What is DCS? (Distributed Control System)

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Over the years, the term DCS has evolved from the original description for the acronym as a Distributed Control System to the use of the term Decentralized Control System and they seem to be somewhat interchangeable nowadays.
Briefly, as a point of the historical review, when PLC’s were invented, they were really good at handling single processes and were primarily used for repetitive, discrete control.
The advent of the DCS was for controlling many autonomous controllers that handled many continuous operations, mainly using analog control.
PLCs, traditionally, were used for single batch or high-speed control, have a relatively simple, low-cost design, and are the core of the system.
Processing time for tasks are typically very fast, operators usually interact and control the system using some sort of graphical display such as SCADA.
A DCS is used for continuous, complex controls, have an integrated control center much like a SCADA, which is the core of the system versus the processors in a PLC system.
The DCS has a number of predefined functions. Processing times are somewhat slower. Operators interact with the control system via an integrated graphical display.
DCS’s also have a claim that when safety is a top priority, the DCS is the most reliable system.
Redundancy may be deployed in either the PLC or DCS applications. You could employ redundant components to negate the possibility of process shutdowns.
Now that we’ve touched on some of the differences in the systems, let’s focus on the DCS and some of its components.
A typical plant starts with a centralized operator control center typically called Operator Stations.
This is where the operator can observe the operations of the plant, view process warnings and alarms, monitor production, and more.
The next level of components may contain servers, archiving computers, and engineering stations.
Communications with the Operator Station level is typically Industrial Ethernet.
Servers are used for the collection of data at the processor level.
Archiving computers are used for storing historical data that may be used for trends or compliance.
Engineering stations are used for creating the projects on which the processes run.
At the next level, you have the master controllers that supervise the individual processors as well as I/O modules.
The next level is the field device level.
Communications between this level and the processor level can be nearly any type that may be compatible with the components.
Components at this level would be devices such as transmitters, switches, valves, motors, remote or distributed I/O, etc.
In short, both PLCs and a DCS have their place in the market today.
PLCs would work best in a small production environment where component failure if no redundant system is deployed, is a small risk for the application, the budget is restricted, or the tasks and I/O count are minimal.
A DCS would be better used in an environment where there are large I/O counts with many continuous processes, a processor failure in one section of the plant is not a problem for production, or risk assessment has determined that an integrated package would be the best option.
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[@realpars]

Want to learn about industrial automation? Go here: www.realpars.com/individual-pricing Want to train your team in industrial automation? Go here: www.realpars.com/pricing-team

[@mariaburman3491]

I'm a Project Manager/Mechanical Engineer currently running a control system project. This was such a great help. Thank you!😀

[@realpars]

You're very welcome! Happy learning!

[@paulbaribor6473]

I’m preparing for an instrumentation interview tomorrow and your page has been so helpful. Thank you.

[@realpars]

That's amazing to hear! Thank you for sharing, and best of luck with your interview!

[@halitekmekci8304]

I can say that as an automation engineer, the entire channel very informative. Thanks for it

[@realpars]

Thanks a lot!

[@Techwem]

Absolutely agreed.. This also comes from automation engineer 😉

[@takashi8572]

I'm a Japanese young instrument engineer and I deeply appreciate your videos.

[@realpars]

That's very kind of you! Happy to hear that.

[@emmanuelsanusi1389]

Thank you RealPars !!

[@realpars]

You are welcome!

[@qaiserbozdar1542]

Thank You very much and a lots of love from my side i am an Electronics Engineering Undergraduate, downloading your each Instrumentation Videos like this one and other such as sensors, VFD, motors etc. I am making a course from your videos for my Self learning. Again Thank You, you are so helpful RealPars.

[@realpars]

Thanks great to hear! You are very welcome!

[@edswrivs3920]

It´s a very clear video, a lot of information organized, congrats REALPARS, you're so professionals, the automation field is very interesting, always i learn something new with you, thank you so much, greeting from Mexico!!

