SAGAR BHARDWAJ

EVOLUTION OF DCS
Different stages of evolution of
Control system are :

Manual or Field control

Pneumatic Single loop control system.
Electronic single loop control system
Centralized control system
Distributed control system.

DISTRIBUTED CONTROL
SYSTEM
DEFINATION :A Control System In Which Different Intelligent

Devices

(Controllers) Are Functionally & Geographically Distributed

To

Control

The

Process

Communication Loop.

And

Integrated

On

Same

ADVANTAGES OF DCS SYSTEM

REDUNDANCY:- The System Consists Of Critical Equipments Which Have Been
Supported By Active Stand By System Which Results In
Increased Reliability.
RELIABILITY

:- Ability Of A System To Operate Efficiently Under PreDetermined Operating Conditions.

ADAPTABILITY:- Ability Of A System To Operate Under Adverse Operating

Conditions Accept Changes And Also Provide Easy Machine
Human Interface.

ARCHITECTURES OF DCS
The master less deterministic type on single network
(Node Server)
The client server type with master less characteristic

on single network
The client server

type with server as master and

interlink between clients on two separate networks.

NODE SERVER
A network with deterministic master less type of
protocol has a real master less node hierarchy,
which means that all the nodes, i.e., all
controllers as well as operator stations will have
the same priority and shall be always
communicating to the network together. In this
case, the failure of any one operator station, i.e.
any one node will lead to the non operation
of that node only and the rest of the
system stays healthy , thereby maintaining
the healthiness of the network.

Node
1

Node
2

Node
3

Node
4

Bus1
Bus2
All healthy
nodes and all
are at same
hierarchy
Node
5

Node
6

NODE SERVER MASTERLESS TYPE DCS

Node
1

Node
2

Node
3

Node
4

Bus1
failure

Node
5

Node
6

Bus2

All healthy
nodes and all
are at same
hierarchy

Failure of Bus-2 causes Bus-1 to take

over without making any difference to
nodes

NODE SERVER MASTERLESS TYPE DCS

failure

Bus1
Bus2

FAILURE OF A NODE WILL

LEAD TO THE FAILURE OF
THE PARTICULAR NODE
ONLY. OPERABILITY IS
INTACT FROM ALL OTHER
NODES

Still Healthy
Nodes keep
system
healthy

NODE SERVER MASTERLESS TYPE DCS

CLIENT SERVER WITH SINGLE

NETWORK
A special case of Client-server architecture
with servers and all its clients connected
directly to the same network. In this
architecture both the controllers and the
operator stations are clients to the server but
communicating directly to the network. All the
data required are being stored in a common
distributed database at the server which keeps
the complete history of the operations and
process data.

CLIENT SERVER WITH SINGLE

NETWORK
In normal operation all the operations and
process data are being communicated from/to
the operator stations/ controllers are routed
through the server, but failure of the server will
lead to a direct communication of the operator
stations to the controllers. The complete
controllability of the controllers from the
operator stations stays intact and the only
difficulty faced is the loss of the historical
trending capability of the control system.

Server

Client 1

Client 2

Client 3

Bus1
Bus2

Client 4

Client 5

Server healthy means

all nodes (clients)
communicating to the
server

CLIENT-SERVER ARCHITECTURE TYPE DCS

BUT MASTER LESS FOR OPERABILITY

server

Client 1

Client 2

Client 3

Bus1
failure

Client 4

Client 5

Bus2
Server healthy means
all nodes (clients)
communicating to the
server

Failure of Bus-2 causes Bus-1 to take

over without making any difference to
nodes

CLIENT- SERVER ARCHITECTURE TYPE DCS

BUT MASTERLESS FOR OPERABILITY

Server

Client 1

Client 2

Client 3

Failure

Bus1
Bus2

Client 4

Failure of server renders

failure of communication
between clients and server

Client 5

Even after failure of

server, the clients
keep communicating
in between and hence
operability is intact

CLIENT SERVER ARCHITECTURE TYPE DCS

BUT MASTERLESS FOR OPERABILITY

CLIENT SERVER WITH TWO

SEPEATE NETWORKS
A network with client server architecture will
have servers as an interconnection point
between the controller nodes and the human
machine interface nodes (HMIs). Both the
controllers and the HMIs are clients to the
server. The failure of the server will lead to
a highly dangerous situation of complete loss
of controllability of the network. No process
information from the controller will be
communicated to the operator station and
instructions from the operator station also
cannot be communicated back to the
controller.

