What is Distributed Control System DCS?

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.
Nowadays, distributed control system 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.

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.

You may also read: What Exactly Is A Smart Grid?

Architecture of Distributed Control System

As the name suggests, DCS has three main qualities. The first one is the distribution of
various control functions into relatively small sets of subsystems, which are of
semiautonomous, and are interconnected through a high speed communication bus.
Some of these functions include data acquisition, data presentation, process control,
process supervision, reporting information, storing and retrieval of information.

The second attribute of DCS is the automation of manufacturing process by integrating

advanced control strategies. And the third characteristic is the arranging the things as a
system. DCS organizes the entire control structure as a single automation system where
various subsystems are unified through a proper command structure and information flow.
These attributes of DCS can be observed in its architecture shown in the diagram below.
The basic elements comprised in a DCS include engineering workstation, operating
station or HMI, process control unit or local control unit, smart devices, and
communication system.

Engineering Workstation:
It is the supervisory controller over the entire distributed control system. It can be a PC or
any other computer that has dedicated engineering software (for example, control builder
F engineering station in case of ABB freelance distributed control system).

This engineering station offers powerful configuration tools that allow the user to perform
engineering functions such as creating new loops, creating various input and output
points, modifying sequential and continuous control logic, configuring various distributed
devices, preparing documentation for each input/output device, etc.

You may also read: What is PID Controller & How it Works?

Operating Station or HMI

This is used to operate, monitor and control plant parameters. It can be a PC or any other
monitoring device that has a separate software tool on which operator can view process
parameter values and accordingly to take control action. For instance, it is a DigiVis
software tool that can run on a simple PC-environment in case ABB DCS.
Operating stations can be a single unit or multiple units where a single unit performs
functions like parameter value display, trend display, alarming, etc. while multiple units or
PCs performs individual functions such as some PCs display parameters, some for trend
archives, some for data logging and acquiring, etc.

Process Control Unit of DCS

It is also called as a local control unit, distribution controller, or process station. A

distributed control system can consists of one or more process stations that can be
extended with different types of I/O units. These controllers consist of a powerful CPU
module, field bus or communication module with extended field bus capability and either
direct or remote connected I/Os.

The field devices like sensors and actuators are connected to I/O modules of this unit.
Some field devices can be directly connected to field bus (such as Profibus) without any
I/O module, which can be termed as smart field devices.

These units acquire the information from various sensors via input module, analyze and
process it based on the control logic implemented and sends the output signals via output
modules to have control on actuators and relays.

In case of <rel “nofollow” a href=”http://new.abb.com/control-systems/essential-

automation/freelance/controller/ac800f” target=”_blank”>ABB DCS, AC800F module
(consider, for instance) acts as process station, which is responsible for acquiring and
controlling the data from the process. This unit consists of a power supply along with CPU
section, Ethernet section, Profibus section and remote communication interface unit for
I/Os interfacing as shown in the figure where first module is AC 800F unit and other one
is remote I/O (also called as communication interface module).

YOu may also read: An Overvew of DC Drives

Communication System
The communication medium plays a major role in the entire distributed control system. It
interconnects the engineering station, operating station, process station and smart
devices with one another. It carries the information from one station to another. The
common communication protocols used in DCS include Ethernet, Profibus, Foundation
Field Bus, DeviceNet, Modbus, etc.

It is not mandatory to use one protocol for entire DCS, some levels can use one network
whereas some levels use different network. For instance, consider that field devices,
distributed I/Os and process station are interconnected with Profibus while the
communication among engineering station, HMI and process station carried though
Ethernet as shown in the figure below.

The major advantage of DCS is the redundancy of some or all levels of the control area.
Most of the cases critical processes are installed with redundant controllers and
redundant communication networks such that problem in main processing line should not
affect the monitoring and control functions because of the redundant processing section.

You may also read: Overview of AC Drives and VFD

Smart or Intelligent Devices

The intelligent field devices and field bus technology are advanced features of DCS
technology that replaces traditional I/O subsystems (I/O modules). These smart devices
embed the intelligence required for simple sensing and control techniques into the primary
sensing and actuating devices. And hence it replaces the need for a DCS controller to
perform routine sensing and control process.

