A Brief presentation on

Comparison between PLC, DCS & SCADA

Prepared By:

Md. Kaisar Jamil

Assistant Manager (Instrument)
Eastern Refinery Limited

Chittagong, Bangladesh.
What is PLC?

PLC stands for "Programmable Logic Controller" which is evolution for early control systems used
with industrial automation and process control.
Program: To perform any kind of task we must perform a particular set of instructions and those set of
instructions is nothing but a program.
Logic: If we have to achieve a desired result; then to perform any kind of task, we can’t go
haphazardly. We must perform step by step a particular sequence of operation to achieve the result.
That sequence of operation is logic for that operation.
Controller: Through a PLC you are trying to control the field element or the process to achieve your
desired result.
So, a PLC is a computer based control system that controls the field element or process through a
particular sequence of instruction, which is nothing but logic and this particular set of instructions are
stored inside the PLC in form of program. It is primarily used to control equipment in an industrial
facility.
PLC is ideal for single batch or high-speed control, it have a relatively simple, low-cost design, and are
the core of the system. Their design is flexible and generic.

PLC Components: 

1. Power Supply: Common power levels used are 24V DC or 120 VAC.

2. Input/ Output assembly (I/O): inputs carry signals from the process into the controller; they
can be input switches, pressure sensors, operator inputs while outputs are the devices that the
PLC uses to send changes out to the world. These act like an actuator the PLC that can change
to adjust or control the process – motors, lights, relays, pumps, etc.
 3. Processor or sometimes called (CPU): The size and type of CPU will determine things like:
the programming functions available, size of the application logic available, amount of memory
available, and processing speed.
4. Programming Device: acts as the brain of the system which receives signal and uses a Binary
language (0 or 1) to process it and give Binary output. It is often a computer or laptop and also
used for running programming tool (software).
DCS
DCS stands for "Distributed Control System".
From the name it is clear that DCS is control system. It is a control system where the total process
divided in number of sub-system; and each subsystem is being controlled by its own controller. So,
basically, in DCS a large process is being controlled by a number of controllers each controlling its
own subsystem. In DCS, we are distributing the control to control the process; we are employing a
number of controllers.
DCS Network Components: 
1. Operator Stations: Operator Stations, in a DCS, are the heart of the system
2. Servers, Archiving and Engineering Computers
Servers: used for the collection of data at the processor level( between operator unit and processors in
field device.
Archiving computers: used for storing operational data that may be used for process study \
development or compliance.
Engineering stations are used for creating the projects on which the processes run such as Logic for
tasks - Graphical displays for operator interaction - Administration of all of those tasks through
installed software packages.
3. Controllers supervise the individual processors as well as I/O modules and are responsible for
providing the data to the servers, which in turn, supply it for operator graphical interface.
4. Field Devices: at this level would be devices such as transmitters, switches, valves, motors,
remote or distributed I/O, etc.

Operator station
HMI Panel

Controllers
CPU
I/Os

I/Os

Sensors, valves Programming device

Sensors, valves & end & end devices
devices
Comparison: PLC vs. DCS
a. Process Type
PLCs were historically designed for discrete operation handling input in binary; whereas DCS
was historically designed for controlling PID controllers or different analog kind of signals.
So, by means of process type, PLC is meant to handle simple/ less complex processes, like gas
analyzers, paper & pulp industries, hydraulic units etc., where as DCS was designed to control
complex kind of processes like oil, steel Industries etc.
b. Hardware package
Initially PLC included the basic needed hardware for operation only. Other software and HMI
(Human Machine Interface) were not part of the package. The HMI or different software will be
needed to handle the networking or communication
When DCS emerged in the market, the idea was to supply a whole package of softwares and
HMI. With DCS, the HMI & the softwares will be making the task easier for comm., networking
or interconnecting different controllers or addition of new controllers.
c. Response time
PLC response time is too fast (10ms or lower), whereas DCS response time is relatively slow
(100ms to 500ms).
Fast response and low scan time makes PLC ideal candidate for safety or firing control.
d. Scalability
PLCs are capable of handling only a few thousand I/Os, whereas DCS is capable of handling
many thousand I/Os. That’s why, PLC is meant for Small scale equipments like hydraulic or gas
analyzers or small paper and pulp industries and DCS is meant for large process spread across
large area.
The software and hardware provided with the DCS is much more capable than that of PLC. It can
easily add any new controller or setup a new networking area.
e. Redundancy
PLCs are normally not redundant whereas DCS is normally redandant; redundancy can be
configured in PLCs but it will cost even more than the DCSs.
f. Programming
PLC programs are supposed to be written in any of the languages like ladder, STL etc. While,
DCS was having a feature of Functional Block Programming. In DCS, programming was quite
easier because, a number of functional blocks already developed inside DCS, which were meant
to control small operations like a block for motor operation, a block for PID controller; all these
things were already available in a package of some functional block.
Now a days, PLC also have a Functional Block Programming feature.
Hybrid Distributed Control System
These differences between PLC & DCS are not applicable now.
The difference between PLC and DCS has been decreasing continuously over the past dacade. PLC or
DCS are now quite capable of handling operations which was only to be meant handled by another
one, such as, safety purpose processes were previously thought of controlled by PLC only, now can
easily be handled by DCS now. Even PLCs now have the functionality of once DCS processed only,
like, PID control or functional block programming etc.

