Compare PLC and DCS: What is the difference?

DCS stands for Distributed Control System. DCSs were designed to control processes, not discrete
operations. As such, a large number of the inputs and outputs are analog like a 4-20mA signal or 0-10V
signal. In Literary meaning, a Distributed Control System (DCS) refers to a control system usually of a
process or manufacturing system, in which the controller elements are not central in location (like the
brain) but are distributed throughout the system with each component sub-system controlled by one or
more controllers. Process plants used to have long series of panel mounted Single Loop Controllers
(Analog/PID controllers).

PLC stands for Programmable Logic Controller. Historically a PLC was in discrete control of
manufacturing processes. Whole discrete logic used to be implemented with relay circuitry. Most of the
inputs and outputs for discrete control are binary, meaning they have only two states: On and Off.

What are attributes and characteristics which differentiate the PLC system from the DCS. There have
been claims and counter claims from different manufacturers that their system is DCS or PLC. The
topic has remained under debate for long, and especially today when we have already entered into new
era of Hybrid Distributed Control Systems, it has become increasingly difficult to select and
differentiate the advantages and drawbacks one can get from different systems.

There are few similarities and dissimilarities which I would like to mention here:

1) DCS are designed or made available to the user in a way that only configuration in form of a
Functional Block has to be carried out unlike PLC, where complete programming has to be
implemented using any one of the different languages available in the system.

Now, Functional Blocks are also available in the PLC systems, which really makes it comparable to
DCS.

2) When DCS started emerging in the market, idea was to supply DCS with whole bunch of
hardware and software packages including for Human Interface, necessary for the complete automation
of the plant, thus facilitating Single Point Configuration in terms of database and communication
possible in general. Additionally, Human Interface does not need separate communication package i.e
DDE server, to communicate with the controller. DCS includes higher levels of application software for
regulatory and batch control.

In case of PLC systems, PLC were not suppose to be in packages but competition with DCS vendors
forced the PLC manufacturers to offer necessary all other softwares and packages.

3) Many DCS are designed such that it is possible to configure cycle time for each Functional Block.
Thus DCS system takes care of cycle time scheduling of the Functional Blocks which are the basic
execution units. This is one of the reason that overall scan time of the DCS is comparatively higher than
the PLC system.

This functionality has been introduced in PLC systems(s) in some form as well.

4) A DCS has inherently multiple processor capability thus making the functionality distributed
across a network. In a typical multi-processors (multi-node) DCS architecture, Engineer has to put in
less efforts for inter-communication of the processors or one controller can easily access the Tag(s)
from the database of the other .i.e the input of FB in one controller can be output of FB of the other
controller.

This is possible now in PLC but more efforts have to be put in.

5) DCS programming is centered around configuration of Functional Blocks and discrete logic is
implemented in DCS using FBs, thus making the DCS inherently an analog control system (although
ladder programming is also possible in some of the DCS also). PLCs were programmed using
Ladder/Relay language , before arrival of IEC 1131-3 standard and Analog control was incorporated
inside Ladder inside Ladder Logic using special FBs. This is probably the reason we look at some of the
process plants that process (Analog) control is done by the DCS, while emergency control (Discrete
Control) is implemented by PLC based systems.

6) PLCs are still being used at RTU stations because of their simple, small and cheaper architecture
as well as engineering (typically the RTU application) instead of big DCS. DCS have been used as the
central system in a SCADA network. In a typical SCADA scenario, one DCS is connected to many
PLCs systems.

7) Being Discrete in nature, PLC was natural choice of manufacturer and end-user to apply it for
safety system. This led to production of specialized safety system conforming to SIL3 certification in
accordance with ANSI / ISA 84.00.01-2004.

Today, a lot has changed, it is difficult to distinguish between two systems in terms of its main features.
Differences between the two has virtually vanished due to Programming / Configuration language
standard IEC-61131.The functionality of the PLC has evolved over the years to include sequential relay
control, motion control, process control, distributed control systems and networking. However, in major
industrial areas and structure markets, it is practice to deploy DCS for process control and PLC based
system for safety control. Perhaps, for a large install base like more than 1000 I/Os system, cost of
installation, addition and maintenance per I/O is less in case of DCS system.

Now, more important is cost, application, system integrity, reliability, maintainability, historical logging
/ intelligent statistics and learning / training. How much support is available from the vendor for the
operation matters most to the operator now. This has resulted into Solutions Packages by vendors to
their customers instead of simply offering individual products. It is DCS or PLC, must come in a
solution package. More and improved System functionalities have made these system more complex
which require strong integration between the operator /user and the manufacturer.

