Distributed Controll System

MS Hendriyawan A., S.T., M.Eng., Ph.D.

Universitas Teknologi Yogyakarta
Definition
• A distributed control system (DCS) is a computerized control system
for a process or plant usually with a large number of control loops, in
which autonomous controllers are distributed throughout the system,
but there is central operator supervisory control.

• The DCS concept increases reliability and reduces installation costs by

localizing control functions near the process plant, with remote
monitoring and supervision.
Hierarchy
• Level 0 contains the field devices such as
flow and temperature sensors, and final
control elements, such as control valves
• Level 1 contains the industrialized
Input/output (I/O) modules, and their
associated distributed electronic
processors.
• Level 2 contains the supervisory
computers, which collect information
from processor nodes on the system, and
provide the operator control screens.
• Level 3 is the production control level,
which does not directly control the
process, but is concerned with monitoring
production and monitoring targets
• Level 4 is the production scheduling level.
Typical applications
• Distributed control systems (DCS) are • Water treatment plants
dedicated systems used in • Sewage treatment plants
manufacturing processes that are
• Food and food processing
continuous or batch-oriented.
• Agrochemical and fertilizer
• Chemical plants
• Metal and mines
• Petrochemical (oil) and refineries • Automobile manufacturing
• Pulp and paper mills (see also: quality • Metallurgical process plants
control system QCS) • Pharmaceutical manufacturing
• Boiler controls and power plant systems
• Nuclear power plants
• Sugar refining plants
• Environmental control systems • Agriculture applications
• Water management systems
Continuous / Batch processing
DCS VS PLC

DCS is PLC Networking !!!

