Difference between PLC,DCS & SCADA

In the past the strength and weakness of both the automation technologies were well understood. So it was easy
for engineers to select the one that suits their application, but now due to the advent of microprocessors both the
technologies are merging.The requirements which are thought to be exclusive to one technology can be found in the other
one too.But still there are some things which are to be checked out before selecting the one that suits your application the
best.
Now a days you cannot really tell the difference between a PLC or a DCS. Since the PLC was integrated with Analog I/O it
crosses the boundary of being just digital and crosses to the realm of DCS in handling Analogs, Bus Systems, Distributed
I/O and etc. Also, since the DCS now handles logics of Digital I/O it also crossed the boundary to the realm of PLC.
As you know PLC as to its name Programmable Logic Controller. Its main purpose is to replace the relay logic controls
which is "On" or "Off". And DCS "Distributed Control Systems" its emphasis is Fast analog handling because of
communications through Bus systems, networking and etc.
Summarizing all these, PLC = DCS......BUT still there are basic differences as below
PLC is a programmable Logic controller which is used mainly for interlocking different equipments.PLC using for
perticular mechine or production unit.PLC is economicaly low cost.PLC'S can handle analog and digital I/O as earliear it
could handle only digital.PLC'S are automatic controllers which is a substitute to hard wired controllers.they are
extensively used for automation.PLC is for stand alone sytem.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 control task.

Programmable Logic Controller

DCS: DISTRIBUTED CONTROL SYSTEMS: THIS SYSTEM DOES WHAT A

PLC WOULD DO, BUT THE DIFFERENCE IS THAT A DCS IS USED IN
MUCH LARGER AND COMPLEX APPLICATION E.G: POWER GENERATION,
SOME COLD ROLLING MILLS etc.
DCS is the System in which controller are distributed geographically and integrated all the control hardwares .which is
connected from the various field devices .DCS having its own network, Controller and HMI etc.Honeywell, Yokogawa,
Invensys, ABB, Emerson are the leading .DCS Vendors.DCS is the System in which controller are

distributed geographically and integrated all the control hardwares which is connected from the various field devices.DCS
having its own network, Controller and HMI etcHoneywell, Yokogawa, Invensys, ABB, Emerson are the leadingDCS
Vendors

Distributed Controller System

If taken from a narrow point of view, maybe PLC and DCS are functionally the same. However, a lot of
plant technicians and engineers are not aware of the other side of the debate, namely the engineering effort and the
commercial ramifications. Of course, for huge plants with I/O's ranging from 10,000 to 30,000 I/O points, and
beyond, it is silly to even think about PLC. From my experience, a DCS is not the same with PLC in the realm of huge
systems such as oil and gas plants, as the following list will show:
1. A PLC is cost-effective up to a certain I/O count, and so is the DCS. But the difference is in their starting points:
the PLC is cost-effective from 0 to a few thousand I/O points; the DCS becomes cost-effective starting from a few
thousand points and beyond.
2. A PLC becomes a subsystem of the DCS in rare occasions when the situation calls for it, i.e., purchase of huge
package systems with engineering schedules incompatible with the DCS schedule (I/O lists cannot be submitted on

time before the DCS hardware freeze date). Note that this package system is a process system using continuous
control, not discrete. Based on this, a PLC can never be larger than a DCS in terms of I/O count.
3. In large plants the DCS is king because most owners want a single source of hardware support and service, and
this mentality naturally denies the PLC a foothold. Package vendors are no longer required to provide PLC for their
system. Everything is connected to the DCS.
SCADA: AS ALREADY EXPLAINED, IT NOTHING BUT A SOFTWARE USED
TO GATHER DATA FROM THE FIELDS INSTRUMENTS WITH THE HELP OF
YOUR DCS OR PLC DEPENDING ON THE APPLICATION VIA THE SERVER
AND MAKING IT AVAILABLE IN AN ANIMATED FORM. THIS IS
USUALLY FOUND IN YOUR CONTROL ROOMS AND DEVELOPMENT ROOM

SCADA

SCADA is the Software tool in which you can able to view/Monitor/Control your Process Variable data and Graphical
representation of your plant etc...It's an operator front end display Example of few SCADA S/W is Wonderware, IFix, RS
View, WinCC etc
SCADA is Supervisory Control and Data Aquisition which is used to control and Monitor small number of Equipments in a
field.SCADA systems are typically used to perform data collection and control at the supervisory level. Some systems are
called SCADA despite only performing data acquisition and not control.The supervisory control system is a system that is
placed on top of a real-time control system to control a process that is external to the
SCADA system (i.e. a computer, by itself, is not a SCADA system even though it controls its own power consumption and
cooling). This implies that the system is not critical to control the process in real time, as there is a separate or integrated
real-time automated control system that can respond quickly enough to compensate for process changes within the time
constants of the process

