After identifying the controlled object, selecting the appropriate control system becomes a critical decision. The choice between a digital DCS (Distributed Control System) and traditional analog instrumentation mainly depends on the project scale and budget. While the implementation differences between these systems are not significant, DCS tends to be more complex and technically demanding compared to analog systems.
In theory, DCS can be applied across various industries due to its versatility. However, most DCS manufacturers specialize in specific sectors. For example, Honeywell is widely used in petrochemical applications, Bailey’s N90 and INFI90 are common in power plants, and Rosemount’s RS3 and Δ-V are popular in chemical processes. Despite this specialization, different industries may require unique features—such as ESC and SOE in power plants, selective control in petrochemicals, or large pure hysteresis compensation in cement production.
From an economic perspective, the cost of DCS systems varies significantly depending on whether they are domestic or imported. Imported systems often offer more advanced control algorithms, such as Smith prediction and 3D matrix calculations, but at a much higher price. Domestic DCS solutions are generally more affordable and meet technical requirements effectively. The structure of controllers from foreign systems might not differ too much, but their preset algorithms and communication interfaces vary. Foreign operating stations typically use minicomputers with UNIX-like systems, which are expensive and have high maintenance costs. In contrast, PC-based systems are cheaper, easier to maintain, and offer better flexibility for software installation and development.
The power supply system of DCS controllers also contributes to the overall cost, as it often includes redundant components for reliability. Additionally, the communication network connecting the controller to the operator station plays a role in pricing. General-purpose Ethernet is relatively inexpensive, while dedicated network interfaces can be costly, reaching up to $20,000.
It's important to note that sometimes foreign vendors may offer lower prices, but this could involve reduced functionality or hidden costs. It’s advisable to consult similar projects and experienced experts before making a final decision.
Another key factor is the technical expertise of the contractor. A contractor familiar with both the process and the DCS system is essential for successful implementation. If a company lacks experience in a particular application, the system performance may suffer. Some companies may even end up using multiple DCS brands, creating a fragmented "coalition" system.
After-sales support is equally important. Foreign manufacturers may charge high prices for spare parts and provide delayed service. Choosing local manufacturers with strong technical support and timely service is usually a safer option. As technology evolves, DCS systems must continue to update. Compatibility between old and new systems is crucial, and some manufacturers may not support seamless upgrades, leading to potential losses.
Technological advancement is another consideration. The DCS should incorporate proven, future-ready technologies, including open systems, fieldbus integration, and third-party software support. However, some manufacturers may push immature products into emerging markets to gain an edge, which can lead to early obsolescence.
In summary, DCS has been in use for over 20 years and has proven reliable in many applications. Selecting the right system involves more than just considering project size and budget—it requires evaluating numerous factors that can determine the long-term success of the system. Proper selection is crucial and should not be overlooked.
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