DCS Configuration, hardware &

software components

Prepared By:
Janki shah
Department – C&I
CONTENT
➢ DCS
➢ DCS CONFIGURATION DIAGRAM
➢ DCS COMPONENTS
➢ GRAPHIC PHILOSOPHY
➢ REDUNDANCY PHILOSOPHY
➢ DCS FUNCTIONS
➢ INTEGRATED PACKAGES WITH DCS

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DCS (DISTRIBUTED CONTROL SYSTEM)
➢ It is a microprocessor based digital control system for
control and monitoring of the entire plant.
➢ It consists of a number of redundant controllers
distributed across functionally/ geographically separated
plant systems.
➢ The entire system of controllers is connected by a network
for communication, control and monitoring.

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DCS CONFIGURATION DIAGRAM

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DCS BASIC COMPONENTS
➢ Marshalling Cabinets
➢ System Cabinets
➢ I/O Modules
➢ Controller
➢ Data highway
➢ Operator/Engineering Stations
➢ Network printers
➢ Gateways for third party devices

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DCS BASIC COMPONENTS
MARSHALLING CABINETS

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DCS BASIC COMPONENTS
SYSTEM CABINETS

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DCS BASIC COMPONENTS
I/O MODULES

Type of Module No. of Channel Functionality

Analog 8-16
➢ Signal Conditioning
Digital 16-32 ➢ A/D Conversion
➢ Signal Validation
Thermocouple 8-16 ➢ Diagnostics
RTD 8-16 ➢ Time stamping

SOE 8-16

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DCS BASIC COMPONENTS
I/O MODULES
Concept of I/O Grouping
▪ No two-identical/ similar equipment to be grouped in
same input/ output module.
▪ Input & outputs cannot be combined in single modules
▪ Redundant instruments shall be assigned to different
cards
▪ I/O modules of one equipment & associated auxiliaries
to be located in the same racks.
▪ I/O of redundant equipment shall be assigned to
separate I/O cards.

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DCS BASIC COMPONENTS
CONTROLLER
Word Length 32 bits
No. of tags per controller 1000

Controller Loading <60%

Loop Execution Time
▪ Interlocks - 100 msec
▪ Closed Loops (fast) - 250 msec
▪ Closed Loops (slow) - 500 msec

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DCS BASIC COMPONENTS
CONTROLLER
Concept of controller segregation
▪ Redundant drive shall not be controlled by a common
controller.
▪ Inter-related controls shall be provided in one controller
▪ Failure of one function shall not affect the plant
operation or cause shut down

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DCS BASIC COMPONENTS
DATA HIGHWAY

Data highway Ethernet

Data highway speed 100 MBPS/1 GBPS

Loading <60%

Transfer to redundant
instantaneous
data highway

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DCS BASIC COMPONENTS
OPERATOR/ENGINEERING STATIONS

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DCS BASIC COMPONENTS
NETWORK PRINTERS

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DCS BASIC COMPONENTS
GATEWAY SERVERS

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GRAPHIC PHILOSPHY
➢ Process Line Colour
➢ Equipment Shape Philosophy
➢ Drive Start/Intermittent/Stop Colour
➢ Control Valve On/Intermittent/Off
➢ Faceplate
➢ Trend Display
➢ Alarm Display

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DRIVE LEVEL LOOP PLATE (SAMPLE)
APS LEVEL Face Plate
GROUP LEVEL SUB-GROUP LEVEL DRIVE LEVEL

BREAK STEP GROUP STEP SUB-GROUP STEP DRIVE

POINT SEQUENCE LOGIC SEQUENCE LOGIC SEQUENCE LEVEL
MACRO MACRO MACRO MACRO MACRO MACRO MACRO
Trend Display
Alarm Display
REDUNDANCY
Redundancy is the duplication of critical components or
functions of a system with the intention of increasing
availability of the system, usually in the form of a backup or
fail-safe.
LEVELS OF REDUNDANCY
➢ I/O card redundancy
➢ I/O bus redundancy
➢ Controller redundancy
➢ Data highway redundancy
➢ Power supply redundancy

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DCS FUNCTIONS
➢ Human Machine Interface
➢ Data Acquisition of plant parameters and status
➢ Interlock and Protection
➢ Monitoring of off-site packages at CCR
➢ Sequence of Events Recording
➢ Historical trending of parameters
➢ Alarm / Event reporting
➢ Logs and Reports
➢ Comprehensive System diagnostics

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Integrated packages with DCS

➢ Master Clock
❑ It synchronizes real time clocks of DCS and all other critical
control systems of Plant with the GPS signals received from
satellites.
➢ Large Video Screen (LVS)
❑ It is provided in control room to show critical parameters of
the Plant in Large display.
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DCS Vendors
➢ L&T AUTOMATION : MHI-Diasys Netmation
➢ EMERSON
➢ ABB
➢ HONEYWELL
➢ YOKOGAWA
➢ SIEMENS

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Questions?
THANK YOU