Data Communication
• Point to Point
Data Communication
• Local Area Network
Data Communication
• Transmission Media
Network Functionality Level
• Device Level
• The device level involves various sensor and actuator devices
of machines and processes. These may include devices such
as sensors, switches, drives, motors, and valves.
• Control Level
• The control level would be the networks industrial controllers
are on. This level may include controllers such as PLCs and
robot controllers. Communications on the control level
includes sharing I/O and program data between controllers.
• Information Level
• The information level is a plantwide network typically
composed of the company’s business networks and
computers. This level may include scheduling, sales,
management, and corporatewide information.
Network Topology
• STAR
• A network controller switch or hub is
connected to several PLC network nodes.
• The configuration allows for bidirectional
communication between switch/hub and each
PLC.
• All transmission must be between the
switch/hub and the PLCs because the network
controller hub controls all communication.
• One problem with the star topology is that if
the switch/hub goes down, the entire LAN is
down.
Network Topology
• BUS
• Uses a single bus trunk cable to which individual PLC nodes are attached by a cable drop that taps off
the main cable.
• Each PLC is interfaced to the bus using a network interface module that is attached using a drop cable or
connector.
• No single station controls the network and stations can communicate freely to one another.
• Bus networks require less cable than all other topologies.
• All the nodes rely on a common bus trunk line, and a break in that common line can affect many nodes.
I/O Bus Network
• Device Bus Network
• Device bus networks interface with low-level information devices such as
pushbuttons and limit switches that primarily transmit data relating to the
on/off state of the device and its operational status.
• Device bus networks can be further classified as bit-wide or byte-wide buses.
• Device bus networks that include discrete devices as well as small analog
devices are called byte-wide bus networks. These networks can transfer 50 or
more bytes of data at a time.
• Device bus networks that interface only with discrete devices are called bit-
wide bus networks. Bit-wide networks transfer less than 8 bits of information
to and from simple discrete devices.
I/O Bus Network
• Process Bus Network
• Process bus networks are capable of communicating several hundred bytes
of data per transmission.
• The majority of devices used in process bus networks are analog, whereas
most devices used in device bus networks are discrete.
• Process bus networks connect with high-level information devices such as
smart process valves and flowmeters, which are typically used in process
control applications.
• Process buses are slower because of their large data packet size. Most analog
control devices are used in controlling such process variables as flow and
temperature, which are typically slow to respond
Network Protocol
• A protocol is a set of rules that two or more devices must follow if
they are to communicate with each other.
• A network protocol defines how data is arranged and coded for
transmission on a network.
• Today, the trend is toward open network systems based on
international standards developed through industry associations.
Network Gateways
• Gateways make communication
possible between different architectures
and protocols.
• Gateways repackage and convert data
going from one network to another
network so that the one can understand
the other’s application data.
• Gateways can change the format of a
message so that it will conform to the
application program at the receiving
end of the transfer.
Serial Communication
• Serial data communication is implemented using
standards such as RS-232, RS-422, and RS-485. The
'RS' means 'Recommended Standard' that specifies
the electrical, mechanical, and functional
characteristics for serial communications.
• The RS-232 type of serial transmission is designed
to communicate between one computer and one
controller and is usually limited to lengths up to 50
feet.
• RS-422 and RS-485 serial transmission types are
designed to communicate between one computer
and multiple controllers, have a high level of noise
immunity, and are usually limited to lengths of 650
feet (for RS-485) or 1650 feet (for RS-422).
DeviceNet
• DeviceNet is an open device-level
network. It is relatively low speed
but efficient at handling the short
messages to and from I/O modules.
• Conventional systems have racks of
inputs and outputs with each I/O
device wired back to the controller.
• The DeviceNet protocol dramatically
reduces costs by integrating all I/O
devices on a 4-wire trunk network
with data and power conductors in
the same cable. This direct
connectivity reduces costly and time-
consuming wiring.
DeviceNet
• The basic function of a DeviceNet I/O bus network
is to communicate information with, as well as
supply power to the field devices that are
connected to the bus.
• The PLC drives the field devices directly with the
use of a network scanner instead of I/O modules.
• The scanner module communicates with
DeviceNet devices over the network to:
• Read inputs from a device.
• Write outputs to a device.
• Download configuration data.
• Monitor a device’s operational status.
DeviceNet Layout
ControlNet
• ControlNet is positioned one level above
DeviceNet. It uses the Common Industrial
Protocol (CIP) to combine the functionality
of an I/O network and a peer-to-peer
network providing high-speed
performance for both functions.
• This open high-speed network is highly
deterministic and repeatable.
Determinism is the ability to reliably
predict when data will be delivered, and
repeatability ensures that transmit times
are constant and unaffected by devices
connecting to, or leaving, the network.
EtherNet/IP
• EtherNet/IP (Ethernet
Industrial Protocol) is an
open communications
protocol based on the
Common Industrial Protocol
(CIP) layer used in both
DeviceNet and ControlNet.
• It allows users to link
information seamlessly
between devices running
the EtherNet/IP protocol
without custom hardware.
PLC Communication Protocol
• MODBUS
• Modbus is a serial communication protocol originally developed by Modicon
for use with its PLCs.
• Basically, it is a method used for transmitting information over serial lines
between electronic devices.
• The device requesting the information is called the Modbus Master and the
devices supplying information are Modbus Slaves.
• Modbus is an open protocol, meaning that it’s free for manufacturers to build
into their equipment without having to pay royalties.
• It has become a standard communications protocol in industry, and is one of
the most commonly available means of connecting industrial electronic device
PLC Communication Protocol
• FIELDBUS
• Fieldbus is an open, serial, two-way communications system that
interconnects measurement and control equipment
• such as sensors, actuators, and controllers. At the base level in the hierarchy
of plant networks, it serves as a network for field devices used in process
control applications.
• Fieldbus uses the daisy-chain topology. With this topology, the fieldbus cable
is routed from device to device.
PLC Communication Protocol
• PROFIBUS-DP
• PROFIBUS-DP (where DP stands for Decentralized Periphery) is an open,
international fieldbus communication standard that supports both analog and
discrete signals. It is functionally comparable to DeviceNet.
• The physical media are defined via the RS-485 or fiberoptic transmission
technologies. PROFIBUS-DP communicates at speeds up to 12 Mbps over
distances up to 1200 meters.
PLC Communication Protocol
• PROFIBUS-DP
Supervisory Control and Data Acquisition
(SCADA)