Few vendors also introduced Hybrid DCS / PLC system or transformed their PLC based system into
DCS by incorporating similar features. DCS vendors have now introduced packages for Asset
Optimization and management which seamlessly integrate with their systems. It is difficult to say
which system to select ? It varies from user to user as discussed above. It is End-User who has to have
all knowledge and courage to take responsibility of his system in totality.
You must automate a process, but you can't decide between a DCS and a PLC. Are these systems really
all that different? The answers depend on a slew of other questions.

Turn the clock back 10-15 years: The programmable logic controller (PLC) is king of machine control
while the distributed control system (DCS) dominates process control. If you manufacture plastic
widgets, you speak PLC. If you produce chemicals, you speak DCS.

Today, the two technologies share kingdoms as the functional lines between them continue to blur. We
now use each where the other used to rule. However, PLCs still dominate high-speed machine control,
and DCSs prevail in complex continuous processes.

The early DCS looked dramatically different from the early PLC. Initially, the DCS performed the
control functions of the analog panel instruments it replaced, and its interface mimicked their panel
displays. DCSs then gained sequence logic capabilities to control batch processes as well as continuous
ones. DCSs performed hundreds of analog measurements and controlled dozens of analog outputs,
using multi-variable Proportional Integral Derivative (PID) control. With the same 8-bit microprocessor
technology that gave rise to the DCS, PLCs began replacing conventional relay/solid-state logic in
machine control. PLCs dealt with contact input/output (I/O) and started/stopped motors by performing
Boolean logic calculations.

The big change in DCS over the past 20 years is its move from proprietary hardware to the personal
computer (PC) and standard LAN technologies. With each advance in PC power, DCSs have moved up
in power. PCs gave us speedy, responsive, multi-media, windowed, operator-process interfaces (OPI).
Relational databases and spreadsheet software enhance the ability of DCSs to store and manipulate data.
Artificial intelligence (AI) technology gives us "smart" alarming. Today's DCS architecturally looks
much like the DCS of 20 years ago, but tomorrow's DCS may control through networked "smart"
devices-with no I/O hardware of its own.

Most DCSs offer redundant controllers, networks, and I/Os. Most give you "built-in" redundancy and
diagnostic features, with no need for user-written logic.

DCSs allow centralized configuration from the operator or engineering console in the control room.
You can change programming offline, and download without restarting the system for the change to be
effective.

DCSs allow inter-controller communications. You can do data exchange in most DCS systems ad hoc
(no need for predefined data point lists). You access data by tag name, regardless of hardware or
location.

DCSs use multi-tasking operating systems, so you can download and run applications aside from the
real-time control functions and still do fractional-second control. DCSs now come in "micro" systems,
to price-compete with PLCs-but with full DCS features and capabilities.

The typical DCS has integrated diagnostics and standard display templates that automatically
extend/update when your database changes. This database is central to the system-you don't have
different databases sitting in the controllers.
DCSs have user-friendly configuration tools, including structured English, control block libraries, SFC
(sequential function chart), and even RLL (relay ladder logic).

Most DCSs allow graphical configuration, provide online diagnostics, and are self-documenting. Most
provide for user-defined control blocks or customized strategies. The controllers execute control
strategies as independent tasks; thus, making changes to part of the control logic has no impact on the
rest.

An important difference between DCSs and PLCs is how vendors market them. DCS vendors typically
sell a complete, working, integrated, and tested system; offering full application implementation. They
offer many services: training, installation, field service, and integration with your Information
Technology (IT) systems. A DCS vendor provides a server with a relational database, a LAN with PCs
for office automation, networking support and integration of third-party applications and systems. The
DCS vendor tries to be your "one-stop shop." The PLC is more of a "do-it-yourself" device, which is
sometimes simpler to execute.

Programmable Logic Controllers. When PLCs were solely replacements for hard-wired relays, they had
only digital I/O, with no operator interface or communications. Simple operator interfaces appeared,
then evolved into increasingly complex interfaces as PLCs worked with increasingly complex
automation problems. We went from a panel of buttons and I/O-driven lamps to PLC full-color
customized graphic displays that run on SCADA software over a network.

PLCs now have many DCS-like control functions (e.g., PID algorithms) and analog I/O. They've moved
past their birthplace: the digital world (switch and binary sensor inputs and output contacts to run
motors and trigger solenoids).