[@realpars]

Great feedback, thanks a lot for sharing! If you have any questions along the way, please feel free to reach out to us at any time! Happy learning!

[@abdulgaffarmohammedshafee9333]

It is increased my technical knowledge & made my trade more happy

[@realpars]

Great to hear that, Abdul! Keep up the learning curve!

[@dr.alim.humada6266]

Excellent explanation, really it is very helpful for those work in control systems (modern systems). Many thanks

[@realpars]

You're very welcome, Ali! Great to receive such feedback.

[@avevaedgevideos78367]

Good video, as always. Just a clarification: - You say that Industrial Ethernet is the way how Operation Stations and Servers (because you may also have redundant servers) communicate. This is correct; however, you’re using the PROFINET logo on that level which is wrong since not all the Industrial Ethernet communications are PROFINET. You have all the entire schema based on Siemens hardware and software so we can have WinCC as example. Clients are connected by standard TCP/IP communications over Industrial Ethernet. In fact, it’s also common link the PLCs with the server using S7 Protocol over Industrial Ethernet instead of PROFINET. PROFINET is more widely used on PLC I/O or PLC Intelligent Device/Sensor or even PLC PLC communications since this protocol has huge advantages at this specific automation level.

[@realpars]

Miguel, thank you for your comment. What you have described is very common, where comms at the PLC and I/O level are Profinet or Profibus and comms between WinCC and servers is S7 Protocol over Industrial Ethernet. This is almost exclusively true for S7-300 and S7-400 PLCs and components, but later S7-1200 and S7-1500 systems typically use Profinet for communications to/from the PLC/servers/WinCC stations. Industrial Ethernet (IE) refers to the use of standard Ethernet protocols with rugged connectors and extended temperature switches in an industrial environment, for automation or process control. Profinet, S7, Ethernet/IP and other protocols all run over Industrial Ethernet. There are many different ways to configure DCS systems, and we, as automation engineers, should be aware of the many different ways that this can be done. DCS system suppliers typically have requirements that limit the hardware and software choices that can be made for their systems, but open HMI applications like WinCC allow a choice of protocols that is quite extensive.

[@thassioam]

Nice as always!

[@realpars]

Thank you!

[@solutionbybrain9978]

Firstly I would like to thanks realpars for all your videos that I looked in your channel, which I called it giving the secure key of all automation. Secondly I would like to have details information about simatic IT with powerfull example ..... regarding an example with management software ERP/PLM and madules MES function block library in simatic pcs7 v9.0 sp1 .

[@realpars]

Thank you! If I understand your comment correctly you are referring to our Course Library on realpars.com/ the lock symbols that you are seeing are course videos that are only available for our paid subscribers. By subscribing to our monthly or yearly package you obtain full access to our Course Library (400+ video courses.) Hopefully, this clears things up a bit. If you have further questions, feel free to comment back here! Happy learning!

[@solutionbybrain9978]

Most welcome sir..... I would like to thanks too....... Can I have the outline course so as to have knowledge in what I am going to subscribe.

[@razikaaouir2111]

thank you so so much for this great work

[@realpars]

You're very welcome!

[@akshaytalware9901]

Nice information... Requested you to please upload video on different protocol used for communicating third party system in automation... E.g DCS to PLC

[@realpars]

Thanks for your topic suggestion, Akshay! I will forward this to our creator team. Happy learning!

[@epal6964]

great video very educational keep it up

[@realpars]

Happy to hear that! Thanks for sharing!

[@basithpp5938]

thanks for the video.. its completely useful for me....all of your video's is different from other channels which i have seen.. explanation is very understandable waiting for another content... is there any course about automation providing by your team? please let me know

[@realpars]

You are very welcome! Great to hear that. We sure have, feel free to have a look through our courses over here realpars.com/

[@margamsravan5969]

Excellent video...mann....i really..appreciate for making this...pls explain elaborately about operating stations,and engeneering station.....do not forget to upload video on redundancy...

