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development was the transmission of all plant measurements to a permanently-staffed central control room. Effectively this was the centralisation of all the localised panels, with the advantages of lower manning levels and easier overview of the process. Often the controllers were behind the control room panels, and all automatic and manual control outputs were transmitted back to plant. However, whilst providing a central control focus, this arrangement was inflexible as each control loop had its own controller hardware, and continual operator movement within the control room was required to view different parts of the process.
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installed in the 1970s and 1980s are still in use today, and there is a considerable installed base of systems in the market that are approaching the end of their useful life. Developed industrial economies in North
America, Europe, and Japan already had many thousands of DCSs installed, and with few if any new plants being built, the market for new hardware was shifting rapidly to smaller, albeit faster growing regions such as China, Latin America, and Eastern Europe.
329:
258:, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control. This is in contrast to systems that use centralized controllers; either discrete controllers located at a central control room or within a central computer. The DCS concept increases reliability and reduces installation costs by localizing control functions near the process plant, with remote monitoring and supervision.
826:" (PAS). The gaps among the various systems remain at the areas such as: the database integrity, pre-engineering functionality, system maturity, communication transparency and reliability. While it is expected the cost ratio is relatively the same (the more powerful the systems are, the more expensive they will be), the reality of the automation business is often operating strategically case by case. The current next evolution step is called
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to incorporate specific functions such as determinism and redundancy. As a result, many suppliers embraced the IEEE 802.4 networking standard. This decision set the stage for the wave of migrations necessary when information technology moved into process automation and IEEE 802.3 rather than IEEE 802.4 prevailed as the control LAN.
750:, which is now a de facto industry connectivity standard. Internet technology also began to make its mark in automation and the world, with most DCS HMI supporting Internet connectivity. The 1990s were also known for the "Fieldbus Wars", where rival organizations competed to define what would become the IEC
689:
Digital communication between distributed controllers, workstations and other computing elements (peer to peer access) was one of the primary advantages of the DCS. Attention was duly focused on the networks, which provided the all-important lines of communication that, for process applications, had
685:
Midac
Systems, of Sydney, Australia, developed an objected-oriented distributed direct digital control system in 1982. The central system ran 11 microprocessors sharing tasks and common memory and connected to a serial communication network of distributed controllers each running two Z80s. The system
586:
With the coming of electronic processors and graphic displays it became possible to replace these discrete controllers with computer-based algorithms, hosted on a network of input/output racks with their own control processors. These could be distributed around plant, and communicate with the graphic
833:
To compound the issue, suppliers were also realizing that the hardware market was becoming saturated. The life cycle of hardware components such as I/O and wiring is also typically in the range of 15 to over 20 years, making for a challenging replacement market. Many of the older systems that were
816:
As the suppliers made the transition to COTS components, they also discovered that the hardware market was shrinking fast. COTS not only resulted in lower manufacturing costs for the supplier, but also steadily decreasing prices for the end users, who were also becoming increasingly vocal over what
672:
etc.) and connected to proprietary Input/Output hardware. Sophisticated (for the time) continuous as well as batch control was implemented in this way. A more conservative approach was setpoint control, where process computers supervised clusters of analog process controllers. A workstation provided
283:
The key attribute of a DCS is its reliability due to the distribution of the control processing around nodes in the system. This mitigates a single processor failure. If a processor fails, it will only affect one section of the plant process, as opposed to a failure of a central computer which would
590:
The introduction of DCSs allowed easy interconnection and re-configuration of plant controls such as cascaded loops and interlocks, and easy interfacing with other production computer systems. It enabled sophisticated alarm handling, introduced automatic event logging, removed the need for physical
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Process control of large industrial plants has evolved through many stages. Initially, control would be from panels local to the process plant. However this required a large amount of human oversight to attend to these dispersed panels, and there was no overall view of the process. The next logical
348:
are connected over proprietary or industry standard networks, and network reliability is increased by dual redundancy cabling over diverse routes. This distributed topology also reduces the amount of field cabling by siting the I/O modules and their associated processors close to the process plant.
