Description

The Distributed Control System (DCS) Trainer is a complete, industrial-grade training solution designed to deliver hands-on applied learning in process automation, monitoring, and control.

The system enables learners to understand and practically implement full DCS architecture field layer, control layer, supervisory layer, and engineering layer covering configuration, diagnostics, commissioning, loop tuning, alarm management, SCADA development, and real-time process supervision.

The platform is suitable for educational institutions, utilities, and basic process industries, and is designed for integration with real process skids (flow, level, pressure, temperature) while remaining expandable for higher-level plant networks.

OBJECTIVE

To enable learners to:

• Implement complete DCS architecture end-to-end
• Configure and commission distributed I/O and controllers
• Design and tune PID, cascade, ratio, feed-forward, feedback, and split-range loops
• Develop SCADA graphics, alarms, trends, and historian
• Perform diagnostics, troubleshooting, and real-time supervision

KEY FEATURES

• Complete DCS stack: Controller, Distributed I/O, Networking, Engineering & Operator Stations
• HART-enabled isolated analog I/O for smart field devices
• Industrial Ethernet (TCP/IP) communications
• Perpetual licenses for Engineering & SCADA software
• Expandable architecture for additional I/O and networks
• Industrial-grade hardware for continuous operation
• Designed for real process integration and advanced control strategies

SYSTEM ARCHITECTURE

• Central DCS/PLC-based Controller (CPU)
• Local/Remote Digital & Analog I/O Modules
• Industrial Ethernet communication infrastructure
• Engineering Workstation
• Operator/SCADA Workstation
• Industrial Power Supplies and protected distribution

  TECHNICAL SPECIFICATIONS (SINGLE TABLE)

  Sl. No.	Item / Module	Technical Description	Qty
  1	Controller (CPU)	Compact industrial DCS/PLC controller; ≥2 MB user memory; supports ≥16 local I/O modules; up to 40 communication nodes; Ethernet-based communication; Make: Allen-Bradley / Siemens / Honeywell / Emerson / Equivalent	1 No.
  2	Digital Input Module	16 DI, 24 V DC; sink/equivalent; industrial isolation; reputed make	1 No.
  3	Digital Output Module	16 DO, 24 V DC; source/equivalent; short-circuit & overload protection; reputed make	1 No.
  4	Analog Input Modules	2 Nos., each 8 AI; 4–20 mA / 0–10 V configurable; loop/external powered; ≥16-bit resolution; reputed make	2 Nos.
  5	Isolated Analog Input Module (HART)	8 isolated AI; 4–20 mA with HART; channel-to-channel isolation; reputed make	1 No.
  6	Analog Output Module (HART)	8 isolated AO; 4–20 mA with HART; ≥16-bit resolution; reputed make	1 No.
  7	Ethernet Communication Adapter	Industrial Ethernet adapter; RJ-45; supports ≥8 I/O modules; TCP/IP	1 No.
  8	Terminal Bases & Mounting	Screw-type terminal bases (standard & isolated); DIN-rail/panel mount; easy wiring & maintenance	1 Set
  9	Industrial Ethernet Switch	Unmanaged; ≥8 ports; 10/100 Mbps; industrial grade	1 No.
  10	SCADA / Operator Software	Perpetual license; graphics, alarms, trends, historian, reports; multi-screen & training tags; vendor support	1 Set
  11	Engineering & Configuration Software	Perpetual license; programming, I/O config, diagnostics, commissioning, documentation & learning	1 Set
  12	Power Supply	Industrial DIN-rail; 24–28 V DC, ≥120 W; input 85–132 / 170–264 VAC; OV/OC/SCP protection	1 No.
  13	Industrial PCs	2 Nos.; Intel i7/equivalent, 16 GB RAM, 1 TB SSD, Gigabit Ethernet (Engineering & Operator)	2 Nos.
  14	Industrial Monitors	Approx. 42″ LED, Full HD (1920 × 1080); HDMI/DP/VGA; continuous operation	4 Nos.
  15	DCS Trainer Workstation	Floor-mounted; Approx. 1800(L) × 800(D) × 1600(H) mm; CR-grade powder-coated frame; ≥25 mm laminated worktop; ≥4 mm insulated mounting panel; integrated power control with MCBs, sockets, cooling provisions for 2 PCs & 4 monitors; proper cable routing & earthing	1 Set

  INTENDED APPLICATIONS

  • DCS & process automation training
  • Control loop design and tuning
  • SCADA, alarms, and historian training
  • Integration with real/simulated process skids
  • Academic labs and industrial skill development centers

  UTILITY REQUIREMENT

  • Electrical Supply: 1φ, 230 V AC, 50/60 Hz
  • Networking: Industrial Ethernet LAN

  GENERAL

  • Application: DCS Architecture, Advanced Process Control & SCADA Training
  • Mounting: Floor-mounted industrial workstation
  • Safety: MCB-protected power distribution, proper earthing, industrial wiring practices