¿Cómo se coordinan y sincronizan las acciones y estrategias de control en múltiples sistemas? (2024)

DCS integration depends at what level you are integrating with. It can start from Level 1 with third party control system to Level 4 with advanced solution suites for analytics, MES etc.Common in all these is cybersecuirty aspect which should be taken into account based on the data flow.Apart from this using open protocols like OPC UA DA/HDA/A&E makes life easier for all parties without compromising security aspects.Also sticking to same vendor has their own merits and demerits with tight integrarion reducing the large portion of man hours for interoperatability testing, network reliabiltiy, data quality issues etc.

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To advance in this area, professionals can contribute by sharing practical experiences, research and development, solutions to specific problems, participating in discussions and promoting security awareness. These contributions can drive the progress and effectiveness of DCS integration, benefiting the community of professionals involved in this area.

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Below tips maybe helpful to navigate the DCS integration challenges effectively:- prioritize compatibility checks- ensure data quality through robust protocols- Better network reliability- implement rigorous cybersecurity plan- Try reading data only means for monitoring (controlling should be done locally)This proactive approach not only mitigates risks but also maximizes the substantial benefits of DCS integration.

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First, a centralized control system is established to oversee all subsystems. This system is responsible for coordinating the actions of each subsystem based on a set of predefined rules or algorithms. Second, communication protocols are established to ensure that each subsystem can effectively communicate its status and receive instructions from the centralized control system. Third, synchronization mechanisms are implemented to ensure that all subsystems operate in harmony. This can involve time synchronization, state synchronization, or both. Finally, feedback loops are used to continuously monitor and adjust the system’s performance. This allows the system to adapt to changes and ensure optimal performance.

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Creating a validation master plan will help setup a strategy on how to integrate various pieces of manufacturing equipment into a DCS.

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Interoperability is crucial for optimizing industrial operations, enabling seamless communication between systems and fostering flexibility, scalability, and innovation. In addition to technical challenges such as lack of standards and system complexity, human factors like resistance to change and concerns about cybersecurity must be addressed. Investing in standards, technologies, practices, and appropriate training is essential to ensure robust and reliable interoperability, driving efficiency in DCS.

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In my experience each DCS system typically has its own proprietary network topologies and protocols enabling native integration of OEM controllers and other nodes. Also this reduces the network being open to cyber requirements due to closed technology. The DCS integration should be always at level 3 or above using high level open and secure protocols like OPC UA etc. Also as experienced engineer, criticial infrastructure using control systems should never be opened to external networks and should be avoided at any cost to reduce risks. Integration can also be done using other open protocols like profinet, Ethernet/IP, IEC 60870/61850 etc. Also using new open time sensitive network topologies also reduces the integration testing req.

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Identify the needs of each system being considered for support and choose a DCS platform that provides the maximum value by supporting the most relevant functional needs by each system. This will facilitate the maximum ability to standardize systems with a single platform and align strategies using a single vendor. This can be achieved by having a good understanding of basic measurement, control, display, and data acquisition engineering fundamentals and the selection of a vendor with a large and stable market share.

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In traditional implementations, one of the DCS's is updated with the tag data from all the systems to maintain synchronous behavior. In recent implementations, the same task is done using multiple structured databases which are updated at a very high frequency. In future runtime variables might be fetched from a Unified namespace. The key to the design decision here is the speed and bandwidth of the communication interface.

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To deepen understanding, we need to detail the advantages and disadvantages of each coordination method (centralized, decentralized and hybrid) within the scope of the Distributed Control System (DCS). This analysis can be based on case studies and simulations that empirically demonstrate the benefits and challenges of different coordination approaches in real situations. Furthermore, exploring new coordination strategies or algorithms could further enhance the performance and efficiency of the DCS, especially in contexts that demand more adaptable and effective solutions.

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DCS synchronization has multiple aspects that needs to tied in together for an effective operation.Starting with time synchronization using NTP or old school time reset trigger bit from master clock device to all slave devices.But new protocols like PTP provides more accuracy when working with SIS systems with 1msec time stamping.Time stamping of device should happen at controller and optionally at IOM level and event collected should be displayed rather than time stamping at server level. If multiple servers are used these servers should have master event database.

