A programmable logic controller (PLC) is a specialized processor/ computer with all the

hardware and software to do a specific automation task, say running a plant/factory.

This means that all the Field/Realworld Inputs are processed by the PLC (using Input
interface hardware )and the same then issues commands to various devices and
actuators(via Output interface). This has some Pros and Cons.

Pros:-

1. As a single processor is working it can easily access all the data / inputs and use
it as it requires.
2. It has a simple architecture and is easier to implement and maintain.
3. It has reduced hardware and reduced cost.
Cons:-

1. As all the functions are done by the same processor it increases the loading on
the controller. For large systems the processing power required can be too
high.
2. There is no physical segregation for critical application such as protections.
3. Failure of the controllers (though redundant controllers can be provided) will
lead to complete shutdown of the control system. For some applications a true
standalone system is required.
4. If the various areas are far away the cabling cost of inputs and outputs to the
PLC can increase to much and for long distance it can be impracticable.
If a standalone system is made for such application then it will be difficult to integrate
them in a common SCADA/ HMI/ interface and the spare for maintaining different
systems will increase cost.

DCS (distributed control system)can solve these problems. In a DCS the entire logic and
hardware is distribute or broken into different microprocessors or Functional
groups(FGs) for ease the implementation and provide segregation.

Pros:-

1. As a single processor is working it can easily access all the data / inputs and use
it as it requires.
2. It has a simple architecture and is easier to implement and maintain.
3. It has reduced hardware and reduced cost.
Cons:-

1. As all the functions are done by the same processor it increases the loading on
the controller. For large systems the processing power required can be too
high.
2. There is no physical segregation for critical application such as protections.
3. Failure of the controllers (though redundant controllers can be provided) will
lead to complete shutdown of the control system. For some applications a true
standalone system is required.
 4. If the various areas are far away the cabling cost of inputs and outputs to the
PLC can increase to much and for long distance it can be impracticable.
If a standalone system is made for such application then it will be difficult to integrate
them in a common SCADA/ HMI/ interface and the spare for maintaining different
systems will increase cost.

DCS (distributed control system)can solve these problems. In a DCS the entire logic and
hardware is distribute or broken into different microprocessors or

These separate Functional groups(FGs) are linked to the same HMI/SCADA/interface.

The entire control of the plant is broken in small groups with each groups having
something similar. For example:- The AC/ventilation system can be separated from the
production part as it is not related functionally.

If separate FGs need to communicate some signals, the same is done through Hardwire
or Network/protocol such as OPC, modbus, profibus etc. As most of the processing is
already done in the other FG the cabling is also reduced.

Protection system and critical systems can be made into a separate FG and this
processor having low input and controls can work with low loading and higher speed.

As a engineer working in Control systems, I too find it very confusing when people use
the term PLC and DCS interchangeable. This is because DCS are an advanced or a larger
implementation of the PLCs. A number of vendors call the same processor as PLC or
DCS depending on the execution or architecture used for the application as illustrated.

I hope this is helpful to you and for any queries do comment.

1. PLC stands for Programmable Logic Controller which can handle the
binary input and output of the logic statement which are stored in its
memory.its a digitally operating system which are logic stored in its memory by
programming system.
 Programmable Logic Controllers, are frequently used to synchronize the flow of
inputs from sensors (Physical) and events with the flow of outputs to actuators
and events. This leads to precisely controlled actions that permit a tight control
of almost any industrial process.
 This is actually a control device that consists of a programmable
microprocessor, and is programmed using a specialized computer language.
 Before, a programmable logic controller would have been programmed in
ladder logic, which is similar to a schematic of relay logic.
 A modern programmable logic controller is usually programmed in any one of
several languages, ranging from ladder logic to Basic or C.
 Typically, the program is written in a development environment on a personal
computer (PC), and then is downloaded onto the programmable logic
controller directly through a cable connection.
 The program is stored in the programmable logic controller in non-volatile
memory.Programmable logic controllers contain a variable
  number of Input/Output (I/O) ports, and are typically Reduced Instruction
Set Computer (RISC) based.
 They are designed for real-time use, and often must withstand harsh
environments on the shop floor.

2. DCS stands for Distributed Control systems .Distributed control

system it controls all types of process variable at a time through this we can
control the whole plant,we can see the status of plant,and handling unit.
 It is a system of dividing plant or process control into several areas of
responsibility, each managed by its own controller, with the whole system
connected to form a single entity, usually by means of communication buses.
 (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. The
entire system of controllers is connected by networks for communication and
monitoring.
 A DCS typically uses custom designed processors as controllers and uses
both proprietary interconnections and Communications protocol
 for communication.
 Input & 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 (a.k.a. field) and transmit instructions to the output instruments in
the field.
 Computer buses or electrical buses connect the processor and modules
through multiplexer or de-multiplexers.
 Buses also connect the distributed controllers with the central controller and
finally to the Human-Machine Interface (HMI) or control consoles.
What are the differences between SCADA and DCS?

 A SCADA system is event driven, while a DCS is state driven.

 RTUs for SCADA and PLC/Controllers for DCS
 DCS is process oriented and SCADA systems are data-gathering oriented
 The DCS (Distributed Control Systems)is usually used in factories and located
within a more confined area. It uses a high-speed communications medium,
such as LAN. Closed loop control is a high priority in this system.
 The SCADA system covers larger geographical areas. It may rely on a variety of
communication links such as radio and telephone. Closed loop control is not a
high priority in this system.
Comparison

 The event driven SCADA needs to get secure data and control over a potentially
slow, unreliable communications medium, and needs to maintain a database of
'last known good values' for prompt operator display. It frequently needs to do
 event processing and data quality validation. Redundancy is usually handled in
a distributed manner.
The state driven DCS is always connected to its data source, so it does not need to
maintain a database of ‘current values'. Redundancy is usually handled by parallel
equipment, not by diffusion of information around a distributed database.

 A SCADA master station or HMI system generally considers changes of state as

the main criteria driving the data gathering and presentation system.
DCS systems consider the process variable's present state to be the main criteria driving
the DCS and tasks are generally run sequentially, rather than event driven. Therefore
alarms or events are not generated when a point changes state, but when the particular
process run.

 Event lists and alarm lists are of major importance to the operator, sometimes
more so than process screens and filtering of these lists is often quite complex,
allowing displays sorted by system area and alarm/event category/importance.
Events and alarm lists are secondary in importance to the process displays, and filtering
may not be as complex and flexible.

PLC is a controller with nearly real time response in milliseconds. This is typically suited
for discrete contols such as machine automation or emergency shutdown of process
plants.

Wherea,DCS has distributed controllers suited for localized process controls

applications. Local Analog controls with PID controllers can control local processes and
report to a supervisory controller for visuals and configurations. Central DCS controllers
may have response times in minutes due to very large numbers of distributed IO
controllers connected to it (100 to 100k+)

Both have overlapping domains for some small to midium sized applications. However,
now the line is very thin for small to medium size applications as PLC may also act as
supervisor to many other local PLC controllers having anolag controls. In many cases
individual PLC can control multitudes of analog loops without loosing its mind.

Due to conventional division of applications for DCS (process) and PLC (discrete)-many
features, templates , network and associated hardware or software templates make users
to continue using in same manner for sake of convenience and relative advantages.