Domestic (in no particular order)
The major domestic manufacturers of DCS include: Zhejiang Supcon, Beijing Hollysys, Nanjing Keyuan, Guodian Zhishen, Shanghai Xinhua, Xinhua Group, Shanghai Automation Instrumentation, etc.
Zhejiang Supcon Technology Co., Ltd.
Supcon Group was founded in March 1993. Its current domestic DCS is mainly the WebField series DCS system, namely JX-300XP, ECS-100 and ECS-700.
*JX-300XP: The system incorporates rapidly developing communication and microelectronic technologies, applies the latest signal processing, high-speed network communication, software platform and software design technologies, as well as fieldbus technology. It adopts a microprocessor and mature advanced control algorithms, comprehensively improving the functionality and performance of the control system. At the same time, it achieves multi-bus compatibility and heterogeneous system integration. Various foreign DCS, domestic DCS, PLCs, and field intelligent devices can be connected to the JX-300XP control system, enabling it to adapt to a wider range of complex application requirements.
*ECS-100: This is a network-based DCS system launched by the company to adapt to the development of network technology, especially the development of Internet and Web technologies. This series of DCS systems integrates fieldbus technology, embedded software technology, advanced control technology, and network technology, achieving multi-bus compatibility and comprehensive integration of heterogeneous systems. Various foreign DCS, domestic DCS, PLCs, and field intelligent devices can be connected to the ECS-100 system, enabling information sharing among process control equipment within the enterprise.
*ECS-700: A large-scale domestically developed DCS system launched by Zhejiang Supcon in 2007. Completely independently developed by Supcon, both its software and hardware possess full independent intellectual property rights. It was designed and developed based on the extensive application of WebField series control systems such as JX-300XP and ECS-100, and is a large-scale control system for large-scale integrated plants. It integrates control technology, open fieldbus standards, and industrial Ethernet security technology.
Beijing Hollysys Group
Founded in 1993, Beijing Hollysys Group is a high-tech enterprise group engaged in the independent design, manufacturing, and application of automated control system platforms and industry solutions.
Hollysys' predecessor was the Sixth Research Institute of the Ministry of Electronics Industry, giving it a strong government background. Since the 1990s, Hollysys has gone through the HS-DCS-1000, HS-2000, and now mainly promotes the HOLLIASMACS system.
*The HOLLIASMACS series includes two models of systems:
HOLLIASMACS-F system: Suitable for small to medium-sized projects (up to 20,000 physical points), with a high-density installation structure, a single cabinet can have up to 1056 terminals;
The HOLLIASMACS-S system is suitable for large-scale projects (up to 100,000 physical points) and has a moderate installation density, with a single cabinet containing up to 720 terminals.
*In terms of communication, the HOLLIASMACS system adopts a four-layer network structure:
1. The first layer of the network is the information management network, which communicates with the system server via a real-time relational database using an Ethernet network with a communication rate of 100Mbps.
2. The second layer network is the monitoring network, which uses Ethernet to interconnect engineer stations, operator stations, and the system server. It uses Ethernet communication with a communication rate of 100Mbps.
3. The third layer network is the system network, which enables the interconnection between field control stations and the system server. It uses the HSIE network protocol and has no IP address.
4. The fourth layer network is the control network that enables communication between the field control station and the process I/O unit. It uses the PROFIBUS-DP protocol with a communication rate of 500Kbps.
All process I/O units exchange data with the master controller via master-slave communication. All controllers (such as DCS and PLC) and smart instruments that support the PROFIBUS-DP protocol can communicate with the MACS as slaves of the master controller, provided that the corresponding GSD file is provided.
Experience
Hardware-wise: Hollysys' software system consists of three software packages from different countries, resulting in poor compatibility and interoperability issues between the various software components. Hollysys, on the other hand, features redundant configuration, a single-CPU design, and industrial-grade embedded chips. It includes power-down protection, seamless switching, surface-mount design, hot-swappable main controller, and a fanless, cage-type design. The system includes a network, control network, master-slave control, and fault indication and diagnosis functions. It also features external master controller address setting, panel system program reset, and online manual master controller switching.
In terms of software: Hollysys' software system consists of three software programs from different countries, which have poor compatibility and interoperability issues between the various software programs.
