Many Possibilities
Today’s DCS technology not only performs its primary regulatory control function as well as or more reliably than its proprietary predecessor, but by incorporating commercially available technology, it also enables far greater flexibility.
An example of this flexibility is in simulation. In the past, if a user wanted a simulator as a training tool for operators, the only option was to acquire controllers and workstations identical to those employed in his system. Over time, with hardware upgrades or system expansions, the only way to keep the simulation realistic was to invest in duplicate hardware for the simulator. With the adoption of PC architecture for DCS controllers, it is now possible to create a virtual simulator, where the actual DCS application software can reside on a desktop PC and one PC can emulate up to 20 DCS controllers. This makes the simulator easier and less expensive to maintain, resulting in a far more flexible and valuable asset.
Along with that inherent flexibility of the modern DCS platform is the vastly increased computing power of current computer technology that offers a host of enhancements that have altered the nature and expectations of plant operations. Traditional functions such as process trending, alarming, logging, and historical data collection have become not only easier to accomplish but also easier to share beyond the control room, making the DCS an integral part of the corporate IT infrastructure. With enhanced data collection, management, and analysis capabilities inherent in a more-powerful platform, opportunities for process improvement within a unit, a plant, and even a fleet become easier to identify and to implement (Figure 3).
3. More zeros over time. The evolution of the DCS. Source: Emerson Power & Water Solutions
Smart Computing
The DCS platform is not alone in capitalizing on the advancements driven by the desktop computing industry. Over the past decade, low-cost, yet powerful, microchips have become fully integrated components in field devices such as transmitters and actuators. Among other features, these "smart" devices can measure and report more than one variable from the process while also providing that data at much higher resolution than is possible with conventional field devices. In addition, they constantly perform self-diagnostics and report on their health, alerting operators to emerging problems before they affect the process.
These smart devices can exist on conventional 4-20 mA twisted pair, or on a fieldbus network that allows multiple devices to reside on a single digital communication bus, as opposed to the older home-run concept of "one device, one wire." Fieldbus architecture enables significant savings in wiring costs for new plants or new control areas over the high cost of traditional device wiring.
Smart devices can also be wireless. In the past several years, wireless field devices have proven themselves in a number of applications, where they enable the gathering of direct process measurements from remote locations without the expense of wiring.
A similar revolution is taking place in diagnostics technology, which was once reserved for major capital equipment. Today, the cost of diagnostic and monitoring devices such as heat or vibration monitors has decreased significantly, making it cost-effective to install them to closely monitor the performance and health of critical plant equipment and to identify negative trends before they affect operations.
The additional wealth of data from field sensors, actuators, and diagnostic equipment leads to another significant development: plantwide asset management systems as an integral component of the DCS architecture. This plantwide asset management concept goes beyond the traditional DCS status alarm concept and allows for detailed and coordinated analysis of plant assets and operations permitting proactive, not just reactive, response to plant conditions (Figure 4).
4. Emerging trends. DCS technology will continue to evolve in response to technology advances such as integrated simulation, high-performance digital bus architecture, wireless applications, cyber-security concerns, and more-capable and robust software applications. Source: Emerson Power & Water Solutions
Another trend that has emerged in the past decade that will grow in importance with the availability of a rich stream of data is intelligent process optimization. Utilizing advanced mathematical techniques such as fuzzy logic, these "smart" applications seek to continuously track actual plant operating conditions, learn as they accumulate experience, and then adjust process setpoints to optimize production based on a defined goal. Such advanced techniques have already been successfully employed in a number of areas, such as NOx optimization, where they help utilities balance emissions against limits or credits available. Currently, even more advanced mathematical models are being applied that take optimization even further, including models that mimic biological responses, such as immune system response.
Along with all the benefits and increased capability of open-system technologies come increased demands for managing those systems. Most significant among those demands is the requirement for increased attention to system security. Although the North American Electric Reliability Corp. Critical Infrastructure Protection standards provide a framework for system security efforts, is vital that users and suppliers work together in implementing security programs that prevent both intentional and unintentional threats to system integrity.
--Robert Yeager (robert.yeager@emerson.com) is president of the Power & Water Solutions division of Emerson Process Management.
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