PLCs are fast: They run an input-compute-output cycle in milliseconds. On the other hand, DCSs offer
fractional second (1/2 to 1/10) control cycles. However, some DCSs provide interrupt/event-triggered
logic for high-speed applications.

PLCs are simple, rugged computers with minimal peripherals and simple OSs. While increasing
reliability, PLC simplicity is not conducive to redundancy. Thus, fully redundant ("hot," automatic,
bumpless) variations of PLCs, with their added hardware and software, sometimes suffer from a
reduction in their reliability-a characteristic PLCs are famous for.

Data exchange typically requires you to preassign data registers and hard code their addresses into the
logic. If you add registers or need to reassign data, you typically have to deal manually with the Domino
Effect.

Typical PLC Relay Ladder Logic (RLL) languages include function blocks that can perform complex
control and math functions (e.g., PID algorithms). Complex multi-loop control functions (e.g., cascade
management and loop initialization) are not typical. For functions too messy to implement in RLL, most
PLCs provide a function block that calls a user-written program (usually in BASIC or C).

PLCs typically operate as "state" machines: They read all inputs, execute through the logic, and then
drive the outputs. The user-written logic is typically one big RLL program, which means you may have
to take the whole PLC off-line to make a change of any size. You also run into database
synchronization problems because of the separation of PLCs and the Man Machine Interface (MMI)
software packages, as opposed to the central databases of DCSs.

A PLC will run in a stand-alone configuration. A DCS controller normally expects an operator interface
and communications, so it can send alarms, messages, trend updates, and display updates.

Many PLC installations use interface software from third-party vendors for improved graphics and
various levels of alarming, trending, and reporting. The PLC and MMI software normally interact by
sitting on the network and using the register exchange mechanism to get data from and to the various
PLCs. This type of communication presumes you have preassigned data registers and can fetch data on
an absolute address basis. This can lead to data processing errors (e.g., from the wrong input) you won't
encounter with the central database of a DCS.

Some PLCs use proprietary networks, and others can use LANs. Either way, the communication
functions are the same-fetch and put registers. This can result in bottlenecking and timing problems if
too many PCs try communicating with too many PLCs over a network.

A PLC may have a third-party package for operator interfaces, LAN interface to PCs and peripherals,
PLC data highway or bus, redundant controllers with local and distributed I/O, local MMI and local
programming capability. The PLC would have redundant media support, but not the redundant
communication hardware or I/O bus hardware you'd find in a DCS. A PLC would have preprogrammed
I/O cards for specific signal types and ranges.

Today, the decision between PLC and DCS often depends on business issues rather than technical
features. Questions to consider are those involving:

The internal expertise to execute the project,

Level of support available from a vendor/integrator,
Basic Process Control Systems BPCS
Distributed Control System (DCS)

The DCS is a control system which collects the data from the field and decides what to do with
them. Data from the field can either be stored for future reference, used for simple process control, use
in conjunction with data from another part of the plant for advanced control strategies.

What must be in the DCS for it to be able to do so much?

Operator Console
These are like the monitors of our computers. They provide us with the feedback of what they are
doing in the plant as well as the command we issue to the control system. These are also the places
where operators issue commands to the field instruments.

Engineering Station
These are stations for engineers to configure the system and also to implement control algorithms.

History Module
This is like the harddisk of our PCs. They store the configurations of the DCS as well as the
configurations of all the points in the plant. They also store the graphic files that are shown in the
console and in most systems these days they are able to store some plant operating data.

Data Historian
These are usually extra pieces of software that are dedicated to store process variables, set points and
output values. They are usually of higher scanning rates than that available in the history module.

Control Modules
These are like the brains of the DCS. Specially customized blocks are found here. These are
customized to do control functions like PID control, ratio control, simple arithmetic and dynamic
compensation. These days, advanced control features can also be found in them.

I/O
These manage the input and output of the DCS. Input and output can be digital or analogues. Digital
I/Os are those like on/off, start/stop signals. Most of the process measurements and controller outputs
are considered analogue. These are the points where the field instruments are hard-wired to.

All above mentioned elements are connected by using a network, nowadays very often used is Ethernet.

The practical and technological boundaries between a Distributed Control System DCS, Programmable
Logic Controller PLC and Personal Computer PC control are blurring. Systems traditionally associated
with process control are being used in discrete applications. Likewise, traditionally discrete solutions
are used increasingly in both batch and continuous process control.

