Key Differences Between PLC and DCS

1. The key differentiating factor between PLC and DCS is that a PLC
is a single entity designed to control the processes. On the contrary,
DCS is a complete system distributed over a large network designed
for controlling the whole operation.
2. The speed of logic operation also crucially differentiates the two. As
PLC is designed to perform high-speed operations, DCS operations
are not expected to be that much quicker as it is intended to perform
bulk processes.
3. PLC is a replacement for electromechanical relay while DCS
replaced single loop controllers by including multiple control
components.
4. The response time of the programmable logic controller is one-tenth
of a second (i.e., decisecond) but that of the distributed control
system is approximately 30 ms.
5. The architecture of PLC is quite simpler than that of DCS.
6. The programmable logic controllers are designed for controlling
machines such as a lathe machine in which the plc handles the
operation of that particular machine.
Whereas the distributed control systems control the complete
process like a power system where multiple machine operations are
to be handled at various locations.
7. PLC possesses a centralized controller which is generally present
within the RTU. However, there is no centralized controller present in
the case of DCS due to distributed network.
8. In general, there are less than 1000 I/O ports supported by PLC.
While DCS can support several thousands of I/O ports thus are
known to be more scalable than PLC.
9. The higher scalability of DCS supports their use in process
enhancement and data integration. Whereas PLC due to low
scalability helps to perform repetitive tasks with reliability.
10. The programming of PLC is application-oriented whereas there is
a set of built-in control functions with a DCS which is configured
according to its various uses.
11. The scan time offered by PLC is around 10 milliseconds which is
quite less than DCS which provides scan time of 100 to 500
milliseconds.
12. PLC offers more difficulty in troubleshooting than DCS due to the
reason that issues are more clearly visible in a distributed network
than within complex machinery.
13. PLCs are comparatively less flexible than DCS in terms of
operator accessibility. However, the more flexible nature of DCS
leads to chances of exposure to unwanted interference by multiple
operators leading to the spurious shutdown.
14. The way PLCs are designed makes them usable
towards dedicated processes. Whereas the designing of DCSs
supports their use in complex processes where frequent
adjustments are required to be done.
15. PLC involves minimum human interaction whereas there is
comparatively more human interaction in DCS.

Basis for
PLC DCS
Comparison

Basic PLC is a single unit that DCS is a complete system

discretely controls that control machine
processes. operations by carrying out
various processes.

Year of Invention 1969 1975

Architecture Simple Comparatively complex

Replaced Electromechanical Single loop controllers

relays

Programmed According to desired Built-in control functions,

application. configured application-wise.

Controls Machine Plant (System)

Controller type Centralized (at RTU De-centralized

station)
Basis for
PLC DCS
Comparison

Scan time 10 milliseconds or less 100-500 milliseconds

Controlling type Discrete Regulatory

Response time Fast Comparatively slow

I/O terminals Less More

Heart of the In plc-based system-plc In DCS-HMI

system

Troubleshooting Difficult Easy

Human Minimum Comparatively more

interaction

Initial cost Not expensive Expensive

Flexibility Less Comparatively more

Utilized for Dedicated processes Complex processes