An advantage of the DCS is installation costs. With a PLC system (multiple PLCs in a plant structure), you still need to create the supervisory and control system. Bayt.com is the leading job site in the Middle East and North Africa, connecting job seekers with employers looking to hire. It has shorter training time required. DCS designs often trade high levels of functionality for repeatability and dependability. However, consumers willing to adopt automated robotics applications in their manufacturing processes still need to understand their differences. Traditionally, a DCS system was expensive, large, complex to implement and only seen as a control solution for continuous or complex batch process industries. Mark Proctor is managing director of industrial spares supplier, FREE Subscription to Engineering magazines. Speaking of advantages, today’s PLC systems offer nearly the same ones as the DCS, excluding the supervisory control and data acquisition (SCADA). With several autonomous controllers, if a controller failed, it would impact only that process and not all of the others, which led to a robust system that virtually eliminated entire plant failure. The DCS’ onboard monitoring and control system is also a plus. Fig. As a utility player, PLCs are highly customisable. In this article, I tried to cover all the PLC basics required. This kind of predictive analysis is particularly important for obsolete part replacement and avoiding costly downtime. For example, take the server halls of data centres: these types of control systems are often seen as hybrids of both DCS and PLC. For all their differences, PLC and DCS are becoming more alike. There is no clear cut fast rule about when to use a PAC, PLC, or IPC. 4.If point 3 is convinced what are the advantage of PCS7 over other DCS like Honeywell ,Yokogawa etc.????? When the batch is complete, PLC-A communicates with PLC-B that the process was complete, and PLC-B then launches the freezing process. Based on the current rate of technological advancement, most experts agree it will be pointless to differentiate between DCSs, DDCs, and PLCs in the future. The data can be displayed in various formats as per user requirements. There were many benefits to the DCS, but one of the primary advantages was that an entire plant could be connected via proprietary communications and controlled by a distributed system. This is all about the Programmable Logic Controller aka PLC. The PLC was actually born more than forty years ago when an antsy design engineer named Dick Morley quit his job over a dispute with his boss (he wanted to work on Saturdays instead of Fridays, so he could ski more…his boss said no) and formed a company with a friend called Bedford Associates. PLC VS DCS . DCS stands for Distributed Control System. By Mondi Anderson, Controls Engineer at Metawater USA and Automation Instructor at RealPars In a nutshell, a PLC or programmable logic controller is a ruggedized computer used for automating processes. An entire DCS is much more expensive than a few PLC’s, but each have their advantages in any given situation and certain automated systems will always require one over the other. The advancement of the microprocessor resulted in a merging of the technologies. The programming of the PLCs was primarily in ladder logic, a format very similar to a schematic. Game on. Whereas in a DCS, asset management software provides alerts of what might break before it does, so a fitting substitution can be made. They have standard libraries and routines built in, but also have the capability to be specially programmed using custom code from scratch. By Mondi Anderson, Controls Engineer at Metawater USA and Automation Instructor at RealPars. 2. There is no monitoring devices in PLC like DCS. He shared it with his team who enthusiastically embraced the design. The Benefits of DCS Using a DCS allows a plant’s engineering staff to supervise and manage a larger number of control loops and other similar plant components and processes. Reliability. One advantage of IPCs is that it is often possible to run the HMI application on the same machine as the automation program and decrease cost. Diagnostics in a PLC system will alert an engineer when something is broken. Demonstrating advantages ABB was able to offer CEE some examples to demonstrate how savings can be realised by using today’s DCS workflow, when compared with a PLC/HMI (SCADA) system. The PLC received device information from the field, solved the logic, and then energized the outputs to produce the desired effect, which generally meant performing repetitive tasks in a reliable and durable manner. These days, there is probably no single factory in the word that … Mark Proctor gives his analysis of DCSs and PLCs in the modern plant. At Bedford, Morley and his friend wrote proposal after proposal, mostly for local tool firms hoping to evolve into the new solid state manufacturing arena with the help of small computers. This saves in development time when programming a PLC. The speed of logic execution is another key differentiator between DCS and PLC. 4. Conversely, PLCs are often used when the value of the product is relatively low and production needs to be flexible. One needs to weigh the system costs and the advantages/disadvantages to make the best decision for the situation at hand. In today’s industries, however, the DCS and PLC are quite similar, save for the integrated monitoring and control. This is another myth. A DCS typically covers an entire process, and is capable of covering an entire plant. Following are the benefits or advantages of SCADA: The system provide facility to store large amount of data. In those early days of automation, there was a clear spilt between DCS and PLC systems, with both types being designed for their specific tasks. This is because a DCS normally has built-in redundancy, ensuring a higher level of system insurance. Here we are comparing PLC with the relays and DCS (Distributed Control System). It provides interface to connect thousands of sensors across wide region for various monitoring and controlling operations. DCS is advanced version of PLC and DCS works in real time frame while PLC not. 