Hollysys' algorithm configuration software is an OEM version of CoDeSYS software from the German company SmartSoftwareSolution. The host software includes its own developed MACS5, as well as CitectOEM software. The controller runtime software is QNX from Canada. In terms of configuration, MACS includes device configuration, server algorithm configuration, database configuration, controller algorithm configuration, and graphical configuration.
In terms of project implementation, there is a strict sequence for various configurations, and each configuration must be programmed (except for graphical configuration). This system exists on a server. If system variables are changed when the control algorithm is changed, the database must be reprogrammed, and changes to the database require a server restart.
When changing the control algorithm, after downloading the main controller, the control points of the controller may not correspond to the points of the server. At this time, it is very dangerous to operate on the operator station. Operating this device may cause other devices to malfunction, which may cause serious personal injury and equipment accidents.
Nanjing SCIYON Automation Co., Ltd.
Founded in 1993, the company launched the NT6000, a domestically developed DCS system with independent intellectual property rights, in 2003.
The NT6000 system enables online configuration and online downloading, and also allows for page-by-page downloading. This means that modified pages can be downloaded during commissioning or actual operation without affecting the operation of other page control strategies, facilitating the commissioning and deployment of the DCS system. This improves the flexibility and efficiency of the DCS system during on-site commissioning.
The NT6000 system adopts a peer-to-peer client station architecture, has no data server, and also has a 1:1 virtual DCS simulation system for simulating and debugging the DCS before it leaves the factory.
Experience
The hardware has some quality issues, but the software works okay. It's cheap, and the after-sales service is excellent. It's suitable for small generator sets. The Keyuan controller is frequently offline; the program resets whenever the controller loses power.
Beijing Guodian Zhishen Control Technology Co., Ltd.
Founded in 2002, the company has established cooperative and agency relationships with many foreign companies, such as Westinghouse Electric Corporation and METSO Corporation of the United States, and has successfully introduced DCS systems such as WDPF, OVATION, MAX1000, and maxDNA. It has also established good cooperative relationships with SCHNEIDER, ABB, Siemens of Germany, and FOXBORO of the United States, and can provide a wide range of automatic control system engineering implementation services.
Experience
As a subsidiary of China Guodian Corporation, Guodian Zhicheng has a wide range of application achievements. However, its embedded industrial control computer (DPU) has lower reliability than the dedicated DPU used in DCS (Distributed Control System), and the controller has experienced network disconnection during actual operation.
Most I/O modules use 16-point and 32-point configurations, which result in poor risk dispersion and excessively long system scan cycles (1 second). The configuration software in 2011 used the VISIO method, but it was not stable enough for complex strategies and was later upgraded and improved. Timing issues need to be considered when writing control programs, and the overall usability of the software is slightly poor.
Primarily used in power plants under the China Guodian Corporation, with limited experience outside the system. While possessing strong engineering service capabilities, its resources are mainly allocated to units above 600MW within the system, leaving insufficient resources for undertaking other projects. Customer involvement in design and configuration is generally required.
Shanghai Xinhua Control Engineering Co., Ltd.
Founded in 1983, the company was one of the earliest domestic DCS manufacturers engaged in the research and development and production of DEH and domestically produced DCS systems. Later, Shanghai Xinhua Control Technology (Group) Co., Ltd. was established on this basis. On March 31, 2005, Xinhua Group transferred its controlling stake in Xinhua Control Engineering Co., Ltd., which engaged in distributed control engineering for power plants, to General Electric Company of the United States. Therefore, strictly speaking, its DCS system is no longer a domestically produced DCS system.
The XDPS-400 originally manufactured by Xinhua Control was the best DCS system among domestically produced DCS systems (without exception, and its after-sales service was excellent).
However, since being sold to GE, the original developers have largely left, causing the system's technical level to stagnate before 2005, failing to keep up with the latest technological developments and meet users' evolving needs. Furthermore, significant changes in the company's organizational structure have hampered engineering implementation and technical services, gradually causing it to lose its leading position in the domestic DCS market.
In 2011, GE Xinhua incorporated some XDPS-400+ technology to redevelop the OC6000DCS system. Aside from retaining some XDPS-400+ technology in its operation and configuration software, it bore no resemblance to the original XDPS-400+ in other aspects. Because this was a completely new DCS system, and due to difficulties in engineering implementation and after-sales service, it did not achieve large-scale promotion and use in China.
Shanghai Xinhua Control Technology (Group) Co., Ltd.