On the other Hand, SCADA Definition:

SCADA stands for "Supervisory Control and Data Acquisition" which is a control system architecture
that uses computers, networked data communications and graphical user interfaces for high-level
process supervisory management
SCADA is not exactly like PLC & DCS. Unlike PLC & DCS, having hardware package like them,
SCADA will not send some binary or analog signal to the field devices to control the process.
Yes, it controls the process, but not like PLC or DCS. SCADA does not include any hardware.

SCADA does not include any hardware package. It will be controlling the process through different
controllers like PLC, DCS or PID controllers. PLC/DCS/PID will be controlling the field element; and
the process will be controlled through SCADA, but the commands, which are given on the SCADA
pages, will be sent the PLC/DCS/PID controllers and then they will be sending the signals to the field
devices to control the process. So, it is quite different from PLC or DCS.

SCADA is the preferred technology for monitoring processes and events that are spread out across a
large geographic area.

SCADA system components

1. Supervisory computers: This is the heart of the SCADA system, gathering data on the process
and sending control commands to the field connected devices and responsible for
communicating with the field connection controllers, which are PLCs, and includes the HMI
software running on operator workstations
2. Remote terminal units (RTUs): connect to sensors and actuators in the process, and are
networked to the supervisory computer system. RTUs are "intelligent I/O".
3. Programmable logic controllers (PLCs): connected to sensors and actuators in the process,
and are networked to the supervisory system in the same way as RTUs. PLCs have more
sophisticated embedded control capabilities than RTUs, and are programmed in one or more
programming languages.
4. Communication infrastructure: This connects the supervisory computer system to the RTUs
and PLCs, and may use industry standard or manufacturer proprietary protocols.
5. Human-machine interface: It presents plant information to the operating personnel
graphically in the form of diagrams, which are a schematic representation of the plant being
controlled, and alarm and event logging pages. The HMI is linked to the SCADA supervisory
computer to provide live data to drive the mimic diagrams, alarm displays and trending graphs.
Comparison: DCS vs. SCADA

DCS is Process oriented whereas SCADA is Data gathering oriented.

DCS will be controlling the process through its dedicated hardware, like different AI, AO, DI & DO
cards. Whereas, SCADA will only be gathering the data from the field, that is, different field element
values at different moment.

DCS is process state driven and scans process continuously.

SCADA never scans the process; it is event driven, SCADA maintains its own database while DCS
does maintain any kind of database of field element values.

DCS consists of one or more controllers used to implement advanced process control techniques &
SCADA systems cannot carry out advanced process control techniques.

SCADA always storing different field element values at different moment and on meeting any kind of
trigger value that is set in the data, it will be raising a command to the associated controller which
might be a PLC or a DCS or a PID controller.

Comparison: PLC vs. DCS vs. SCADA

Upon comparison, A feedback control loop is directly controlled by the PLC; several of these control
loops can be controlled by DCS, but the SCADA software monitors the overall performance of the
loop/ loops.

DCS is a control device that has higher capabilities compared to an ordinary PLC. On the other hand,
SCADA is mainly a software environment that can communicate with PLC's and probably DCSs also
for that matter in order to monitor the functionality of those devices and perform data acquisition and
data logging to a monitoring platform.

Conclusion

Stated above are how we can derive differences between PLC, DCS & SCADA. Though, PLC & DCA
aren’t really comparison able with SCADA as the principle of operation of SCADA is quite different
than PLC & DCS (kind of like comparing apples and oranges).