A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used for automation of electromechanical processes, such as control

of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a limited time, otherwise unintended operation will result. The automotive industry is one of the largest users of PLCs. PLCs were programmed in "ladder logic", which strongly resembles a schematic diagram of relay logic. PLCs can be programmed in a variety of ways, from the relay-derived ladder logic to programming languages such as specially adapted dialects of BASIC and C. Another method is State Logic, a very high-level programming language designed to program PLCs based on state transition diagrams. PLC-like programming combined with remote I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in certain applications. Regarding the practicality of these desktop computer based logic controllers, it is important to note that they have not been generally accepted in heavy industry because the desktop computers run on less stable operating systems than do PLCs, and because the desktop computer hardware is typically not designed to the same levels of tolerance to temperature, humidity, vibration, and longevity as the processors used in PLCs. A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind of dynamic 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. DCS is a computerized control system used to control the production line in the industry. The entire system of controllers is connected by networks for communication and monitoring. DCS is a very broad term used in a variety of industries, to monitor and control distributed equipment. A DCS typically uses custom designed processors as controllers and uses both proprietary interconnections and communications protocol for communication. Input and output modules form component parts of the DCS. The processor receives information from input modules and sends information to output modules. The input modules receive information from input instruments in the process (or field) and transmit instructions to the output instruments in the field. Computer buses or electrical buses connect the processor and modules through multiplexer or demultiplexers. Buses also connect the distributed controllers with the central controller and finally to the Humanmachine interface (HMI) or control consoles. DCSs are connected to sensors and actuators and use setpoint control to control the flow of material through the plant. The most common example is a setpoint control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation

device to open or close until the fluidic flow process reaches the desired setpoint. Large oil refineries have many thousands of I/O points and employ very large DCSs. DCSs may employ one or more workstations and can be configured at the workstation or by an offline personal computer. Local communication is handled by a control network with transmission over twisted pair, coaxial, or fiber optic cable. A server and/or applications processor may be included in the system for extra computational, data collection, and reporting capability. What are the differnces between Programmable Logic Controllers and Distributed Control System? First PLC is a digital computer used for automation electromechanical processes while DCS is a automated control system that is distributed through a machine to provide instructions to different parts of the machine. Interms of functionallity PLC is a one unit used to control particular machine or production unit and the DCS is number of PLCs distributed over a control network over the entire plant. PLC is used Commonly with On\Off (Digital) Control and may be expanded with Analog I\O Modules for Analog Control and used for a Unique Task and the DCS is used Commonly with Process Control Systems as it is Combined of Many control Cards, PLCs. PLC is basically oriented for one job only, suppose if PLC fails then whole system will shut down while in DCS there is redundant PLC for each PLC so that if primary system fails then its standby plc takes over the charge. In PLC, we cant change configuration online. We have to go offline to change configuration while in DCS, parameters can be changed online. Total cost and size of PLC is much less than DCS system. Programmable Logic Controllers or Distributed Control System: Which is better? 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, Long-term maintainability, and Life-cycle costs. PLCs and DCSs overlap in their features, but also have distinct strengths and weaknesses. When deciding between the two, know who will deliver and support your system, and how they will do it. 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.