Introduction to Distributed Control Systems

1. Aug 23, 2015
What is legacy DCS. How it looks?

2. Aug 23, 2015
What is DCS?
• Integrates the PLCs and process controllers of a
process line.
• Enables you to manage the process as a complete
system.
• DCS lets you see the “big picture”.
• Improve the overall efficiency and quality of your
plant.
• In a process industry, DCS is a for plant activity.

3. Aug 23, 2015
What is DCS?
• Instantaneous controlling and monitoring of plant is
dominant function for DCS at the control room.
• Up to some extent, DCS is performing reporting &
analysis job for plant.

4. Aug 23, 2015
Challenges of legacy DCS?
Sharing information
from DCS - missing

5. Aug 23, 2015
What challenges does legacy DCS have?
• Proprietary communication Bus. No access to data
without software and /or hardware from the DCS
manufacturer.
• Data Output from DCS is printed on paper. Analysis of
the data becomes cumbersome and many a times
impossible task.
• Plant information cannot be made available on-line to
top executives.
• Maintenance of the proprietary spares/peripherals.
• Spares from the suppliers are exorbitantly costly.

6. Aug 23, 2015
What challenges does legacy DCS have?
• Alarms are printed continuously, leading to wastage
of stationary.
• Graphic page and the trend page print from the DCS
is costly.
• Configuration of various reports with calculations and
various layouts is a time consuming – manual.
• Lack of MIS.
• Delay in decision making process.
• Operational effectiveness – room for improvement.

7. Aug 23, 2015
What is the way to ease challenges?
Indus’ way!

8. Aug 23, 2015
What are the key benefits?
Structured information
Proposed
Un-structured information
As - is

9. Aug 23, 2015
What is the way to ease challenges? Structure it.

10. Aug 23, 2015
What are ePlant objectives?
• Fetch the data from proprietary DCS system and
store
on commercial PC thru RS232 port.
• Make the process data on-line for better monitoring of
the plant at various levels of management.
• Store the required data in database format for in-
depth analysis of the plant performance.
• Data is analyzed.
• Information is shared thru LAN / Web.
• No extra hardware required.

11. Aug 23, 2015
What are the key benefits?
Proposed
solution

12. Aug 23, 2015
What are the key benefits?
• One shot view of the plant on any PC on LAN.
• Database of plant parameters can be established for
any analysis.
• Instant POP-UP for any critical alarm to the concern
authority.
• Important graphics can be configured for various
users.
• Multi trends for data comparisons.

13. Aug 23, 2015
What are the key benefits?
• Reports of Raw material, utilities, power and finished
goods, for specific consumption analysis
• Efficiency calculations of Heat exchangers, reactors,
distillation columns etc can be configured into Excel
sheet from the data captured in structured form.

14. Aug 23, 2015
What are the subsequent benefits?
• Freedom from proprietary piracy
• Analyzed tag data can shared beyond the DCS
• Complements your efforts on information flow
• Sharing of DCS info on LAN / Web
• Information sharing at minimal cost
• Produce & publish trend analysis thru eOffice (Indus tool)
• Produce and publish the alerts to the designated
• Graphical analysis of plant information
• Operational effectiveness – leapfrog

15. Aug 23, 2015
What will make it work?
• Dedicated p4 and above PC.
• Connectivity to DCS through RS232 port.

16. Aug 23, 2015
What is its credibility?
• Bayer ABS, Gujrat – Tata Honeywell DCS
• Birla Cellulosic, Gujrat – Tata Honeywell DCS
• Godrej industries, Gujrat – Tata Honeywell DCS
Exit