Client 1

Client 2

Client3

server

Network I /Bus1

Network I /Bus2

Network II /Bus1
Network II /Bus2
Client 4

Client 5

CLIENT SERVER ARCHITECTURE TYPE DCS

WITH SERVER AS MASTER

Client 1

Client 2

Client3

server

Network I /Bus1
failure

Network I /Bus2

Failure of Bus-1 causes Bus-2 to take

over without making any difference to
nodes
Network II /Bus1
Network II /Bus2
Client 4

Client 5

CLIENT SERVER ARCHITECTURE TYPE DCS

WITH SERVER AS MASTER

Client 1

Client 2

Client3

Data
lost

server
failure

Data
lost

Failure of the server will lead to failure of

complete network and loss of operability

Client 4

Client 5

STEAM GENERATION PLANT OF

NFL PANIPAT
Steam generation plant has three Boilers
of BHEL make, each having MCR (Max.
Capacity Rating) of 150 T/hr respectively,
producing superheated steam at a
Pressure of 100 Kg/cm2 & at a
temperature of 500 0 C
All the three boilers are controlled by DCS.

SGP DCS SYSTEM

Distributed control system for steam generation plant is
being procured from M/s ABB . The system is known as

WORKSTATION BASED SYMPHONY

HARMONY INDUSTRIAL IT SYSTEM.
The control and monitoring philosophy has been split in
to two categories i.e. closed loops and Open loops
( mainly indications).
The closed loops are being powered , monitored and
controlled in the DCS whereas the open loops are being
powered and configured in the MUX system and
monitored in the DCS system.

SGP DCS SYSTEM NODE

DISTRIBUTION
There are total 10 nodes in system which are directly connected to
C-NET.
Sr.No

No. of nodes

Used for

Three (3)

Three Boilers

One(1)

Common section

One(1)

EWS

Five(5)

OWS

The EWS & OWS are also to Ethernet switch through O- NET cable.

Two printers are on O-NET.

SGP DCS SYSTEM PANEL

CONFIGURATION
DCS system panels for each boiler comprises of
four panels, one is system panel, and the rest
three are termination panel.
AI terminates through HMS panel whereas AO
terminate directly , DI/DO terminate through
relays.
System panel have three set of controllers in
redundant,one for OLCS, one for CLCS & last
for MUX. System panel communicates using NIS
& NPM. Similarly OWS communicate on C-NET
using NIS & ICT.

DATA FLOW

LINE-1
LINE-2

O-NET
NODE-9

NODE-8

NODE-7

NODE-6

NODE-10

NODE-5

ITC

ITC

ITC

ITC

ITC

ITC

NIS

NIS

NIS

NIS

NIS

NIS

REDUNDENT C - NET
NIS

NIS

NIS

NIS

NPM

NPM

NPM

NPM
NODE-4

NODE-1
BOILER-1

BOILER-2
NODE
-2

BOILER-3
NODE
-3

COMMON

C-NET
C-NET is a unidirectional, high speed
serial data network that operates at a
10 megahertz communication rate. It
supports a central network with up to
250 system NODE connections.

SYSTEM CARDS

THERE ARE DIFFERENT TYPES OF CARDS IN SYSTEM PANEL FOR

VARIETIES OF INPUTS/OUTPUTS1)TEMPERATURE CARD FOR THERMOCOUPLE/RTD,( IMAS123)
2)ANALOG INPUT CARD FOR 4-20 ma, (IMFEC12)
3)ANALOG OUTPUT CARD FOR 4-20 ma(IMASO11)
4)DI CARD FOR CONTACT INPUT (IMDSI 13)
5) DO CARD FOR CONTACT OUTPUT (IMDS0 14)
6) NETWORK INTERFASE SLAVE (NIS-21)
7) NETWORK PROCESS MODULE (NPM-12)
8) BRC 300 ( CONTROLLER)
9) MFP 12 ( CONTROLLER)
10) ITC- (FOR COMMUNICATING WITH THE COMPUTER)

DCS SYSTEM
4-20 mA out of smart Txs., Superimposed with
hart signal, are terminated to HMS. Here, HART
Signal and 4-20 mA signals are separated using
patch cards. 4-20 mA goes to terminate to AI
cards through DCS Marshelling cabinet.
Termination of this 4-20 mA depends on
whether this is field powered or system powered.