These field devices can be directly connected to field bus so that sourcing of multiple
measurements to the next higher level control station is possible via digital transmission
line by eliminating extraneous hardware such as local I/O modules and controllers.

Working & Operation of DCS System

The operation of DCS goes like this; Sensors senses the process information and send it
to the local I/O modules, to which actuators are also connected so as to control the
process parameters. The information or data from these remote modules is gathered to
the process control unit via field bus. If smart field devices are used, the sensed
information directly transferred to process control unit via field bus.
 The collected information is further processed, analyzed and produces the output results
based on the control logic implemented in the controller. The results or control actions
are then carried to the actuator devices via field bus. The DCS configuring,
commissioning and control logic implementation are carried at the engineering station as
mentioned earlier. The operator able to view and send control actions manually at
operation stations.

you may also read: Power Distribution in Industries

Difference between SCADA and DCS (DCS vs SCADA)

Although both DCS and SCADA are monitoring and control mechanisms in industrial
installations, they have different goals. There exist some commonality between DCS and
SCADA in terms of hardware and its components, however, there are certain
requirements by the end applications that separates a robust and cost-effective DCS from
the viable SCADA system. Some of the differences between DCS and SCADA are listed

below.
1. DCS is process oriented, whereas SCADA is data-gathering oriented. DCS emphasizes
more on control of the process and it also consists of supervisory control level. And as
a part of doing so, it presents the information to the operator. On the other hand,
SCADA concentrates more on acquisition process data and presenting it to the
operators and control centre.
2. In DCS, data acquisition and control modules or controllers are usually located within a
more confined area and the communication between various distributed control units
carried via a local area network. SCADA generally covers larger geographical areas
 that use different communication systems which are generally less reliable than a local
area network.
3. DCS employs a closed loop control at process control station and at remote terminal
units. But in case of SCADA there is no such closed loop control.
4. DCS is process state driven where it scans the process in regular basis and displays
the results to the operator, even on demand. On the other hand, SCADA is event driven
where it does not scan the process sequentially, but it waits for an event that cause
process parameter to trigger certain actions. Hence, DCS does not keep a database of
process parameter values as it always in connection with its data source, whereas
SCADA maintains a database to log the parameter values which can be further
retrieved for operator display and this makes the SCADA to present the last recorded
values if the base station unable to get the new values from a remote location.
5. In terms of applications, DCS is used for installations within a confined area, like a
single plant or factory and for a complex control processes. Some of the application
areas of DCS include chemical plants, power generating stations, pharmaceutical
manufacturing, oil and gas industries, etc. On the other hand SCADA is used for much
larger geographical locations such as water management systems, power transmission
and distribution control, transport applications and small manufacturing and process
industries.
In spite of these major differences, the modern DCS and SCADA systems come with
common standard facilities while dealing process plant automation. However, the choice
between DCS and SCADA depends on its client and end application requirement. But if
the client choice between these two, by gaining equal requirement from the process, DCS
is the economical choice as it help to reduce the cost and offer better control

The Main difference between Neutral, Ground and Earth?

 To understand the difference between Neutral, Ground and Earth, we must understand
the need of these things first.
Neutral
Neutral is return path for an AC circuit which is supposed to carry current in normal
condition. This current may be because of many reasons, primarily because of phase
current imbalance and some time because 3rd and 5th harmonics also.
 Also read: What is the difference between Real Ground and Virtual Ground?
There may be others reasons too but the magnitude of this current is in fraction of phase
current and in few case it can be even double of phase current. So Neutral wire is always
assumed to be charged (in active circuit). This neutral wire is given to ground (by
grounding) to make the second terminal of neutral wire at zero potential.
Earth or Ground
Earth or Ground is for safety concerns against leakage or residual currents on the
system via least resistance path. While phase and neutral is connected to main power
wiring, earth may be connected to body of equipment or to any system which in normal
condition doesn’t carry current but in case of some insulation failure, is supposed to carry
some minor current.
 Also read: The purpose of Earth or Ground wire in over-Head Transmission lines.
This current is not directly coming from live or phase wire, but is from secondary links
which was not in touch with live system in normal condition. This current is usually much
lesser than main line current or phase current and mostly is in order of mA. But this
leakage current is good enough to kill someone or may risk fire. Such current are being
provided a low resistance path and sent to earth via earth wire.
Because of the difference in application we never mix grounding of neutral and earth.
However both are made grounded (of-course the process may be different). If both will
 be mixed then the earth wire which is not supposed to carry any current in normal
condition , may have some charges across and will become hazardous.

