DEFINITION OF DCS

A distributed control system (DCS) refers to a control system of a process plant and
industrial process wherein control elements are not only located in central location (like the
brain) but are also distributed throughout the system with each component sub-system
controlled by one or more controllers so the intelligence is distributed across the sections of
the plant. DCS follows hierarchy in its control philosophy with various function spread
across.
DCS (Distributed Control System) is a computerized control system used to automate
processes in various industries. (https://www.youtube.com/watch?v=EkXcUfeFyIM)
BRIEF HISTORY OF DCS
Because of the reliability problems and high cost of the control process computer systems of
the 1960s, there were few new process computer projects in the early 1970s. The rare
projects that were started in this period were based on medium-priced minicomputers that
were designed to be small in size. At the same time, two developments occurred in
electronics that profoundly changed the application of digital computers to process control.
The first was the development of integrated circuits and microprocessors. The second was
the release of the distributed control system (DCS) by Honeywell in 1969. This new design
concept was based on the idea of widely distributing the control to computer modules. Each
of these modules controlled several instrument loops, generally one to four. They
were connected by a single high-speed data communications link, called a data highway that
made possible communications between each of the computer modules and the central
operator console. This design allowed the operator to monitor the operation of each local
process.
In the mid-1970s, microprocessor-based modules replaced hardwired computer modules.
The typical DCS had the configuration shown in Figure1. Todays distributed control systems
are much more powerful and faster than the first systems because of improvements in
microprocessors and other electronic circuits.

Fig. 1: Typical DCS configuration.

Distributed control systems today consist of one or more levels of control and information

collection, as shown in Figure 2. The lowest level is process control and measurement on
the plant floor. At this level, microprocessor- based controllers such as programmable
controllers execute loop control, perform logic functions, collect and analyse process
data, and communicate with other devices and to other levels in the system.
In Figure 2, the process data collected at level 1 is transferred to level 2. At this level,
process operators and engineers use operator consoles that have a keyboard, mouse, and
video display to view and adjust the various processes being controlled and monitored by
the system. Also, at level 3, process and control engineers implement advanced control
functions and strategies, and members of the operations management team
perform advanced data collection and analysis on process information. The various plant
management systemssuch as inventory management and control, billing and invoicing,
and statistical quality controlexist at level 3. The highest level (level 4) is used in large
industrial plants to provide corporate management with extensive process and operations
information.

Fig. 2: Distributed Control System Level

(http://whatisinstrumentation.blogspot.com/2012/12/distributed-control-system-or-dcsbrief.html)
DCS APPLICATIONS
The abbreviation DCS stands for Distributed Control System. The first DCS generation
originates from the seventies and has been put on many process installations. Meanwhile,
these systems have evolved and dispose of powerful control units (PLCs) connected with
fieldbus systems and have modern PC-based operating stations.
The engineers of Industrial Automation Partners BV have a thorough knowledge of the
systems of the leading DCS suppliers. These include ABB, Emerson, Honeywell,
Siemens, Automation-X and Yokogawa. Training certificates from the applicable DCS
systems are usually available.
Besides the know-how about the different technologies, knowledge about the type of
industry is an advantage as well if you select IAP. IAP has years of experience with projects
in the following branches of industry: oil and gas (extraction, production and storage), energy
generation (and waste incineration), water and the environment (production and purification),
chemical industry, paper and cement.
(http://www.iapbv.nl/EN-distributed-control-system-applications.php)
Distributed control systems are most frequently used in batch-oriented or continuous
process operations, such as oil refining, power generation, petrochemical manufacturing,

papermaking, food and beverage manufacturing, pharmaceutical production, and cement

processing. DCSs may control any of a number of different equipment types, including:

Variable speed drives

Quality control systems
Motor control centers (MCC)
Kilns
Manufacturing equipment
Mining equipment
(http://www.globalspec.com/learnmore/networking_communication_equipment/networking_e
quipment/distributed_control_systems_dcs)
THE ADVANTAGES OF DCS SYSTEMS
The major advantages of functional hardware distribution are flexibility in system design,
ease of expansion, reliability, and ease of maintenance. A big advantage compared to a
single-computer system is that the user can start out at a low level of investment. Another
obvious advantage of this type of distributed architecture is that complete loss of the data
highway will not cause complete loss of system capability. Often local units can continue
operation with no significant loss of function over moderate or extended periods of time.
Moreover, the DCS network allows different modes of control implementation such as
manual/auto/supervisory/computer operation for each local control loop. In the manual
mode, the operator manipulates the final control element directly. In the auto mode, the final
control element is manipulated automatically through a low-level controller usually a PID.
The set point for this control loop is entered by the operator. In the supervisory mode, an
advanced digital controller is placed on the top of the low level controller (Figure 1). The
advanced controller sets the set point for the low-level controller. The set point for the
advanced controller can be set either by the operator or a steady state optimization. In the
computer mode, the control system operates in the direct digital mode shown in Figure 1.
One of the main goals of using DCS system is allowing the implementation of digital control
algorithms. The benefit of digital control application can include:
Digital systems are more precise.
Digital systems are more flexible. This means that control algorithms can be changed and
control configuration can be modified without having rewiring the system.
Digital system cost less to install and maintain.
Digital data in electronic files are easier to deal with. Operating results can be printed out,
displayed on color terminals, stored in highly compressed form.
Disadvantages of Distributed control system:
Increased software development cost, more complex failure diagnosis and dependence on
communication technology. These have been over come to a great extent by the
development of high level languages and structured programming concept,
communication technology (e.g. fiber optics) and fault diagnosis methods.
(http://instrumentationandcontrollers.blogspot.com/2011/09/distributed-control-system.html)