261:
Distributed control systems first emerged in large, high value, safety critical process industries, and were attractive because the DCS manufacturer would supply both the local control level and central supervisory equipment as an integrated package, thus reducing design integration risk. Today the
721:
As a result, suppliers also began to adopt
Ethernet-based networks with their own proprietary protocol layers. The full TCP/IP standard was not implemented, but the use of Ethernet made it possible to implement the first instances of object management and global data access technology. The 1980s
754:
standard for digital communication with field instrumentation instead of 4–20 milliamp analog communications. The first fieldbus installations occurred in the 1990s. Towards the end of the decade, the technology began to develop significant momentum, with the market consolidated around
Ethernet
812:
The impact of COTS, however, was most pronounced at the hardware layer. For years, the primary business of DCS suppliers had been the supply of large amounts of hardware, particularly I/O and controllers. The initial proliferation of DCSs required the installation of prodigious amounts of this
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business, such as
Rockwell Automation and Siemens, were able to leverage their expertise in manufacturing control hardware to enter the DCS marketplace with cost effective offerings, while the stability/scalability/reliability and functionality of these emerging systems are still improving. The
875:
Increasingly, and ironically, DCS are becoming centralised at plant level, with the ability to log into the remote equipment. This enables operator to control both at enterprise level ( macro ) and at the equipment level (micro), both within and outside the plant, because the importance of the
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Central to the DCS model was the inclusion of control function blocks. Function blocks evolved from early, more primitive DDC concepts of "Table Driven" software. One of the first embodiments of object-oriented software, function blocks were self-contained "blocks" of code that emulated analog
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Because of the shrinking hardware business, suppliers began to make the challenging transition from a hardware-based business model to one based on software and value-added services. It is a transition that is still being made today. The applications portfolio offered by suppliers expanded
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The more wireless protocols are developed and refined, the more they are included in DCS. DCS controllers are now often equipped with embedded servers and provide on-the-go web access. Whether DCS will lead
Industrial Internet of Things (IIOT) or borrow key elements from remains to be seen.
266:
and DCS systems are very similar, but DCS tends to be used on large continuous process plants where high reliability and security is important, and the control room is not geographically remote. Many machine control systems exhibit similar properties as plant and process control systems do.
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It was believed that if openness could be achieved and greater amounts of data could be shared throughout the enterprise that even greater things could be achieved. The first attempts to increase the openness of DCSs resulted in the adoption of the predominant operating system of the day:
682:
hardware control components and performed tasks that were essential to process control, such as execution of PID algorithms. Function blocks continue to endure as the predominant method of control for DCS suppliers, and are supported by key technologies such as
Foundation Fieldbus today.
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hardware, most of it manufactured from the bottom up by DCS suppliers. Standard computer components from manufacturers such as Intel and
Motorola, however, made it cost prohibitive for DCS suppliers to continue making their own components, workstations, and networking hardware.
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integrated into the DCS infrastructure. Plant-wide historians also emerged to capitalize on the extended reach of automation systems. The first DCS supplier to adopt UNIX and
Ethernet networking technologies was Foxboro, who introduced the I/A Series system in 1987.
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traditional DCS suppliers introduced new generation DCS System based on the latest
Communication and IEC Standards, which resulting in a trend of combining the traditional concepts/functionalities for PLC and DCS into a one for all solution—named "
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The DCS largely came about due to the increased availability of microcomputers and the proliferation of microprocessors in the world of process control. Computers had already been applied to process automation for some time in the form of both
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as the final control element. The DCS sends the setpoint required by the process to the controller which instructs a valve to operate so that the process reaches and stays at the desired setpoint. (see 4–20 mA schematic for example).
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affect the whole process. This distribution of computing power local to the field Input/Output (I/O) connection racks also ensures fast controller processing times by removing possible network and central processing delays.
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A DCS control room where plant information and controls are displayed on computer graphics screens. The operators are seated as they can view and control any part of the process from their screens, whilst retaining a plant
739:(COTS) components and IT standards. Probably the biggest transition undertaken during this time was the move from the UNIX operating system to the Windows environment. While the realm of the real time operating system (
607:, for example, was an early computer that had input/output hardware to gather process signals in a plant for conversion from field contact levels (for digital points) and analog signals to the digital domain.
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records such as chart recorders, allowed the control racks to be networked and thereby located locally to plant to reduce cabling runs, and provided high level overviews of plant status and production levels.
466:
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Large oil refineries and chemical plants have several thousand I/O points and employ very large DCS. Processes are not limited to fluidic flow through pipes, however, and can also include things like
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considerably in the '90s to include areas such as production management, model-based control, real-time optimization, plant asset management (PAM), Real-time performance management (RPM) tools,
718:. UNIX and its companion networking technology TCP-IP were developed by the US Department of Defense for openness, which was precisely the issue the process industries were looking to resolve.
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microprocessors, while the front end ran eleven Z80s in a parallel processing configuration with paged common memory to share tasks and that could run up to 20,000 concurrent control objects.
743:) for control applications remains dominated by real time commercial variants of UNIX or proprietary operating systems, everything above real-time control has made the transition to Windows.