The company was established on the basis of the former Shanghai Xinhua Control Engineering Co., Ltd., and is a high-tech enterprise dedicated to industrial automation and informatization. In July 2012, it was acquired by Zhejiang Chint Electric Co., Ltd. for 315 million yuan.
The XDC800 is a high-quality domestic DCS control system. It is based on the Xinhua controller XCU, which is composed of a 32-bit CPU. It is equipped with standard Ethernet and fieldbus to form a communication network with a ring network structure or a star network structure. It runs the OnXDC visual graphical configuration software developed by Xinhua Group and is a technical platform for industrial process control and process industry control systems.
Shanghai Automation Instrumentation Co., Ltd.
The SUPMAX800 domestic DCS system is a small-to-medium-sized domestic DCS system independently developed and manufactured by the DCS Company of Shanghai Automation Instrumentation Co., Ltd.
This system is based on a high-performance 100M full-duplex switch, a star-topology, redundant industrial Ethernet architecture, and a star network structure for the full-duplex switch. It can provide interfaces for connecting to PLCs and other external systems or subsystems.
Shandong Luneng Control Engineering Co., Ltd.
Shandong Luneng Control Engineering Co., Ltd., established in 1998, was formerly known as the Thermal Control Technology Research Institute of Shandong Electric Power Research Institute. It is one of the high-tech enterprises in Luneng Science and Technology Park. In 1999, it was recognized by the Shandong Provincial Department of Science and Technology as a "High-tech Enterprise" and a "Shandong Provincial Software Development and Production Enterprise," and subsequently as a "Shandong Provincial Software Product Enterprise." It successfully passed the "Double Software" certification and ISO9000 quality system certification.
The company is committed to the research and development and application of fieldbus technology and distributed control systems, as well as the design, development, production, assembly, commissioning, professional training and technical consulting services of power plant process control systems.
Our main products include LN1000, LN2000, and LN3000 distributed control systems, LK series fieldbus intelligent acquisition modules, and LK instruments and meters.
The products are mainly used in thermal power, heating, chemical, and building materials industries. The estimated usage will reach more than 1,000 sets.
International (in no particular order)
Major international manufacturers of DCS include Honeywell, ABB, and Emerson.
Honeywell
Honeywell DCS systems mainly include: Alcont, ExperionLS, ExperionPKS, ExperionHS, PlantScape, TDC2000, TDC3000, TPS, security systems, etc.
*1.Alcont
Each generation of Alcont can be easily integrated with Experion technology, and is a system designed for control, measurement, monitoring and integration of industrial enterprises and manufacturing plants.
*2.ExperionLS
ExperionLS provides reliable, flexible, and easy-to-operate distributed control systems (DCS) for small and medium-sized manufacturing enterprises. Compared to other cumbersome and non-scalable solutions, each ExperionLS system can save customers up to $20,000 in technical support costs annually.
With its out-of-the-box functionality and flexibility, ExperionLS requires less implementation and maintenance costs than systems designed for large-scale production or smaller PLC-based systems. ExperionLS offers stand-alone automation solutions that can meet both continuous process control and batch control needs.
*3.ExperionPKS
Honeywell's Experion process knowledge system is a system that integrates asset efficiency, process performance, people efficiency, and operational flexibility to improve productivity and effectiveness.
The Experion system incorporates a distributed control system (DCS) and adds an advanced automation control platform, which can improve business profitability and eliminates concerns about integration with TDC2000/TDC3000/TPS.
*4.ExperionHS
ExperionHS is a small-to-medium-scale process control system built on the proven ExperionPKS platform technology. It is a comprehensive solution that integrates multiple types of controllers, including hybrid controllers (HC900), logic controllers (MasterLogics), and safety controllers (SafetyManager).
ExperionHS further extends this proven technology to meet the specific needs of various industries. The solution is simple and intuitive, making it easy for plant managers, maintenance engineers, process engineers, and operators to use in industries such as oil, chemical, pharmaceutical, cement and glass, and food and beverage. Advanced Control Programming (APC) can also be implemented on the ExperionHS platform to improve output and product quality while reducing energy consumption.
*5. PlantScape
PlantScape is a scalable hybrid controller from Honeywell for discrete and connected control processes. Currently, there is no new version of PlantScape; it can be integrated into Experion systems.
*6.TDC2000
The introduction of the TDC2000 in 1975 has kept Honeywell at the forefront of the automation control industry. Both the TDC2000's software and hardware can be easily integrated into the Experion system.