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. PLCs are designed to meet the needs of applications that require scan rates of ten milliseconds or less. The takeaway from this comparison is that, with today’s technologies, either system can control an entire plant. A DCS or distributed control system is similar to a PLC in that it has rugged computer controllers, however, the DCS contains multiple autonomous controllers that are distributed throughout a system, also used for automating processes. In essence, some industrial plants are now employing more than one captain to ensure critical systems are well managed. That’s when Morley began to think outside the box, literally. S Bharadwaj Reddy May 1, 2019 January 30, 2020. In contrast, there are more programmers available for hire in the PLC arena and with the new programming languages such as function block, sequential function, etc., the advantage of function block programming is no longer exclusive to the DCS. How to choose between PLC and DCS Systems ? Do you know the Difference between DCS and PLC Systems ? The benefits of a DCS are combined with the benefits of a PLC, without the disadvantages of both systems. As good fortune would have it, during the design phase of Morley’s creation, an executive at GM presented a request for a solid state controller that would make plants more reliable and durable, one that could also replace the hardwired and unreliable relay systems that were pervasive in manufacturing. Advantages of PLC over Relays: PLC increases the reliability, flexibility, and accuracy of the automation system. This is why DCS is now used in smaller applications, whereby it is not spread across the whole plant, but rather a complex subsection that needs reliable control. Mondi Anderson works as a Controls Engineer at Metawater USA, a global company focused on water treatment technologies, equipment and engineering. Because of the specialized training, DCS programmers are a bit harder to come by. Another advantage is the onboard monitoring and control system. The first name on the team sheet, your DCS is dependable, hardworking and controls the whole outfit. Function block programming saved a lot of time and redundant programming. Also beneficial was that the DCS had function block programming. The speed of logic execution is another key differentiator between DCS and PLC. Another major benefit of the DCS was the integrated monitoring and control system similar to today’s SCADA systems. A few thousand I/O points can be handled by a PLC whereas DCS can handle many thousands of I/O points and accommodate new equipment, process enhancements, and data integration. Essentially, the difference between PLC and DCS forty years ago was considerable, and if you owned a large plant with continuous processes, you likely would have chosen a DCS. It is also no longer as cumbersome either - modern DCS hardware resembles a PLC in size. On the other hand, PLCs evolved from solid state relays and, as opposed to DCS, were used where process restarts were not a major concern, but processing speed was important. This is why DCS is now used in smaller applications, whereby it is not spread across the whole plant, but rather a complex subsection that needs reliable control. For example, take the server halls of data centres: these types of control systems are often seen as hybrids of both DCS and PLC. You can reach her at: mondi.anderson@gmail.com, or email the RealPars team at: hello@realpars.com. PLC-A could process the ice cream batch. PLCs are fast, no doubt about it. He wondered if he could create an automated programmable controller that could handle his clients’ everyday jobs. The DCS appeared around 1975, out of necessity. Take the ice cream sandwich example. 1. ... DCS stands for Distributed Control System and PLC stands for Programmable Logic Controller. So if you have a large facility with parts of your process strewn throughout, then a DCS will assist you better. The plant would have a production line for the ice cream, and one of the autonomous controllers would process the batch of ice cream. After the ice cream batch was complete, another autonomous controller would process the freezing of that ice cream. DCSs have been the primary solution for process automation but now many PLC vendors are arguing that a single integrated architecture based on PLCs and/or PACs is the best approach to total plant automation. Boom…GM heard about Morley’s work and eventually contracted with Modicon to purchase over $1 million worth of their innovative programmable controllers (it was several years later, when personal computers or PCs were invented and the “logic” part of the name was added to create the term, PLC). DCS vs. PLC DCS stands for Distributed Control System. On the other hand, engineers expect a DCS to offer an out-of-the-box control system with features such as - historian, sophisticated alarms and logic from pre-existing function blocks. You can see that with today’s technologies, a wide and robust PLC system could do virtually the same thing that the DCS can do. Most plant floor technicians are familiar with ladder logic programming however, DCS programmers and technicians typically need more specialized experience in database functions, as well as IT-related networking knowledge. A DCS's regulatory control loops generally scan