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introduced their own DCS system called Damatic (latest generation named Valmet DNA). In 1980, Bailey (now part of ABB) introduced the NETWORK 90 system, Fisher Controls (now part of
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introduced their own independently produced DCS's - TDC 2000 and CENTUM systems, respectively. US-based Bristol also introduced their UCS 3000 universal controller in 1975. In 1978
352:
The processors receive information from input modules, process the information and decide control actions to be signalled by the output modules. The field inputs and outputs can be
755:
I/P, Foundation Fieldbus and Profibus PA for process automation applications. Some suppliers built new systems from the ground up to maximize functionality with fieldbus, such as
1207:"Siemens - SIMATIC PCS 7 - SIMATIC PCS 7 (SIMATIC, PCS 7, process control system, SIMATIC PCS7, Add Ons, solutions for industry, process automation, process industry)"
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DCSs in very high reliability applications can have dual redundant processors with "hot" switch over on fault, to enhance the reliability of the control system.
842:, and many others. To obtain the true value from these applications, however, often requires a considerable service content, which the suppliers also provide.
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Level 3 is the production control level, which does not directly control the process, but is concerned with monitoring production and monitoring targets
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Level 2 contains the supervisory computers, which collect information from processor nodes on the system, and provide the operator control screens.
36:
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Levels 1 and 2 are the functional levels of a traditional DCS, in which all equipment are part of an integrated system from a single manufacturer.
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visibility into the process using text and crude character graphics. Availability of a fully functional graphical user interface was a way away.
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A pre-DCS era central control room. Whilst the controls are centralised in one place, they are still discrete and not integrated into one system.
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DCS was completed by the Australian business Midac in 1981–82 using R-Tec Australian designed hardware. The system installed at the
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1079:"Group History | Azbil Corporation Info | About the azbil Group | Azbil Corporation (Former Yamatake Corporation)"
108:
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used a serial communications network, connecting campus buildings back to a control room "front end". Each remote unit ran two
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Distributed control systems (DCS) are dedicated systems used in manufacturing processes that are continuous or batch-oriented.
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Example of a continuous flow control loop. Signalling is by industry standard 4–20 mA current loops, and a "smart"
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Level 1 contains the industrialised Input/Output (I/O) modules, and their associated distributed electronic processors.
891:. With these interfaces, the threat of security breaches and possible damage to plant and process are now very real.
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applications. Recent research focuses on the synthesis of optimal distributed controllers, which optimizes a certain
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The accompanying diagram is a general model which shows functional manufacturing levels using computerised control.
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The introduction of Microsoft at the desktop and server layers resulted in the development of technologies such as
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The first industrial control computer system was built 1959 at the Texaco Port Arthur, Texas, refinery with an
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In the 1980s, users began to look at DCSs as more than just basic process control. A very early example of a
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Level 0 contains the field devices such as flow and temperature sensors, and final control elements, such as
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703:
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D'Andrea, Raffaello (9 September 2003). "Distributed Control Design for Spatially Interconnected Systems".
984:
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653:, (now part of ABB) developed the 1010 system, Foxboro the FOX1 system, Fisher Controls the DC system and
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or two-state signals that switch either "on" or "off", such as relay contacts or a semiconductor switch.
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The drive toward openness in the 1980s gained momentum through the 1990s with the increased adoption of
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Although 4–20 mA has been the main field signalling standard, modern DCS systems can also support
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they perceived to be unduly high hardware costs. Some suppliers that were previously stronger in the
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Stout, T. M.; Williams, T. J. (1995). "Pioneering Work in the Field of Computer Process Control".
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physical location drops due to interconnectivity primarily thanks to wireless and remote access.
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641:(now also part of ABB) introduced DCI-4000 (DCI stands for Distributed Control Instrumentation).
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1014:"Distributed Control for Identical Dynamically Coupled Systems: A Decomposition Approach"
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the 1055 systems. All of these were DDC applications implemented within minicomputers (
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were used in the control of industrial processes since the beginning of the 1960s. The
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Eloranta, Veli-Pekka; Koskinen, Johannes; Leppänen, Marko; Reijonen, Ville (2014).
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system. Fieldbus technics have been used to integrate machine, drives, quality and
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in the traditional sense, but where production control and scheduling takes place.
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Distributed control plane for safe cooperative vehicular cyber physical systems
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display in the control room or rooms. The distributed control system was born.
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to control the flow of material through the plant. A typical application is a
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1158:"ABB System 800xA - process, electrical, safety, telecoms in one system"
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The latest developments in DCS include the following new technologies:
783:
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1259:." IET Cyber-Physical Systems: Theory & Applications, Oct. 2019 ).
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Designing distributed control systems: a pattern language approach
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Many vendors provide the option of a mobile HMI, ready for both
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digital protocols, such as Foundation Fieldbus, profibus, HART,
954:. Wiley series in software design patterns. Chichester: Wiley.
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27:
Computerized control systems with distributed decision-making
1127:
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790:, Forbes Marshall with the Microcon+ control system and
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with System 800xA, Emerson Process Management with the
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Functional levels of a manufacturing control operation
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DCSs are connected to sensors and actuators and use
809:applications to one DCS with Valmet DNA system.