Today's control hardware are constructed from many of the same standard industry components such as
Intel processors. Therefore the only real difference between control systems is at the software level.
Copyright 2012 PAControl.com - Basic Process Control Systems BPCS
All Rights Reserved.

ABB / Industrial IT - Advant Master DCS

Advant OCS (Open Control System) is an ABB solution for operators to improve their manufacturing
productivity and achieve sustainable competitive advantages.

In 1992, based on the success of the Master systems in the 80's, the Master system began its evolution
to Advant OCS. This evolution introduced high capacity controllers and I/O with an improved
redundancy scheme. Also included were modern UNIX workstations, and in 1996 S800 I/O was added
providing modular flexible remote I/O.

In 2000, Advant OCS with Master Software began its next step in the evolution process with the
introduction of Industrial IT enabled products. ABB's commitment to protecting your investment
continues with these enhancements by providing connectivity to our latest control offering.

A versatile and complete range of process I/O systems within the Advant family enables optimal user
configurations:

S100I/O - A rack-based I/O system for AC400 controllers

S600I/O - A rack-based I/O system for AC100 controllers
S800I/O - A highly modularized and flexible I/O-system

Numerous characteristics and functions facilitate and improve operation, monitoring, and reengineering
of each process in a company. 800xA Operations (Process Portal) and the proven AdvaCommand for
Unix solution (based on HP-UX) are available as an operator station for Advant OCS with Master
Software.

The intuitive operator software provides consistent access and interaction with data from multiple
control and I/O to plant and enterprise information.
ABB Advant Master Control Systems
Honeywell - Experion PKS
Honeywell Experion Process Knowledge System (PKS)

Experion is Honeywell's unified system for process, business, and asset management that helps
industrial manufacturers increase their profitability and productivity.

Experion takes customers well beyond Distributed Control System (DCS) functionality with an
advanced automation platform solution and innovative application integration to improve business
performance and peace of mind. And there's no need to worry about upgrading from TDC 2000/TDC
3000 or TotalPlant Solution (TPS).

The unique, patent pending design of Series C combines sleek styling and function to provide process
I/O with reduced footprint, easier installation and maintenance, and longer life. The Series C form
factor benefits extend to multiple modules, such as the Series C C300 Controller, the Fieldbus Interface
Module, the Control Firewall, and HART analog modules.

The Control Execution Environment (CEE) is the common core software used in the various controllers
supported by ExperionTM. This includes the C200 Process Controller, the C300 Process Controller, the
Application Control Environment (ACE) and the C200 Simulation Environment (SIM-C200). The CEE
provides an execution and scheduling environment where control strategies are configured from a rich
set of standard and optional function blocks using a single builder tool, Control Builder.

Function blocks are grouped and wired together in a container to perform a specific control function
such as a valve control strategy. The Control Execution Environment (CEE) supports two types of
containers: the Control Module in which continuous and discrete controls are combined; and an SCM,
which is used for sequence control. Function blocks support the complete control application range,
such as continuous, discrete and batch control.

Emerson Process Management / DeltaV

DeltaV is the creation of Emerson Process Management's technological innovators, who worked in an
off-site "out-of-the-box" think tank to build an automation system that could integrate and leverage
today's digital world and cutting-edge technological innovations to make a value step-change in the
process industries.
The name DeltaV is derived from the engineering equation for acceleration: dv/dt, the change in
velocity over the change in time. The DeltaV system makes planning, engineering, installing,
commissioning, training, operating, and maintaining your process EASY, which accelerates your
success in improving your plant performance.

The DeltaV system scales the complete range of applications from an isolated process area to a
complete plant-wide automation system. Whether you need tens of I/O or tens of thousands of I/O-any
size you want! The DeltaV system provides all the tools to manage your process easier than ever before.

The complete family of controllers is available to power your most advanced control strategies. Full
controller and power supply redundancy is available for your mission-critical applications. The
controller and I/O sub-system is rated for Class I, Division 2 and Zone 2 environments to reduce your
installation costs.

DeltaV workstations are based on the latest Intel-based microprocessors running the Microsoft
Windows XP /Windows 2003 operating system. A complete range of applications is provided to cover
system configuration, operator interface, engineering, maintenance, and integration functions.

The DeltaV control networka high-speed Ethernet LANprovides system communications and
connects the various system nodes. The control network can be fully redundant. DeltaV
remote services extend the operations, engineering, and diagnostic applications across your enterprise
network.

