes inIormation Ior use by other devices in the maxdna system.
REDUNDANT DPU OPERATION:
One DPU is designated as the primary and the other DPU , the secondary.
The primary is always an even address while the secondary is an odd address
The ip address oI the secondary dpu is one number greater than the address oI the
primary dpu.
InIormation between the backup pair is exchanged by means oI a 100mbps ethernet
interIace.
a cat5e ethernet cable is used to connect the two DPUs together.
Process control can be transIerred automatically(Iailover) or manually between primary &
secondary.
Automatic Iailover can occur Irom either the primary dpu to the secondary DPU or vice
versa & this occurs based on the health oI both DPUS.
Manual takeover can be achieved by pressing the takeover button on the Iront panel oI
the module.
BLOCK DIAGRAM OF A DPU






CONTROL PROCESSOR (CP) :
All control actions are achieved by executing programs.
IOM PROCESSOR (IOM) -
Responsible Ior scanning all the i/o modules connected to the dpu. This Iunction is achieved
by means oI the iom Ipga.
SHARED MEMORY:
Facilitates sharing oI data between the cp & iom. This data sharing is controlled by the shared
memory Ipga.
COMPACT FLASH (64MB/128MB ).
THIS CARRIES:
Dpu soItware Iiles.
Dpu initialisation inIormation.
control algorithm which is downloaded

Dpu software files in the compact flash contains
Win ce .net os & bios., iom Iirmware ,Iirmware Ior shared memory Ipg,Iirmware Ior
iom Ipga ,iom diagnostic code .
Dpu initialization file in the compact flash contains:
Dpu name ,ip address,other conIiguration inIormation,Compact Ilash is non-volatile
& can be moved Irom one dpu to another.
maxPAC I/O SYSTEM:
Maxpac i/o system links the maxdna dcs with real world process control i/o.
The i/o system comprises the i/o modules & the dpu.
The i/o modules & dpu are mounted in a i/o rack assembly.
The rack assembly carries a backplane which provides the i/o bus .the i/o bus is the
communication bus between the dpu & the i/o modules. All i/o modules communicate
with the dpu thro` the i/o bus.the communication is closely controlled by the dpu.
The rack used in the maxdna system is a 8 pac.
I/O SYSTEM RACK ASSEMBLY -8 PAC RACK
O Provides the system power & Iield power connections to the i/o modules & the dpu
carries the i/o bus over which the dpu & the i/o modules communicate.
10

O i/o modules & the dpu plug into connectors in the i/o backplane.
on any i./o bus, only one / one redundant pair oI dpus can reside .
O Upto 60 i/o modules can reside on a i/o bus.
O The i/o bus can extend to a maximum length oI 30 It.
O Multiple i/o racks that share the i/o bus can be installed in a cabinet.

There are 2 types oI I/O module:
O Analog Input/Output modules.

O Digital Input/Output module


Digital Input/Output modules:

NAME: TYPES NOS OF PINFUNCTION
IOP331 24Vdc common input

16 High level at 40 to 150 oI rated voltage
Field to logic isolation
IOP332 48Vdc common input 16 High level at 40 to 150 oI rated
voltage.Field to logic isolation.LED
indication Ior HIGH input

IOP333- 120Vac/dc isolated
input

16 High level at 40 to 150 oI rated
voltage.Field to logic isolation.LED
indication Ior HIGH input

IOP334 240Vac/dc isolated
input

16 High level at 40 to 150 oI rated
voltage.Field to logic isolation.LED
indication Ior HIGH input

IOP350 Form C Relay output

10





CONFIGURATION OF I/O MODULES:
There are 3 basic conIiguration by which i/o module can be conIigured:
SHARED(COMMON) CONFIGURATION.


REDUNDANT CONFIGURATION.

11


MIXED CONFIGURATION.




1





BASIC OPERATION OF THE 3 CONFIGURATION:
O In SHARED COMMON CONFIGURATION there is 2 DPU,2 I/O
MODULUS and one common I/O BUS.The I/ O module share a common I/O
bus Ior the both main DPU and the REDUDANT DPU.


O In REDUNDANT CONFIGURATION there is 2 DPU,2I/O MODULUS
(one main and one redudant) and 2 I/0 bus (one Ior main DPU AND I/O BUS
and other Ior redudanT I/0 BUS and redundant DPU)


O In MIXED CONFIGURATION. There is a Y CABLE attached with both the
DPU and the I/0 BUS.






1

CONCLUSION

The DCS oIIers a compromise between advance control techniques and present day
technology. It is extremely diIIicult to Iorecast the rate and Iorm oI progress oI DCS, but
there is strong evidence that development is both rapid and cumulative. Though a DCS is not
designed to replace a computer, it is useIul and cost eIIective Ior medium sized control
systems. However with the capability oI PLCs to Iunction as local controllers in distributed
control systems as well as their ability to Iunction as standalone controllers and also with
advancement in PLCs, line oI demarcation between PLCs and DCS has been blurred to a
great extent.








































14

BIBLIOGRAPHY


AUTOMATNG MANUFACTURNG SYSTEMS
HUGH JACK

PROCESS CONTROL AND OPTMZATON
LPTAK

http://program-plc.blogspot.com

www.globalautomation.info