264:Supervisory control and data acquisition (SCADA)
649:(DDC) and setpoint control. In the early 1970s
686:was installed at the University of Melbourne.
1147:Foxboro I/A Series Distributed Control System
447:Processes where a DCS might be used include:
223:
8:
921:Plant process and emergency shutdown systems
309:Level 4 is the production scheduling level.
230:
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31:
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625:and Japanese electrical engineering firm
254:for a process or plant usually with many
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828:Collaborative Process Automation Systems
731:The application-centric era of the 1990s
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1053:IEEE Annals of the History of Computing
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578:Evolution of process control operations
383:and their associated quality controls,
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151:
95:
59:
43:
1018:IEEE Transactions on Automatic Control
977:IEEE Transactions on Automatic Control
1281:Applications of distributed computing
7:
694:The network-centric era of the 1980s
1012:Massiaoni, Paolo (1 January 2009).
25:
344:The processor nodes and operator
926:Safety instrumented system (SIS)
637:) introduced the PROVoX system,
371:fed by a flow meter and using a
316:Levels 3 and 4 are not strictly
51:
866:Mobile interfaces and controls
436:or the H 2 control criterion.
1:
846:Modern systems (2010 onwards)
748:OLE for process control (OPC)
485:Environmental control systems
152:Information and communication
863:, logging and data historian
639:Fischer & Porter Company
358:4–20 mA DC current loop
1302:
1177:Emerson Process Management
777:Emerson Process Management
467:quality control system QCS
290:Referring to the diagram;
244:distributed control system
1255:F. Foukalas and P. Pop, "
916:Industrial control system
824:Process Automation System
722:also witnessed the first
651:Taylor Instrument Company
424:Modern DCSs also support
1030:10.1109/tac.2008.2009574
737:commercial off-the-shelf
526:Automobile manufacturing
999:10.1109/tac.2003.816954
786:with the SPPA-T3000 or
704:University of Melbourne
96:Industrial technologies
857:systems and protocols
700:Direct Digital Control
647:direct digital control
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1286:Industrial automation
571:
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389:motor control centers
385:variable speed drives
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60:Manufacturing methods
18:Decentralized control
870:Embedded web-servers
807:condition monitoring
666:Varian Data Machines
480:Nuclear power plants
472:Boiler controls and
463:Pulp and paper mills
459:(oil) and refineries
440:Typical applications
250:) is a computerized
1276:Control engineering
1129:Foundation Fieldbus
906:Building automation
861:Remote transmission
340:operates correctly.
88:Agile manufacturing
1192:2018-02-03 at the
623:Yamatake-Honeywell
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346:graphical displays
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83:Lean manufacturing
1246:Azbil Corporation
1065:10.1109/85.366507
961:978-1-118-69415-2
901:Annunciator panel
792:Azbil Corporation
767:& Plantscape
759:PlantPAx System,
397:mining operations
262:functionality of
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502:Sewage treatment
490:Water management
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403:facilities, and
365:setpoint control
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1162:www.abb.com
1059:(1): 6–18.
1024:: 124–135.
795: [
677:Development
549:Agriculture
474:power plant
465:(see also:
430:fuzzy logic
405:many others
1270:Categories
1217:2007-03-29
1196:SPPA-T3000
1096:Valmet DNA
937:References
518:fertilizer
434:H-infinity
985:CiteSeerX
801:with the
771:systems,
761:Honeywell
618:Company.
573:overview.
507:Food and
271:Structure
175:IEC 62264
134:Six Sigma
1190:Archived
1141:Archived
1118:DCI-4000
1038:14384506
895:See also
855:Wireless
765:Experion
757:Rockwell
752:fieldbus
627:Yokogawa
605:IBM 1800
415:fieldbus
37:a series
35:Part of
1107:INFI 90
885:Android
784:Siemens
670:MODCOMP
614:of the
595:Origins
556:History
492:systems
476:systems
1036:
987:
958:
780:DeltaV
662:PDP-11
631:Valmet
612:RW-300
599:Early
545:plants
504:plants
498:plants
419:modbus
165:ISA-95
160:ISA-88
1034:S2CID
931:TANGO
911:EPICS
799:]
769:SCADA
763:with
356:e.g.
204:SCADA
179:B2MML
956:ISBN
887:and
741:RTOS
724:PLCs
716:UNIX
516:and
428:and
387:and
1061:doi
1026:doi
995:doi
889:iOS
819:PLC
773:ABB
708:Z80
659:DEC
248:DCS
199:DCS
194:PLC
170:ERP
139:TQM
129:TOC
124:QRM
119:VDM
114:TPM
109:RCM
104:PLM
1272::
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1087:^
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