[@realpars]

Thanks for your support, Margam!

[@CrazyLazys]

Did they ever upload this? :)

[@qaiserbozdar1542]

It is requested to you that upload working and necessity of flobass computer S600+ and also about motorized and pneumatic valves. It will be helpful to me but also other electronics engineering pioneers.

[@surendrakverma555]

Very good. Thanks 🙏🙏🙏

[@realpars]

Our pleasure! Happy learning

[@generaltechnologyknowledge5165]

Good explanation

[@realpars]

Thank you!

[@san1122222]

You forgot to mention that both plc and full cpus can be used in a dcs (for example ABB's dcs).

[@englishstudymasumahmed7565]

keep doing, a great video.

[@realpars]

Thanks, will do!

[@daizbrahim1378]

Really very interested but i want study more and more. Thank you very much

[@realpars]

That's great! Luckily we have lots of content to study :). Happy learning, keep up the good work!

[@quangluu7531]

Thanks for share

[@realpars]

You are welcome!

[@danielbarrantesvillalobos106]

Hi, can you tell me what software do you use to the schematics & cabinets diagrams ?

[@realpars]

Hi Daniel, I am actually not sure about this as this is done by our graphic and animation department.

[@laithjawad9208]

Thanks for your efforts, kindly request to prepare for DCS Experion of Honeywell System

[@realpars]

Hi Laith, Thanks for the topic suggestion, I will definitely go ahead and forward this to our creator team. Happy learning!

[@UdhayaTechInventor]

Really nice

[@realpars]

Thank you!

[@harisingh6188]

Thank you for it

[@realpars]

You're very welcome, Hari!

[@iDrunkky]

Can you explain in more detail about servers

[@kaizoku47]

server is related to all the slaves ( plcs or the RTUs) , as a master then distribue the data to all the operation systems

[@anuradha1890]

Nice vedeo

[@user-bl6mv4nv9h]

Thank you

[@realpars]

You are welcome!

[@lyaeusv3828]

Hello I have a question sir what is the function of the server ? Does it convert the signal to something like OPC ua in order to communicate with control station and other machinery that are located far away ? Also the archive is it something like a Maria dab or sql database? Great video btw !

[@realpars]

In a DCS system, the server can perform many functions, such as HMI Server (holds tag database, screen files, etc.), Batch Server (controls steps and recipes in a modular batch process control scheme), or other Application Server, such as communications (for example, OPC-UA as you mentioned). The Archive is commonly called a Historian, which is an integrated data collection and retrieval system, based on technology such as SQL.

[@namangoku2649]

Awsome as usual Please make some more videos on this topic. if possible create a video series on it because there is no one to teach us as you and i want more knowledge on this topic so please add my request in your reqeust ques.

[@realpars]

Thank you! I will forward this topic request to our creator team.

[@namangoku2649]

@@realpars always welcome

[@kiykio4299]

Thank you, I'm from Egypt I'm a new subscriber. Is there any advice from where to start?

[@aniketkamble3236]

Very informative

[@realpars]

Thank you!

[@Techwem]

For more videos related to DeltaV, Honeywell, Yokogawa or ABB DCS, Visit our Channel and Subscribe.

[@aniketkamble3236]

@@Techwem Thanks for the suggestion

[@erkebulanserikkaliyev913]

Hi, can anyone share library about automation engineering. Thanks in advance.

[@mouizimran1032]

Hi Sir, Nice video. 1. Kindly make video on differences between PLC and DCS 2. Different communication protocols and their differences and pros and cons

[@qaiserbozdar1542]

Appreciated Mr Mouiz Imran

[@realpars]

Thanks for the topic suggesiton, Mouiz Imran. I will definitely pass it on to our creator team!

[@mouizimran1032]

@@realpars Hey Thanks for the response. It's really good that you are open to suggestions. My best wishes with RealPars team.

