Distributed Control System

DCS has been found in many industrial fields such as chemical plants, oil and gas industries, food processing units, nuclear power plants, water management systems, automobile industries, etc

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In recent years, the use of smart devices and field buses makes Distributed Control System (DCS) to be prominent in large and complex industrial processes as compared to the former centralized control system. This distribution of control system architecture around the plant has led to produce more efficient ways to improve reliability of control, process quality and plant efficiency.

 

What is DCS System?

A Distributed Control System (DCS) is a specially designed automated control system that consists of geographically distributed control elements over the plant or control area. It differs from the centralized control system wherein a single controller at central location handles the control function, but in DCS each process element or machine or group of machines is controlled by a dedicated controller. DCS consists of a large number of local controllers in various sections of plant control area and are connected via a high speed communication network.

In DCS control system, data acquisition and control functions are carried through a number of DCS controllers which are microprocessor based units distributed functionally and geographically over the plant and are situated near area where control or data gathering functions being performed as shown in the figure above. These controllers able to communicate among themselves and also with other controllers like supervisory terminals, operator terminals, historians, etc.

Distributed individual automatic controllers are connected to field devices such as sensors and actuators. These controllers ensure the sharing of gathered data to other hierarchal controllers via different field buses. Different field buses or standard communication protocols are used for establishing the communication between the controllers. Some of these include Profibus, HART, arc net, Modbus, etc.

DCS is most suited for large-scale processing or manufacturing plants wherein a large number of continuous control loops are to be monitored and controlled. The main advantage of dividing control tasks for distributed controllers is that if any part of DCS fails, the plant can continue to operate irrespective of failed section. 

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