in the 100 to 500 millisecond range. Every day, thousands of new job vacancies are listed on the award-winning platform from the region's top employers. Bottom line? There are some advantages of programmable logic controller (PLC) are given below, It has very faster scan time. A DCS is used when the value of the products manufactured is high, the production is continuous and failures in the system result in damage to process equipment - for example, if a glass kiln dropped below a certain temperature. Morley got to work drafting an idea for a programmable controller. Check out our free e-newsletters to read more great articles.. ©2020 Automation.com, a subsidiary of ISA, A subsidiary of the International Society of Automation. Benefits of DCS for Hybrid Industries versus Conventional PLC Approach: Your questions answered Webcast presenters Jerry Espy, Frank Prendergast, and Jerry Bartlemay answered questions about topics such as cybersecurity risk, the emergency of the … DCS can be preferred when advanced process control is required and contain a large facility that’s spread out over a wide geographic area with thousands of I/O points. About Bayt.com. A distributed control system (DCS) centralizes plant operations to provide flexibility and simplicity by allowing central control, monitoring and reporting of individual components and processes. It has capable to communication with computer in plant. What's the main difference between DCS & PLC? The idea of using a PLC-based system rather than a DCS has become a philosophical and technical debate in the industry. The company name stuck through a couple of acquisitions, then morphed into what is now Schneider Electric. Abig differentiator of DCS over PLC/SCADAis the standardisation they provide. 3. PLC (especially Compact PLC) has a lower cost associated with it as compared to the other automation technology. Function block programming, if you aren’t familiar with it, is a section or several lines of code behind a single interface. The best way to think about DCS and PLC is like this: in the majority of cases, a PLC controls a machine and a DCS controls a plant. Interestingly, this debate over the virtues of DCS vs. PLC has been ongoing since these two architectures came into existence 40 years ago. It was over 35 years ago that the first DCS systems were installed in glass industry processes. They were initially developed to replace hardwired relays, sequences and timers used in the manufacturing process by the automation industry, but today they have scaled and are being used by all kind of manufacturing processes including robot based lines. This allows them to accurately control motors and drives running at high speeds. This makes it easier to implement and maintain. A DCS today is just as functionally and cost-effective as a PLC in fast logic sequential tasks. DCS was originally developed for analogue control. Yet another advantage of the DCS is installation cost savings. Figure 2. The PLC is cost effective from 0 to a few thousand I/O points. “The ability to employ a single, hybrid control strategy that combines the benefits of both DCS and PLC/HMI control is a huge advantage for a company today, enabling them to run completely different processes from the same controller environment,” Ryan said. The proposals didn’t exactly meet Morley’s creative nature—they were so similar and repetitive that, being the antsy type, he eventually grew bored. A DCS combines one or more PLCs with an HMI, and allows the integrator to build both together. PLC Pros: 1. Modern industrial applications are demanding the reliability of a DCS system but the flexibility of a PLC. PLCs have a simpler architecture, as is evident from the diagrams above. 5. Here again the DCS has an advantage over a PLC. One of the drawbacks to the DCS has been the scarcity of programmers that have some experience with it. A DCS takes much longer to process data, … Today, we will dive into some of the advantages of PLCs. Benefits or advantages of SCADA. This advantage occurs because of the autonomous controller can be located in close proximity to the process versus pulling long runs of I/O wire across a plant. In the beginning, the PLC was used primarily for discrete controls. There are many advantages that a PLC system holds over a relay system. Systems can be shut down for maintenance, troubleshooting or upgrades without damage to equipment or significant downtime costs. A DCS or distributed control system is similar to a PLC in that it has rugged computer controllers, however, the DCS contains multiple autonomous controllers that are distributed throughout a system, also used for automating processes. It has great computational capabilities. DCS designs often trade high levels of functionality for repeatability and dependability. A DCS will be able to take advantage of all the aspects of an automated system, from the machines and sensors to the controllers and computers. You can slap in as many controllers and networks as you can afford. A PLC can become a “sub-system” of a DCS when the application calls f… A DCS typically covers an entire process, and is capable of covering an entire plant. In her lengthy career, Anderson has worked in a wide variety of industries, and with all of the top PLC systems, as well as the top names inHMI/SCADA. Learn about some of the advantages that PLC systems have over a relay system. Like a good captain, the highest priority of a DCS is to deliver reliability and availability. , a format very similar to a schematic increasingly capable of covering an entire plant PLC basics required we dive... Day, thousands of sensors across wide region for various monitoring and control system and PLC systems autonomous... 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