[@qaiserbozdar1542]

@@realpars Hurrah, Thank you RealPars

[@wagdyelabsy]

Please, At the stage of master controllers, The controllers in this case are plcs? Or there is a special controllers for Dcs systems?

[@realpars]

Thank you for your question. It's a combination of both. PLCs control the factory production area, while DCSs manage everything. Distributed control systems (DCSs) are software packages running on industrial PCs. They communicate with control hardware and provide a centralized human-machine interface (HMI) for the controlled equipment. Programmable logic controllers (PLCs) form the core of DCSs and other computer control systems. Happy learning from RealPars!

[@winner1338]

Almost 10 years of electrical designing. I feel like i know nothing T-T Lots of my colleagues keep telling me that i know a lot, it's good to have you in the company, there aren't many like you in this field, I'm important to the company, ... But inside me, i feel awkward because i know I'm not what they thinking. This channel is so very useful for me. Summary of many objects I didn't know.

[@realpars]

We're very happy to hear that!

[@stringsandhamers]

Hello, thank you for this video, so if my scada can manage more than one plc it could be a dcs?

[@scottsommer5450]

Yes, if you use the definition of DCS as "decentralized control system". I would not get hung up on definitions; they seem to change from time to time. The important concept is that operator stations are used to monitor and control the process, supported by servers and other computers to host tag databases, operator displays, configuration stations, and engineering stations. We call these integrated, distributed systems "DCS systems".

[@stringsandhamers]

@@scottsommer5450 thank you

[@visakhpradeepedathil2177]

No scada may have more than one plc or rtu

[@motasembellah1363]

could you please, explain the OPC-technology and especially OPC UA

[@realpars]

Thanks for the suggestion, I have forwarded this to our creator team, hopefully, they can create a video about this.

[@Emregondem]

DCS is big plc, example Honeywell C300

[@salehsaleh5988]

I hope if you could make a whole DCS course as the PLC one, is it in the plan? Thanks alot

[@realpars]

Hey Saleh! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

[@talhagondal4215]

You should provide the References and sources from where you pick Data.... BTW learn alot

[@realpars]

Thanks for the feedback, Talha! This video is based on Mondi's experience (RealPars instructor) as an automation and control engineer. There is not that much of reference to be added here.

[@talhagondal4215]

I suggest him a Topic "Model Predictive control" please make video on this and try to explore

[@user-jn2vq4vo8q]

thank you very much indeed just I have Q ? what the difference between Dcs & Pcs

[@realpars]

Hi there, Thanks for your comment! You might want to have a look at this course video kzbin.info/www/bejne/n3ecapyBoamjrqM Happy learning!

[@girivaradpm9694]

Could you please upload videos on interfaces in dcs,computer controlled systems,das,ddc

[@realpars]

Hey! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

[@Techwem]

For more videos related to DeltaV, Honeywell, Yokogawa or ABB DCS, Visit our Channel and Subscribe.

[@shivamRudram]

What is difference between the microprocessor used in PIC microcontroller or other microcontroller boards and the microprocessor inside the DCS controller which can handle @ 1000 I/o 's ?

[@realpars]

A PLC and a DCS both need a processor capable of handling the various computational and I/O tasks required by these devices. The primary CPU microprocessor for these devices are typically based on commercial versions of multi-core processors, with customizations to accommodate the features of each CPU. In addition, firmware downloaded on EEPROM provides additional functionality for the CPU, such as OPC-UA or web support. The ability to handle large numbers of I/O rests in the memory provided by the CPU (additional chip sets included on the CPU board) and the internal data structure addressable by the CPU (firmware).

[@shivamRudram]

Thanks for the reply

[@mdhuzefatamboli4195]

Great I am still learning plc and dcs so can I get some data to learn and practice please

[@realpars]

Happy learning!

[@kaizoku47]

we are waiting for the scada and dcs comparison

[@realpars]

Thanks for the topic suggestion, Mouadh! I will pass it on to our creator team.

