To address the risk of system instability in conventional distributed control systems (DCS) in complex industrial settings which is caused by asynchronous evolution of control configuration data, a dynamic synchronization technology system covering the entire lifecycle of equipment is developed. It delves into the potential risk transmission mechanisms of DCS configuration data during conversion and synchronization, and presents a synchronization assurance mechanism based on dynamic verification and full-chain tracing. By creating a mirrored digital twin mapping model, it enables two-way mapping of configuration data between physical controllers and upper-computer systems. Together with a dual-state cooperative closed-loop synchronization protocol stack, this forms a triple-integrated architecture of “source-storage-operation”. Breaking through the limitations of conventional synchronization modes, this system ensures strong consistency of configuration data even under complex operating conditions. Verified in a thermal power plant’s DCS project, the proposed technical solution significantly improves the control system’s fault-tolerance under abnormal conditions, effectively ensuring safe and stable operation of power generation units. This offers key technological support for the independent and controllable upgrade of critical information infrastructure in the energy sector. The research holds great reference value for similar industrial control systems, and its design concept can be applied to various fields such as process industry and smart manufacturing.

distributed control system  /  configuration data  /  synchronization technology  /  consistency