MULTIPLEXER SYSTEM
Supplied by MTL,England.
Multiplexers are used for cable saving. Here non
critical signals have been taken through MUX.
There are four MUX stations for each boiler
installed in field itself.
All the twelve MUX stations having redundant
supply . MUX -1 & 2 for each boiler caters
mainly AI whereas MUX-3 & 4 caters mainly
DI/DOS.

MULTIPLEXER SYSTEM
The MUX uses redundant EBIM (Ethernet
bus interface module) processing data at
very high speed of 100 Mbps, whereas the
controller (MFP12) used in DCS system
for third party communication is Modbus
compatible, hence MOXA switches are
used to convert Ethernet to Modbus.

MULTIPLEXER SYSTEM
Hence redundant Ethernet cable have been laid
from each of the MUX to redundant MOXA
switches from MOXA, Ethernet Cable been laid
for HMS/MUX PC where WORKBENCH
Software is loaded for status monitoring of all
MUX modules.
Also RS-485 Cable laid from MUX-1 & 2 having
AIs only to HMS PC, through RS-485 to RS-232
Converter, for catering smart transmitters with
the help of CORNERSTONE Software loaded on
the same HMS/MUX PC.

SER-SEQUENCE OF EVENT
RECORDER
There is one SER of 512 points
comprising of two SER Stations - EL1 &
EL2.
SER Stations

DI Cards

No of events
handling capacity

EL1

288

EL2

224

DATA FLOW BETWEEN BRC AND C NET

NIS

C-NET
C-NET

TO
FIELD

FROM
FIELD

NPM

TU

SLAVE

BRC

TU

SLAVE

BRC

CAPTIVE POWER PLANT IN NFL

PANIPAT
In NFL Panipat We have Captive power
plant which has
MCR 230 T/hr at
Pressure of 100Kg/cm2 and at a
temperature of 500oC
In NFL Panipat we have Two Turbo
Generators (TGs) each having a capacity
of 15MW
Boiler of CPP and Turbine of TGs is
controlled by DCS.

CPP DCS SYSTEM

1. Distributed control system for CPP was originally procured from

M/s ABB The system was BAILEY NETWORK 90

2. Later on it was up graded with Symphony Harmony Industrial IT
System for turbine side
3. The boiler side is up graded with INFY 90 System.
4. In this way CPP have to separate DCS System.
5. Both systems are connected to a pair of redundant server.
6. CPP DCS System is Client server based Architecture.

NODE DISTRIBUTION OF CPP DCS SYSTEM

1. It Has 16 (Sixteen) Nodes connected to C NET

Sr.No.

No. of Nodes

Used for

Three(3)

Automatic Boiler Controller(ABC)

Four(4)

Burner management system(BMS)

Three(3)

Sequence (SEQ)

Two(2)

Turbine of TG 1 & 2.

One(1)

Common Section

Two(2)

RTDS 1 & 2

One(1)

EWS

OPERATING STATIONS DISTRIBUTION OF

CPP DCS SYSTEM
Four

Operating

Station

Are

Connected

Through

Redundant O Net To RTDS 1 & 2.

A. Two Stations Are Loaded with History.
B. One Station Is Loaded with Configuration Software.
The

Operating

Station System

Professional Based.

Is

Windows

2000

ARCHITECTURE OF CPP DCS SYSTEM

ABC

SEQ

BMS

TG-1

TG-2

COM

C - NET

RTDS2

RTDS1

EWS

O-NET

HIS P

HIS R

CLIENT

COMPOSER

COMPARISON OF DCS OF SGP

& CPP OF NFL PANIPAT
SGP

CPP

Architecture is Node
Server based.
Operating system is
Window XP
Professional based.
All critical loops are
redundant
DCS is PGP based

Architecture is Client
server based.
Operating system is
Windows 2000
professional based.
All critical loops are
not redundant .
DCS is PPB based.

DCS COMPARISON OF VARIOUS MODELS OF

VARIOUS COMPANIES
COMPANY
S.N
O.