*7.TDC3000
To improve performance more effectively, operators must have access to historical plant data and node information, monitor historical process control data, trends, and averages. By using Honeywell's GUS human-machine interface process control technology and advanced software capabilities, operators can easily grasp the latest information.
*8.TPS
TPS is an automation system developed by Honeywell based on the Windows 2000 system. It includes distributed control system capabilities, advanced application software, multi-faceted control, batch control, optimization, plant historical data, and information management systems. TPS nodes, including GUS and APP, are directly connected to the LCN network via TDC.
*9. Security System
Safety systems can reduce safety costs, lower risk levels, increase output, and improve overall factory performance.
Experience
Six years ago, netizens gave Honeywell DCS positive reviews:
TDC3000, back in the day, practically monopolized China's petrochemical industry; it was number one. TPS, on the other hand, has been around for over a decade. The first version was based on NT4, later on Win2000. In short, it was excellent and powerful! Most impressively, the 35-year-old TDC2000 system could be seamlessly integrated into PKS, which boasted the ability to integrate all Honeywell systems without any issues. It was the undisputed world's leading DCS provider.
ABB Group
ABB Group is a Fortune Global 500 company, headquartered in Zurich, Switzerland. ABB was formed in 1988 by the merger of two international companies with more than 100 years of history: ASEA of Sweden and Brown Boveri of Switzerland.
ABB's DCS control systems mainly include: 800xA, AdvantOCS with Master Software, AdvantOCS with MOD300 software, Freelance - a distributed control system for process industries, SymphonyMelody, SattOCS, SymphonyDCISystemSix, Harmony/INFI90, and safety systems.
*1.800xA
Extended automation, a flagship automation system applied to control and monitoring, instrumentation, electrical integration, safety and maintenance in process industries.
*2.AdvantOCSwithMasterSoftware
AdvantOCS (Open Control Systems) is a suite of solutions offered by ABB to help operators improve their volume productivity and gain a sustainable competitive advantage. The AdvantOCS with Master software has begun its next update process, introducing products that require activation by industrial IT (information technology). With these technological advancements and ABB's ongoing provision of updated controller information to customers, ABB will continue its commitment to protecting customer investments.
*3. AdvantOCS with MOD300 software
The MOD300 distributed control system, introduced in 1984, features complete control languages CCF and TCL, a redundant communication network (DCN), redundant controllers, historical data reporting, and bulk data I/O. In 1998, the MOD300 system's functionality was enhanced by adding an SC controller, Taylor ladder logic (TLL), and a TRIO controller. In 1992, the MOD300 system began its evolution towards AdvantOCS, introducing high-capacity controllers and a redundant, improved I/O system. It also included modern Unix operating system workstations. In 1996, the S800 I/O system was added to the existing modular distributed flexible I/O.
*4. Freelance - Distributed Control Systems Applied to Process Industries
ABB's Freelance is a distributed control system for process industries, combining the advantages of DCS and PLC, offering the size of a PLC and the functionality of a DCS. Its integrated environment facilitates engineering, commissioning, maintenance, and fieldbus management, while its intuitive operator interface simplifies system operation and diagnostics.
*5. SymphonyMelody
After thousands of successful applications in power plants, chemical plants, water and wastewater industries, petrochemical industries, and metal industries, Melody has proven itself to be a high-performance control system. In 2003, with the introduction of the IndustrialIT 800xA system, SymphonyMelody began its next phase of development as part of its upgrade process.
*6.SattOCS
SattOCS offers a full range of services, from products to comprehensive solutions, tailored to customer requirements. Tens of thousands of industrial programs demonstrate the breadth and diversity of applications, including food processing, water, energy, pharmaceuticals, chemicals, and infrastructure. SattOCS products and systems encompass most automation control solutions, such as DCS systems, PLCs, Sacda, I/O, and programming tools.
*7. SymphonyDCISystemSix
In 1979, the DCI-4000 system was introduced, providing redundant controllers with a flexible I/O arrangement.
Running a modular controller language (called Controlware), the DCI-4000 system provided an operator platform with a redundant proprietary network as the interface. The DCI-5000 system, introduced in 1985, offered an open network interface using redundant Ethernet communication. The System 6, introduced in 1992, combined rack-mounted distributed controllers with flexible I/O. Operator interfaces enabled products based on X-Windows and MS-Windows.