[@kaizoku47]

@@realpars thank you very much

[@brandonjheysonvilchezberau5430]

It would be good if they made a channel in Spanish, I think they would have a lot of acceptance and gain many followers...!!! Greetings from Peru.

[@abouakrekhan3028]

Nice

[@realpars]

Thank you!

[@MM-vi9kh]

Please 😭😭, What is the difference between FCS and DCS in uses??

[@realpars]

A DCS is typically used to control plants with many continuous process units and a relatively high number of I/O distributed throughout the plant. A Fieldbus Control System (FCS) is used for the same purpose, but its architecture is somewhat different. A true FCS is a totally digital control platform and does not require I/O multiplexers or I/O cabinets, per se. The networked structure of an FCS reduces hardware requirements. However, an FCS is more complex and requires a higher level of expertise to design and maintain.

[@EMEXONLINE]

Do you offer courses for Foxboro IA?

[@realpars]

Hi Essa, Thanks for your comment, we currently do not have any course videos on Foxboro IA. Feel free to browse through our course library to see all the different topics we are covering bit.ly/30AVJaR Happy learning!

[@jbombbeats2129]

Could you do a video about troubleshooting with a multimeter? Voltage testing, resistance testing, & how to determine if a part is bad?

[@jbombbeats2129]

Also, I'd like to say that you're videos are clear & very easy to understand! They've helped me grasp a lot of concepts & I am very grateful!

[@scottsommer5450]

Jake, thank you for your support and comments. We will certainly take a look at adding videos that deal with using a multimeter as a troubleshooting device. We have been focusing on programming and design in our videos, but a troubeshooting video will certainly have a broad appeal. Thank you for the suggestion!

[@iran_siemens]

Hi, I'm following your videos and they are very useful to me. But if you apply a little bit of it, is not it better? For example about pid This will be more understandable in the software environment thank you Alireza Dehghani

[@realpars]

Thanks for sharing your thoughts with us, Alireza! We appreciate that!

[@harrisonchilembo2050]

Hello am an operator of a casting control room anode furnace,at the smelter plant in Zambia at mopani copper mines,I would like to learn DCs operations.

[@gedionatphysicsmathelectro1867]

How is this different from an old system control bus like IEEE488 ?? as opposed to serial control data ???

[@realpars]

IEEE 488 is a parallel data bus, such as was used heavily in the 70's and 80's in the absence of fast serial interfaces. IEEE 488 was used for printers and other devices as well. Modern serial interfaces are fast and efficient, mainly due to advances in the hardware (physical) layer.

[@gedionatphysicsmathelectro1867]

@@realpars You are right on how the IEE488 differs from Serial. My question was, how does IEE488 and Serial bus concept would differ from DCS data processing and collection methodology. The bulky IEEE488 was used to control multiple devices as well as collect data. I have even made use of it as machine shop CNC controller. Looking how we draw a DCS operational flow chart using electronics, optics, pneumatics and Hydraulics, I find it very similar to the tiny little microprocessor operational flow chart before I start drawing the actual circuitry. I also find DCS and PLC a set function (mathematically speaking) within SCADA.

[@brandonjheysonvilchezberau5430]

Sería bueno que hagan un canal en Español, creo que tendrían mucha aceptación y ganarían muchos seguidores..!!!

[@realpars]

Hi Brandon, Thanks for your comment! We currently only provide our course videos in English, you are always able to turn on the English subtitles as that might make it a bit easier for you. Our apologies for any inconvenience! Happy learning!

[@tranducanan1373]

It means PLC is a smaller controller: 1 simple PLC( example: 1 kit of s7-1500). And DCS are larger controller: many PLCs( example 1 factory with many kits of S7-400) ?

