ASSIGNMENT # 4

“Industrial Control Systems of DCS, SCADA and PLC”

Submitted To-

Engr. Dr. Sadiq Hussain

Submitted By-

Muhammad Abdullah (2k17-che-202)

Section-

Subject-

Instrumentation & Process Control

Department of Chemical Engineering

NFC IET MULTAN

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TABLE OF CONTENTS

1. Introduction of DCS……………………………………………3
2. Basic Elements of DCS………………………………………...4
3. Advantages of DCS…………………………………………….5
4. Introduction of SCADA………………………………………..6
5. Basic Elements of SCADA…………………………………….6
6. Advantages of SCADA………………………………………...8
7. Introduction of PLC…………………………………………….9
8. Elements of PLC………………………………………………..10
9. Advantages of PLC…………………………………………….11
10. How does DCS differs from PLC……………………….11
11. Difference between DCS and SCADA…………………..12
12. References………………………………………………..12

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 1. Introduction of DCS
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.

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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.

2. Basic Elements of Distributed Control System

Distributed Control System continuously interacts with the processes in process control
applications ones it gets instruction from the operator. It also facilitates variable set points and
opening and closing of valves for manual control by the operator. Its human-machine interface
(HMI), faceplates, and trend display give the effective monitoring of industrial processes.

I. Engineering PC or controller
This controller is the supervisory controller over all the distributed processing
controllers. Control algorithms and configuration of various devices are executed in this
controller. Network communication between processing and engineering PC can be
implemented by a simplex or redundant configurations.

II. Distributed controller or Local control unit

It can be placed near to field devices (sensors and actuators) or certain locations where
these field devices are connected via the communication link. It receives the instructions from
the engineering station like set point and other parameters and directly controls field devices.

It can sense and control both analog and digital inputs/outputs by analog and digital I/O
modules. These modules are extendable according to the number of inputs and outputs. It
collects the information from discrete field devices and sends this information to operating and
engineering stations.

In the above figure, AC 700F and AC 800Fcontrollers act as a communication interface

between field devices and engineering stations. Most of the cases these act as local control for
field instruments.

III. Operating station or HMI

It is used to monitor entire plant parameters graphically and to log the data in plant
database systems. The trend display of various process parameters provides effective display
and easy monitoring.

These operating stations are of different types such as some operating stations (PCs) used to
monitor only parameters, some for only trend display, some for data logging, and alarming
requirements. These can also be configured to have control capabilities.

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IV. Communication media and protocol
Communication media consists of transmission cables to transmit the data such as coaxial
cables, copper wires, fiber optic cables and sometimes it might be wireless. Communication
protocols selected depend on the number of devices to be connected to this network.
For example, RS232 supports only for 2 devices and Profibus for 126 devices or nodes. Some
of these protocols include Ethernet, DeviceNet, the foundation filed bus, Modbus, CAN, etc.

In DCS, two or more communication protocols are used between two or more areas such as
between field control devices and distributed controllers and another one between distributed
controllers and supervisory control stations such as operating and engineering stations.

3. Advantages of DCS

 Expedite commissioning and start-up

 Increase production capacity
 Improve reproducibility of processes
 Decrease process and quality variability
 Improve long-term stability and consistency
 Optimize paperless operation
 Simplify configuration of continuous and batch control
 Streamline application development and verification
 Minimize downtime
 Lower maintenance costs
 Reduce lifecycle costs
 Expedite payback on investments

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 4. Introduction to SCADA
SCADA is an acronym that stands for Supervisory Control and Data Acquisition.
SCADA refers to a system that collects data from various sensors at a factory, plant or in other
remote locations and then sends this data to a central computer which then manages and
controls the data.

SCADA systems are used not only in industrial processes: e.g. steel making, power
generation (conventional and nuclear) and distribution, chemistry, but also in some
experimental facilities such as nuclear fusion. The size of such plants range from a few 1000
to several 10 thousands input/output (I/O) channels. However, SCADA systems evolve rapidly
and are now penetrating the market of plants with a number of I/O channels.

“A collection of equipment that will provide an operator at remote location with enough
information to determine the status of a particular piece of an equipment or entire substation
and cause actions to take place regarding the equipment or network.”

5. Basic Components of SCADA System

A basic SCADA system consists of following components:

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 I. Human Machine Interface
II. Supervisory System
III. Remote Terminal Units
IV. Programmable Logic Controllers (PLCs)
V. Communication Infrastructure
VI. SCADA Programming

I. Human Machine Interface

It is an I/O device that allows a human operator to control the process data. This is
achieved by linking SCADA’s databases and software programs for providing management
information like detailed schematics, scheduled maintenance, data diagnostics and logistic
information. The operating personnel can also see the graphical representation of data.

II. Supervisory System

This system acts as a communication server between the HMI software in control room
workstations and its equipment like PLCs, RTUs, sensors etc.

Smaller Supervisory Control and Data Acquisition systems have only a single PC that serves
as a supervisory or master system. Larger Supervisory Control and Data Acquisition systems
have multiple servers, sites for disaster recovery and distributed software applications. The
servers are configured as dual-redundant or hot-standby formation for continuously monitoring
server failure.

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III. Remote Terminal Units
This system contains physical objects that are interfaced with Remote Terminal Units
(RTUs). These electronic devices are controlled by microprocessors and are used for
transmitting recorded data to the supervisory systems. They also receive data from the master
system in order to control the connected objects. They are also called as Remote Telemetry
Units.