ABB

YOKOGAWA

MODEL

Advant with 460

controller

Syphony
Harmony IT

Infi-90

CS 3000

CS 1000

HMI
Architecture

Node Server option

Node Server
option

Client Server

Node Server

Client Server

Operating
System

Window Based

Window Based

Window Based

Window Based

Window Based

Window NT

Window NT or XP

Window NT

Window
NT,XP,2000

Window NT,2000

Using C-Net 10 Mbps

Using C-Net 10
Mbps

Using C-Net 10
Mbps

Using V-Net 10
Mbps

Using VL-Net 10
Mbps

A) Power
Supply

Yes

Yes

Yes

Yes

Yes

B) System Bus

Yes

Yes

Yes

Yes

Yes

C) Controller

Yes

Yes

Yes

Yes

optional with extra

D) I/O Module

optional with extra

Present in critical
loop

optional with
extra

Present in critical
loop

optional with extra

E) Server

Yes

Yes

Yes

Yes

Yes

F)
Memory(system
)

Yes

Yes

optional with
extra

Yes

optional with extra

Data Bus

Redundancy

DCS COMPARISON OF VARIOUS MODELS OF

VARIOUS COMPANIES
COMPANY
S.N
O.

ABB

YOKOGAWA

Advant with 460

controller

Syphony
Harmony IT

Infi-90

CS 3000

CS 1000

A) System

User Defined

User Defined

User Defined

User Defined

User Defined

B) Controller

68040/25 MHz,
Motorola

32- bit, Motorola

RISC

32- bit, Motorola

RISC

VR5432(133MHz)

Proprietary

C) Controller
Memory

Up to 8Mb

16Mb

16Mb

32Mb

Online
Replacement

Yes

Yes

Yes

Yes

Yes

Online
Configuration

Yes

Yes

Yes

Yes

Yes

System Memory

User Defined

User Defined

User Defined

User Defined

User Defined

I/O capacity

>10000 tags posible

Sutable for large

plant

only for medium

plant

Up to 100000 I/O

only for medium

plant

10

Web Connection

Possible with
isolation

Possible with
isolation

Possible with
isolation

Possible with
isolation

Possible with
isolation

11

Scan time<200ms

Possible

Possible

Possible

Possible

Possible

MODEL
Processor

DCS COMPARISON OF VARIOUS MODELS OF

VARIOUS COMPANIES
COMPANY
S.N
O.

FOXBORO

HONEYWELL

SIEMENS

MODEL

IA Series

Experience PKS

TPS with gus

Teleperm XP

Telemerm ME

HMI
Architecture

Node Server option

Client Server

Node Server
option

Node Server

Client Server

Operating
System

Window Based

Window Based

Window Based

Window Based

DOS Based

Window NT,XP,2000

Window NT,XP,2000

Window NT

STRUK

Using Device-Net 10
Mbps

Using LAN Up to 100

Mbps

Using LCN 5
Mbps

UsingCS-272
<10Mbps

A) Power Supply

Yes

Yes

Yes

Yes

Yes

B) System Bus

Yes

Yes

Yes

Yes

Yes

C) Controller

Yes

Yes

optional with
extra

optional with
extra

optional with extra

D) I/O Module

Present in critical loop

optional with extra

optional with
extra

optional with
extra

optional with extra

E) Server

Yes

Yes

Yes

Yes

optional with extra

F)
Memory(system)

Yes

optional with extra

Yes

Yes

optional with extra

Data Bus

Redundancy

DCS COMPARISON OF VARIOUS MODELS OF

VARIOUS COMPANIES
COMPANY
S.NO
.
5

MODEL

FOXBORO

HONEYWELL

SIEMENS

IA Series

Experience PKS

TPS with gus

Teleperm XP

Telemerm ME

A) System

User Defined

User Defined

User Defined

User Defined

INTEL PII

B) Controller

N/A

C 200

N/A

Virtual Processor

INTEL
80188(20MHz)

Processor

C) Controller
Memory

4000Kb

156Kb

Online
Replacement

Yes

Yes

Yes

Yes

Yes

Online
Configuration

Yes

Yes

Yes

Yes

Yes

System Memory

User Defined

User Defined

User Defined

User Defined

User Defined

I/O capacity

Up to 100000 I/O

Up to 100000 I/O

10000 tags

10

Web Connection

Possible with
isolation

Possible with
isolation

Possible with
isolation

Possible with
isolation

N/A

11

Scan time<200ms

Possible

Possible

Possible

Possible

Possible

only for medium

plant