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A distributed control system (DCS) refers to a control system of a process plant and
industrial process wherein control elements are not only located in central location (like the
brain) but are also distributed throughout the system with each component sub-system
controlled by one or more controllers so the intelligence is distributed across the sections of
the plant. DCS follows hierarchy in its control philosophy with various function spread
across.
DCS (Distributed Control System) is a computerized control system used to automate
processes in various industries. (https://www.youtube.com/watch?v=EkXcUfeFyIM)
BRIEF HISTORY OF DCS
Because of the reliability problems and high cost of the control process computer systems of
the 1960s, there were few new process computer projects in the early 1970s. The rare
projects that were started in this period were based on medium-priced minicomputers that
were designed to be small in size. At the same time, two developments occurred in
electronics that profoundly changed the application of digital computers to process control.
The first was the development of integrated circuits and microprocessors. The second was
the release of the distributed control system (DCS) by Honeywell in 1969. This new design
concept was based on the idea of widely distributing the control to computer modules. Each
of these modules controlled several instrument loops, generally one to four. They
were connected by a single high-speed data communications link, called a data highway that
made possible communications between each of the computer modules and the central
operator console. This design allowed the operator to monitor the operation of each local
process.
In the mid-1970s, microprocessor-based modules replaced hardwired computer modules.
The typical DCS had the configuration shown in Figure1. Todays distributed control systems
are much more powerful and faster than the first systems because of improvements in
microprocessors and other electronic circuits.
Distributed control systems today consist of one or more levels of control and information
collection, as shown in Figure 2. The lowest level is process control and measurement on
the plant floor. At this level, microprocessor- based controllers such as programmable
controllers execute loop control, perform logic functions, collect and analyse process
data, and communicate with other devices and to other levels in the system.
In Figure 2, the process data collected at level 1 is transferred to level 2. At this level,
process operators and engineers use operator consoles that have a keyboard, mouse, and
video display to view and adjust the various processes being controlled and monitored by
the system. Also, at level 3, process and control engineers implement advanced control
functions and strategies, and members of the operations management team
perform advanced data collection and analysis on process information. The various plant
management systemssuch as inventory management and control, billing and invoicing,
and statistical quality controlexist at level 3. The highest level (level 4) is used in large
industrial plants to provide corporate management with extensive process and operations
information.