In 1997, DCI System 6 officially became part of the Symphony product line. Since then, the system has undergone several improvements, including a Windows-based product, an open communication protocol, increased speed and memory capacity, and a multi-user engineering environment. In 2002, SymphonyDCI began its next upgrade process, introducing the S800 and S900 I/O series, which require industrial information technology activation.
*8.Harmony/INFI90
SymphonyHarmony is a proven process control system suitable for a wide range of industrial applications. Harmony is widely used in power generation, chemical, pharmaceutical, pulp and paper, water and wastewater treatment, petrochemical, metallurgical and mining, food and beverage, cement and sugar industries – with over 6,000 systems installed worldwide.
*9. Security System
ABB has over 30 years of experience in implementing safety systems, providing users with certified safety controllers and safety instruments, lifecycle services, and capabilities ranging from Safety Integrity Level (SIL) determination to certified execution. ABB's main safety systems include: 800xAHI, Plantguard, and Safeguard.
*10.Compact800
The Compact800 series products can be used individually or in combination to create low-cost control solutions to meet diverse customer needs. Designed with innovative concepts and manufactured to specific standards, the Compact800 series can be used in conjunction with other products in the automation market. The compact HMI800, the AC800M controller with its compact control configuration software (ControlBuilder), the Panel 800, S800LI/O, and S800I/O series all play a crucial role in customized control solutions.
Experience
We're currently using ABB's AC800, which has two pairs of redundant controllers that automatically switch over if a problem occurs during operation. However, the issue is that each pair of controllers uses different cards, essentially creating two strings of cards, one controller supporting one string. If any card in a string fails, that controller becomes unusable, and the system switches to the other. The problem is, if cards on different controllers fail simultaneously, the redundancy becomes useless, and none of the controllers can function. Although the probability of this happening is low, I still find it dangerous.
Emerson Electric Company (USA)
*DCS performance characteristics:
1. The system has flexible configuration, high reliability, can reduce investment and engineering costs, and requires less operation and maintenance.
2. Integrated modular software; advanced process control, equipment management, and management execution.
3. It has a virtual testing function (the virtual testing software needs to be purchased separately).
System and network configuration
1. The DeltaV system is fully configured with redundancy and fault tolerance.
2. PlantWeb (Smart Factory) uses a process control network (process graphics, historical events, variable management) with AMS software (software under Emerson Process Management, including AMS ValveLink and AMS Suite) to effectively diagnose field equipment and reduce maintenance costs.
3. PlantWeb (Plant Management Network) offers real-time and reliable network functionality, characterized by digitalization and predictive intelligence technologies.
4. Maximum number of place values: 30,000.
5. Fastest scan cycle: 100 milliseconds
Data exchange between different networks
Open network architecture and OPC (used across platforms) technology, PROFIBUSDP, AS-I bus, FF bus, HART.
Maintainability
1. Key components such as controllers, power supplies, and data communication systems are all redundant and fault-tolerant.
2. Self-diagnostic capabilities and hot-plugging/swapping functionality. (Maintainability)
3. Simple hardware structure.
4. The actual application effect of bus communication is very good, with a good online debugging system that can adjust online control valves (based on the powerful service software developed by Emerson Process Management).
*System Software
1. The user interface uses the Windows 2000 system and is easy to operate.
2. DeltaV's advanced control software and AMS device management software.
3. In addition to basic control software such as self-tuning, more complex control software such as fuzzy control, predictive control, and simulation can also be purchased.
security system
1. Dual-channel redundant security system.
2. The standard system configuration can reach SIL3 level.
3. Redundant controller, power supply module and I/O unit.
4. It can connect to smart meters and has remote diagnostic capabilities (also based on the powerful functions of its own software).
5. It can be seamlessly connected with its own DCS system.
6. It has powerful SOE event logging capabilities.
*shortcoming
1. It is said that the cost of software and services in the later stages is relatively high.
2. There are no explicit restrictions on the coexistence of host computer software with other software (e.g., antivirus software). If coexistence occurs, response is not guaranteed.
*Card
AnalogAI
AI4-20mA, 8pt
Single-channel isolation
The received signal range of 1-22.5mA has excessive signal strength.
Process testing
For example, when used for temperature detection, the accuracy is to 0.1%.
AnalogAO
AO4-20mA, 8pt
Single-channel isolation
Signal response 1-23mA
RTDCard
8 channels, 16-bit precision, 0.05% error
2-wire 3-wire 4-wire Pt100
Pt200Pt500Ni120Cu10
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