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Time Synchronization may not be a challenge for small plants or if they are not relying on reports generated by other systems than DCS.But if it's critical then use of NTP Server along with NTP Clients will resolve the issue.

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In the area of distributed control systems (DCS), synchronization is like the rhythm in an orchestra: it's what keeps all the instruments playing together, harmoniously. It is crucial because in industrial environments, such as factories, each process needs to be perfectly coordinated to ensure safety and efficiency. To achieve this, we use precise communication protocols and timing systems to ensure all parties are in sync. This allows us to control processes in real time and integrate different systems smoothly and efficiently.

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In the area of distributed control systems (DCS), synchronization is like the rhythm in an orchestra: it's what keeps all the instruments playing together, harmoniously. It is crucial because in industrial environments, such as factories, each process needs to be perfectly coordinated to ensure safety and efficiency. To achieve this, we use precise communication protocols and timing systems to ensure all parties are in sync. This allows us to control processes in real time and integrate different systems smoothly and efficiently.

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Considering the crucial importance of efficient integration and fluid operation of the Distributed Control System (DCS), it is imperative to adopt best practices. I fully agree with the need to establish clear objectives, select compatible hardware/software, and use appropriate protocols to facilitate interoperability. Furthermore, the idea of implementing flexible control architectures, performing regular system testing and preventative maintenance seems to be a sensible approach to ensure continuous and reliable operation of the DCS. Without a doubt, investing in team training is essential to ensure effective operations and maximize the benefits of DCS integration.

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There are 03 prominent challenges:1) Failure to update software/hardware to their latest versions because of budget issues.2) Additionally, in regions like Africa and Asia, a notable issue is the tendency for end users to overlook cybersecurity threats, often relegating responsibility to DCS Engineers or IT Staff instead of engaging cybersecurity specialists.3) Another concern lies in the omission of training for Engineers and Technicians on the latest available technologies.These observations are based on my personal experiences, acknowledging that your perspective may differ and is genuinely respected.

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In my experience the main DCS challenge, is hardware obselesence due to the use of proprietary HW and an OEM that has a short lifespan components.SW obselesence is a part that can be covered using virtualization were SW run independent of HW atleast at L2 nodes like DCS servers & stations.But DCS L1 HW like IO modules etc doesnt have such options else to move to soft controllers that run on virtual environment with high available options and talk to open IO based hardware decoupling the requirment of using proprietary hardware. One of such move is done by a org. Open process automation using different HW from different OEM but same software.In 20th century with lots of online materials and soft manuals everyone can be a DCS specialist.

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In addition to technical solutions, it is crucial to invest in qualified human material to face the challenges of developing a Document Control and Distribution System (DSCD). Well-trained and capable teams are essential to deal with systems integration, manage complexity, ensure data quality and security, resolve conflicts and adapt to changes. Therefore, investment in developing staff skills and knowledge is fundamental to the success of the project.

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Most of the things about the DCS are already covered. I would just like to add two things though small but crucial for the system. One is the maintenance and replacement of backup batteries for the processor units. Sometimes this is overlooked and may cause catastrophic results. Second thing is the regular backup of the system, which should be taken periodically to keep updated the system backup. This comes handy in case there's a program mismatch or corruption of the program. This is true not only for the DCS but other systems and programs should also be backed up periodically, as sometimes the glitches in one system also affect the ability of others to work properly. All back up data should be recorded clearly to avoid any confusion.

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We shouldn't forget DCS security aspect.Based on my experience:1. A virus infection in one point can easily spread out to other workstations that can cause shutdown and production loss; not to mention the tedious process of cleaning and reinstallation of all application software.2. Access and control should be restricted to authorized personnel only while external devices shouldn't be allowed to be connected to the system.3. A 3rd party cybersecurity software or group or person should be involved in handling DCS security.4. As much as possible, DCS should be insulated from external network or internet to avoid cyber attack.

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Security is always a concern, especially in this age of cyber attacks and nation state sponsored cyber warfare. This especially true of connections outside the DCS process. Correct firewall or secure data transfer devices properly segments a system so an attack on one segment does not propagate across the whole system.

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