Unlike PLC/HMI solutions, the completely integrated DeltaV system features a single database that
coordinates all configuration activities. System configuration is globally distributed in the run-time
environment.
Emerson - DeltaV
Hybrid Systems
PID Control Theory Tutorial

The P stands for proportional control, I for integral control and D for derivative control. This is also
what is called a three term controller.

The basic function of a controller is to execute an algorithm (electronic controller) based on the control
engineer's input (tuning constants), the operators desired operating value (setpoint) and the current plant
process value. In most cases, the requirement is for the controller to act so that the process value is as
close to the setpoint as possible. In a basic process control loop, the control engineer utilises the PID
algorithms to achieve this.

The PID control algorithm is used for the control of almost all loops in the process industries, and is
also the basis for many advanced control algorithms and strategies. In order for control loops to work
properly, the PID loop must be properly tuned. Standard methods for tuning loops and criteria for
judging the loop tuning have been used for many years, but should be reevaluated for use on modern
digital control systems.

While the basic algorithm has been unchanged for many years and is used in all distributed control
systems, the actual digital implementation of the algorithm has changed and differs from one system to
another.

How a PID Controller Works

The PID controllers job is to maintain the output at a level so that there is no difference (error) between
the process variable (PV) and the setpoint (SP).

In the diagram shown above the valve could be controlling the gas going to a heater, the chilling of a
cooler, the pressure in a pipe, the flow through a pipe, the level in a tank, or any other process control
system.

What the PID controller is looking at is the difference (or "error") between the PV and the SP. It looks
at the absolute error and the rate of change of error. Absolute error means -- is there a big difference in
the PV and SP or a little difference? Rate of change of error means -- is the difference between the PV
or SP getting smaller or larger as time goes on.

When there is a "process upset", meaning, when the process variable or the setpoint quickly changes -
the PID controller has to quickly change the output to get the process variable back equal to the
setpoint. If you have a walk-in cooler with a PID controller and someone opens the door and walks in,
the temperature (process variable) could rise very quickly. Therefore the PID controller has to increase
the cooling (output) to compensate for this rise in temperature.

Once the PID controller has the process variable equal to the setpoint, a good PID controller will not
vary the output. You want the output to be very steady (not changing). If the valve (motor, or other
control element) are constantly changing, instead of maintaining a constant value, this could case more
wear on the control element.

So there are these two contradictory goals. Fast response (fast change in output) when there is a
"process upset", but slow response (steady output) when the PV is close to the setpoint.

Note that the output often goes past (over shoots) the steady-state output to get the process back to the
setpoint. For example, a cooler may normally have it's cooling valve open 34% to maintain zero
degrees (after the cooler has been closed up and the temperature settled down). If someone opens the
cooler, walks in, walks around to find something, then walks back out, and then closes the cooler door -
- the PID controller is freaking out because the temperature may have raised 20 degrees! So it may
crank the cooling valve open to 50, 75, or even 100 percent -- to hurry up and cool the cooler back
down -- before slowly closing the cooling valve back down to 34 percent.

Controller System for Industrial Automation

The element linking the measurement and the final control element is the controller. Before the advent
of computers, the controllers are usually single-loop PID controllers. These are manufactured to
execute PID control functions. These days, the controllers can do a lot more, however, easily 80 to 90%
of the controllers are still PID controllers.

Analogue vs Digital Controllers

It is indeed difficult to say that analogue controllers are definitely better than digital controllers. The
point is, they both work. Analogue controllers are based on mechanical parts that cause changes to the
process via the final control element. Again like final control elements, these moving parts are
subjected to wear and tear over time and that causes the response of the process to be somewhat
different with time. Analogue controllers control continuously.

Digital controllers do not have mechanical moving parts. Instead, they use processors to calculate the
output based on the measured values. Since they do not have moving parts, they are not susceptible to
deterioration with time. Digital controllers are not continuous. They execute at very high frequencies,
usually 2-3 times a second.

Analogue controllers should not be confused with pneumatic controllers. Just because a controller is
analogue does not mean it is pneumatic. Pneumatic controllers are those that use instrument air to pass
measurement and controller signals instead of electronic signals. An analogue controller can use
electronic signals. Compared to pneumatic controllers, electronic controllers (can be analogue or
digital) have the advantage of not having the same amount of deadtime and lag due to the
compressibility of the instrument air.
PLC |