 Also Read: Grounding and Earthing Installation | Step by Step

Good to Know:
Difference between Earthing and Grounding.
There is no different between Earthing and Grounding but these are the same terms used
for Earthing or Grounding.

The Main Difference between Active and Passive Components

Active and Passive Commonest (Very Easy Explanation with Examples)

Active Components:
Those devices or components which required external source to their operation is called Active
Components.
For Example: Diode, Transistors, SCR etc…
Explanation and Example: As we know that Diode is an Active Components. So it is required
an External Source to its operation.
Because, If we connect a Diode in a Circuit and then connect this circuit to the Supply voltage.,
then Diode will not conduct the current Until the supply voltage reach to 0.3(In case of

Germanium) or 0.7V(In case of Silicon). I think you got it

Passive Components:
Those devices or components which do not required external source to their operation is called
Passive Components.
For Example: Resistor, Capacitor, Inductor etc…

Explanation and Example: Passive Components do not require external source to their
operation.
Like a Diode, Resistor does not require 0.3 0r 0.7 V. I.e., when we connect a resistor to the
supply voltage, it starts work automatically without using a specific voltage. If you understood

the above statement about active Components, then you will easily get this example.
 In other words:

Active Components:
Those devices or components which produce energy in the form of Voltage or Current are
called as Active Components
For Example: Diodes Transistors SCR etc…

Passive Components:
Those devices or components which store or maintain Energy in the form of Voltage or Current
are known as Passive Components
For Example: Resistor, Capacitor, Inductor etc…

In very Simple words;

Active Components: Energy Donor
Passive Components: Energy Acceptor
Also Passive Components are in linear and Active Components are in non linear category.
Main Difference between contactor and Starter
The magnetic starter is very similar to the magnetic contactor in design and
operation. Both have the feature of operating contacts when the coil is
energized. The important difference between contactors and starters is the
use of overload heater element in the starter. (For protect the motor from
over heating or over load protection)

A Complete Guide about Solar Panel Installation

A Complete Note on Solar Panel Installation. Calculation about No of Solar Panels,

batteries Rating / Backup time, Inverter/UPS Rating, Load and required Watts. with
Circuit Diagrams.

If you pick this post related to solar panel installation, You will be able to;
→ To calculate the no of solar panel (with rating)
→ To calculate the rating of Solar panel
→ To calculate the rating of batteries for Solar panel system
→ To calculate the back up time of batteries
→ To calculate the charging current for batteries
→ To Calculate Charging time for batteries
→ UPS Rating for load requirement and much more…
Before starting, We recommend to read this Article about Solar panel installation and
Photovoltaic Pane Selection for home.
PV: Types of Solar Panel and Which one is the best PV Panel

Now lets begin,

Suppose,
Load = 800 Watts
Inverters Rating =?
Required Backup time for batteries = 3 Hours
Required No of Solar Panel =?
No of batteries =?

Solution:
Inverter should be greater 25% than the total Load
800 x (25/100) = 200
800+200 = 1000 Watts
This is the rating of the UPS (Inverter)

Now the required Back up Time in Hours = 3 Hours

Suppose we are going to install 100Ah, 12 V batteries,
12V x 100Ah = 1200 Wh
Now for One Battery (i.e. the Backup time of one battery)
1200 Wh / 800 W = 1.5 Hours
But our required Backup time is 3 Hours.
Therefore, 3/1.5 = 2→ i.e. we will now connect two (2) batteries each of 100Ah, 12V.
If the number of batteries given, and you want to know the Backup Time for these given
batteries, then Use this formula.
1200 Wh x 2 Batteries = 2400 Wh
2400 Wh / 800 W = 3 hours.
So this is a 12 V inverter system, Now we will install two (2) batteries (each of 12V, 100 Ah) in
Parallel.

Why Batteries in Parallel, not in Series?