IV. Programmable Logic Controllers

PLCs find their use in the Supervisory Control and Data Acquisition system through
sensors. They are attached to the sensors in order to convert the sensor output signal into digital
data. They are preferred over RTUs because of their configuration, flexibility, affordability and
versatility.

V. Communication Infrastructure
Generally, a combination of direct wired connection and radio is used in Supervisory
Control and Data Acquisition systems. However, SDH/ SONET can also be used for larger
systems like railways and power stations. Among the compact SCADA protocols, few
recognized and standardized protocols deliver information only when the RTUs are polled by
the supervisory station.

VI. SCADA Programming

SCADA programming in HMI or master station is used for creating diagrams and maps
that provide vital information during process or event failure. Most of the commercial
Supervisory Control and Data Acquisition systems use standardized interfaces in
programming. C language or derived programming language is generally used for such
programming.

6. Advantages of SCADA System

The advantages of Supervisory Control and Data Acquisition system include:

 Improvement in Service Quality

 Improvement in Reliability
 Reduction in operation and maintenance costs
 Easy to monitor large system parameters
 Real time information on demand
 Reduction in Manpower
 Value added services
 Ease in Fault Detection and Fault Localization (FDFL)
 Reduction in Repair Time (System Down Time)
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 7. Introduction of PLC
A PLC is an industrial-grade digital computer designed to perform control functions
especially for industrial applications. The majority of PLCs today are modular, allowing the
user to add an assortment of functionality including discrete control, analog control, PID
control, position control, motor control, serial communication, and high-speed networking.
Compared to older technologies, the PLC is easier to troubleshoot, more reliable, more cost-
effective, and far more versatile.

Programming Logic Controller (PLC)

PLC Working Schematic

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8. Basic Elements of PLC
(1) Power supply:
The power supply converts facility electrical distribution voltage, such as 230 VAC, 120
VAC or 125 VDC to signal level voltage used by the plc processor and other modules.

(2) Processor:
The processor module contains the microprocessor that performs control functions and
computations, as well as the memory required to store the program.

(3) Input/Output (I/O):

These modules provide the means of connecting the processor to the field devices.
Examples of these modules are Analog Input Module, Analog output module, Digital input
module, Digital output module etc.

These are used to connect devices between plc and field devices like flow transmitters,
pressure transmitters, control valves, analyzers, substation feeders for motor control etc.

(4) Communication:
Communications modules are available for a wide range of industry-standard
communication network connections. These allow digital data transfer between PLCs and
to other systems within the facility.

Most commonly used modules are Modbus communication cards or Serial communication.

Some PLCs have communications capability built-in to the processor, rather than using
separate modules.

(5) Communication Media and Protocols:

The most common communication media used are copper-wire, coaxial, fiber-optics, and
wireless. The most common “open” communication protocols are Ethernet, Ethernet/IP,
and DeviceNet.

“Open” systems generally provide “plug and play” features in which the system software
automatically recognizes and communicates to any compatible device that is connected to
it.

Other widely accepted open protocols are Modbus, Profibus, and ControlNet.

(6) Redundancy:
Many PLCs are capable of being configured for redundant operation in which one processor
backs up another.

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 This arrangement often requires the addition of a redundancy module, which provides
status confirmation and control assertion between the processors. In addition, signal wiring
to redundant racks is an option.

9. Advantages of PLC

 They are user friendly and easy to operate

 They eliminate the need for hard-wired relay logic
 They are fast
 It is suitable for automation in industries.
 Its input and output modules can be extended depending upon the requirements

10. How does a DCS Differ from a PLC?

A PLC is a single, recognizable piece of hardware, so it’s a natural tendency to compare the
two items — after all, they both provide an advanced level of control for machinery…

The concept of a PLC is to provide control at a local level for just a single machine or cluster
of a few machine centers. In this system structure, the control program is stored within just one
controller for each part of a larger system. Often, there is very little redundancy, unless you
have multiple PLCs.

These days, it’s very common for a PLC system to be upgraded with remote I/O, expanded to
many machines with multiple HMIs and VFDs to monitor and control entire processes. This
level of implementation starts to become much more similar to a DCS.

In fact, we really don’t call this type of control a PLC anymore. This is called a process
automation controller or PAC — such as a Rockwell ControlLogix system, or a Siemens S7-
1500 system. Even a small modern PLC can easily control remote automation elements,
making it an effective PAC as well.

The main difference remains that in the case of a DCS, the control of the system is performed
at a higher level than in the I/O controller itself. The distributed I/O only exists to read system
information and control outputs. Then all information is routed back to the main controller,
with levels of redundancy to reduce downtime risks and provide easier control modifications
when needed.

In these systems, the I/O modules, the networking adapters, the servers and computers, and
finally the software suites to control everything are all provided from the same manufacturer
to ensure compatibility.

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11. Difference between SCADA and DCS (DCS vs
SCADA)

I. 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 center.
II. 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.
III. 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.

12. References:

"PLC Programming Basics Part I". Control Systems & Automation. 2019-07-23.
Retrieved 2020-02-23.
Keller, William L Jr. Grafcet, A Functional Chart for Sequential Processes, 14th Annual
International Programmable Controllers Conference Proceedings, 1984, p. 71-96
Boyes, Walt (2011). Instrumentation Reference Book, 4th Edition. USA: Butterworth-
Heinemann. p. 27. ISBN 978-0-7506-8308-1
D'Andrea, Raffaello (9 September 2003). "Distributed Control Design for Spatially
Interconnected Systems". IEEE Transactions on Automatic Control. 48 (9): 1478–
1495. CiteSeerX 10.1.1.100.6721. doi:10.1109/tac.2003.816954.

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