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In more complex pilot plants and full-scale plants, the control loops are of the order of hundreds. For such large processes, the commercial distributed control system is more appropriate. There are many vendors who provide these DCS systems such as Baily, Foxboro, Honeywell, Rosemont, Yokogawa, etc. In the following only an overview of the role of DCS is outlined.
Conceptually, the DCS is similar to the simple PC network. However, there are some differences. First, the hardware and software of the DCS is made more flexible, i.e. easy to modify and configure, and to be able to handle a large number of loops. Secondly, the modern DCS are equipped with optimization, high-performance modelbuilding and control software as options. Therefore, an imaginative engineer who has theoretical background on modern control systems can quickly configure the DCS network to implement high performance controllers.
A schematic of the DCS network is shown in figure 3. Basically, various parts of the plant processes and several parts of the DCS network elements are connected toeach others via the data highway (fieldbus). Although figure 3 shows one data highway, in practice there could be several levels of data highways. A large number of local data acquisition, video display and computers can be found distributed around the plant. They all communicate to each others through the data highway. These distributed elements may vary in their responsibilities. For example, those closest to the process handle high raw data traffic to the local computers while those farther away from the process deal only with processed data but for a wider audience.
The data highway is thus the backbone for the DCS system. It provides information to the multi-displays on various operator control panels sends new data and retrieve historical data from archival storage, and serves as a data link between the main control computer and other parts of the network.
On the top of the hierarchy, a supervisory (host) computer is set. The host computer is responsible for performing many higher level functions. These could include optimization of the process operation over varying time horizons (days, weeks, or months), carrying out special control procedure such as plant start up or product grade transition, and providing feedback on economic performance.
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