Because this is a 12Vinverter System, so if we connect these batteries in parallel, then the
Voltage of batteries (12 V) remains same, while it’s Ah (Ampere Hour) rating will be increase
(Remember: In parallel Connection, Voltage will be same in each wire or section, while current
will be different i.e current is additive e.g. I1+I2+I3…+In = 100Ah +100Ah = 200Ah
In Series Circuits, Current is same in each wire or section while voltage is different i.e. Voltage
is additive e.g.V1+V2+V3….Vn..
For The above system if we connect these batteries in series instead of parallel, then
The rating of batteries become V1+V2 = 24V while the current rating would be same i.e.100Ah.

We will now connect 2 batteries in parallel (each of 100Ah, 12V)

Therefore for 2 Batteries,
200 Ah 12V,
Now Required Charging Current for these two batteries.
(Charging current should be 1/10 of batteries Ah)
200Ah x (1/10) = 20A
Now the required No of Solar Panels
P = VI
P = 12V x 20 A
P = 240Watts

This is our required watts for solar panel (only for battery charging, and then battery will supply
power to the load)
Now
240W/60W = 4 Solar panels

Therefore, we will connect 4 Solar Panels (each of 60W,12V,5A) in parallel.

Circuit Diagram for the above Calculation for Solar Panel Installation

Click image to enlarge

This was only for battery Charging (and then battery will supply power to the desired Load) i.e.
for those electrical appliances, which will get power through inverter (from charged batteries)
Now suppose there is some (Directly connected to the panels through inverters (without battery)
load about 10A, which we have connect directly to the solar panel (No batteries required)
In this case, required current (20 A for Batteries Charging and 10 A for direct connected load
through Inverters during sunshine only but batteries will be also charging while panel supply
power to the direct connected load.
In this case, total current,
20A + 10 A = 30A
Now I = 30 A, then required Power
P = V x I = 12V x 30A = 360Watts
(This is for both Direct Load and Batteries Charging)
Now,
360/60W = 6
Therefore, we will Connect 6 No of Solar panels (each of 60W, 12V,5A)
And We use Charge Controller about ampere rating i.e, the charging current for 200Ah battery
is 20-22 Amperes (22A (For Battery Charging)+10A(for direct DC Load)…So we can use a
charge controller about 30-32 Amp.
Note: this calculation is base on ideal case, so it is recommended to always choose a Panel
some bigger then we need. Because when Solar Panel charges the battery so it is wasting
some power on charging too.
this is another Circuit Diagram for the above Calculation for Solar Panel Installation
Click image to enlarge

By: Engr Wasim Khan

Copyright material @ www.electricaltechnology.org/
Parallel Connection of Solar Panel and Series Connection of Batteries with Automatic
UPS System. (OR)… How To Wire Two 24V Solar Panels in Parallel with Two, 12V
Batteries in Series with Automatic UPS System (For 24 V System).

Parallel Connection of Batteries with Solar Panel

or

How to Wire 12 V Solar Panel to Two, 12V batteries ,with Automatic UPS System?
Batteries can be wired in either parallel, series or both Series-Parallel depending on your
application requirements.
Most Solar panels come in 12/24/36 etc volts.If you are using a 12V system and want to add
extra capacity to your system you will wire your batteries in parallel.
For example if you have an 120Ah (amp hour) battery you could run light bulb or fan that drew
5 amperes for 24 hours. If you added two batteries in parallel your battery bank would be able to
run the same bulb or fan for 48 hours.
 Parallel
Connection of Batteries with Solar Panel with automatic UPS system

Series Connection of Solar Panel and Parallel Connection of Batteries with Automatic
UPS System.
(OR) How To Wire Two 6V Solar Panel To Two, 12V Batteries with Automatic UPS
System.
Wiring batteries together in parallel has the effect of doubling the capacity while keeping
the voltage same because we know that Voltage in Parallel circuit is same while the current in
parallel circuit is different .
This figure shows , two 12V 300Ah batteries connected in parallel will allow you to double the
capacity, and producing 12V with 600Ah out the end.
It mean that if you are using one, 12 Volt Battery, then it will work for 300Ah. But if you are using
two 12 Volts batteries in parallel, then it will give you the same 12 Volts but for 600Ah.
So you can double the capacity of batteries to wire them in parallel.
 click image to enlarge

Series Connection
of Solar Panel and Parallel Connection of Batteries with Automatic UPS System