[@realpars]

Yes and no. A controller in a DCS system is designed to perform a specific set of tasks that are centered around configurable tasks, IO channels, and block-oriented logic. PLCs are designed to perform a specific set of tasks centered around logic operations and IO communications. You are correct that even small DCS controllers have more power than many small PLC CPUs, like the Siemens S7-1200. However, the S7-400 is the "brain" of a very powerful DCS system known as PCS7. Over the past 10 years, PLCs and DCS controllers have become similar in size (both physical and logical) and in function.

[@idaras2012]

I want to become an automation technician train by Realpars How long will it take me by your training schedule ? Note : I need to be present and NOT ONLINE Please I need a feedback

[@realpars]

Hi there, Thanks for your comment, and great to hear your interest! 

Our course library is specifically designed to provide all the tools needed for beginners to evolve to an advanced level through our hands-on courses. You do not need to attend specific classes or be online, you are able to complete all of our video courses on your own pace whenever suits you. Feel free to browse through our course library to see all the different topics we are covering. bit.ly/30AVJaR Just to let you know, that we also have a free course on PLC Hardware bit.ly/2XnnUrF
 If you are interested, you will obtain full access to our complete course library (400+ video courses) by subscribing to either our monthly package for €22.12 a month or our yearly package for €159.28,-.

 Additionally, you will have access to our Technical Team - consisting of high ranking engineers with a lifetime of experience - who are here to help you out with any questions you might have along the way! 
 Hope this helps! If I can be of any further assistance, please let me know - I’m more than happy to help!

[@AshishKumar-vj6gt]

Please sir make a video on How to communicate CPU 315-2DP WITH CP343-1 & with this how I will read my I/O WHICH are connected with ET-200S IM151-3PN.

[@realpars]

Thanks for the topic suggestion, Ashish! I will surely pass it on.

[@AshishKumar-vj6gt]

Good morning sir..When you make this CPU& CP COMMUNICATION WITH IO READING PLEASE Explain & show step by step as you did in your all videos... thank you

[@aqx1729]

Difference between Et200M and Et200s ?

[@scottsommer5450]

Great question! ET-200S is a small form factor, compact, low I/O count I/O system (2 to 16 I/O per card) that can be installed in on a DIN rail. ET-200M is a higher density I/O subsystem that is rack-oriented with I/O cards capable of 8 to 64 I/O points per card. ET-200M also supports specialty cards, like position control, CAM control, and axis control. ET-200S is similar to A-B Point I/O. ET-200M is similar to CompactLogix I/O.

[@aqx1729]

@@scottsommer5450 thanks much

[@user-mc2zl8oc9k]

top

[@mnada72]

I think there is a confusion here , what you describe here is more Scada than DCS , as long as there is a server that collect data this is more Scada, true DCS has peer to peer communication between its components. and doesn't rely on server to collect data I know there is no clear boundaries here and technology transforms but true DCS rely on peer to peer coms.

[@realpars]

Thank you for your comment. As you mention, there is no longer a very clear boundary between DCS and SCADA architectures anymore. SCADA typically has a single server/computer that serves all of the functions of the control system including graphics, database, historian, etc. For a DCS, many of these same functions are typically executed in the controllers, but servers are many times required for the historian, batch execution, and advanced alarming.

[@sharifhossain8830]

Sir We know that PLC is a Controller SCADA is a Software What is DCS? it is Controller or Software?

[@realpars]

A DCS is most like a PLC. It is comprised of controllers and I/O cards, and is highly configurable with built-in functions and faceplates. Software is used for both PLC and DCS systems to configure and program the systems, and in each case, software is used to configure operating displays.

[@imtemplar1940]

Digital combat simulator

[@mostafaelmasry8770]

Please translate into Arabic

[@realpars]

Hi Mostafa, Thanks for your comment! We currently only provide our course videos in English, you are always able to turn on the English subtitles as that might make it a bit easier for you. Our apologies for any inconvenience! Happy learning!

[@mostafaelmasry8770]

@@realpars Thank you, Mr

[@thassioam]

Nice as always!

[@realpars]

Thank you!

[@derina.maleek9408]

Thank you

[@realpars]

You are very welcome!