SCADA is the Software tool in which you can able to

view/Monitor/Control your Process Variable data and
Graphical representation of your plant etc...
It's an operator front end display
Example of few SCADA S/W is Wonderware, IFix, RS View,
WinCC etc
IN SHORT!
PLC:

in manufacturing processes(for production of things)

for simple batch control

intensive logic controls

can handle a no. of I/O s at a time

downtime => lost production

usually,no need of redundancy

fast logic scan(=reading I/Ps executing instructions and providing O/Ps)

compact

easily customised

for smaller applications

DCS:

in process control (for production of stuff)

for complex batch control

advanced analog loop controls

downtime=>lost production+damage to process equipment+ may lead to dangerous conditions

so Redundancy must

large in size

cant be easily customised

for larger applications and plant-wide

In detail
What are you manufacturing??
PLC:for simple batch control i.e.,manufacturing a batch of goods(things)
Eg.,in bottling plants
DCS:for complex batch process i.e.,producing a product by transmission from raw materials(producing stuff)
Eg.,in oil refining plants,in steel making
Specific to type of control
PLC: very logic control intensive.Can handle a no. of digital and analog I/O's at a time.
DCS: Regulatory/Analog loop control.It also provides ratio/cascade/model-predictive /feed forward control

Effect of downtime
What is downtime?
It is the time that the process takes to come to normal operation after a catastrophic failure.
PLC: Downtime results in only lost production and does not typically damage the process conditions or equipment.

For eg.,if there is some problem in the manufacturing process of a bottling plant, even if the process is stopped for a while,
resuming the process back to its normal operation is simple and not time tacking. providing redundancy will be costlier
than handling the downtime expenses so generally redundancy is not provided by this.
DCS: Downtime results not only in lost production but also leads to dangerous conditions or damages the process
line and resuming the process is expensive and difficult too.
For eg.,In steel making process if the process stops abruptly and the pipelines with process fluid contents may freeze and
damage the pipelines this would lead to more expenses.
Degree of customisation
PLC:It delivers a tool-kit of functions and building blocks that can be easily customized.So it can be used for varied
applications by programming it according to the application.
DCS: Its highest priority is high reliability so standard functions are baked in to provide a complete solution to a
particular application. So it can't accept many custom modifications.
Up-front cost
PLC: in $$.
DCS: in $$$$ ;However its superior to PLC in operation and proprietary in general.
Size
PLC: compact
DCS: large
Replacement
PLC: replaced the conventional relays
DCS: replaced the pneumatic & single loop controllers
DCS is Distributed Control Systems which is used to control very big plants by using simple GUI screens.PLCs are
interfaced with DCS for interlocking.

INTRODUCTION TO FLOW METERS

A flow meter is a device used to measure the flow rate or quantity of a gas or liquid passing through a pipe.

figure(1)

They are wide variety of flow meters using in the industrial applications. Some of them are,

1) Coriolis Flow Meter.

2) Vortex Flow Meter.
3) Differential Pressure Flow Meter.
4) Turbine Flow Meter.
5) Electro Magnetic Flow Meter.
6) Ultrasonic Flow Meter.

Selecting A Flow Meter:

The basis of flow meter selection is a clear understanding of the requirement of the particular application. Therefore time
should be invested in fully evaluating the nature of the process fluid and of the overall installation. Here are some key
questions which we need to answer before selecting the flow meter.
1) What is the fluid being measured by the flow meter?
2) Do you require rate measurement and/or totalization from the flow meter?
3) If the liquid is not water, Then what is the Viscosity of liquid?
4) Is the fluid clean?
5) What is the minimum and maximum flow rate of the flow meter?
6) What is the minimum and maximum process pressure?
7) What is the minimum and maximum process temperature?
8) Do you require a local display on the flow meter or do you need a electronic signal output?
9) Is the fluid chemically compatible with the flow meter wetted parts?
10) Is this is a process application, what is the size of pipe?

Flow meter selection guide

DIFFERENTIAL PRESSURE FLOW METER:

In differential pressure transmitter, The measurement of the flow of fluid in a pipe is based on theBernoullis Equation.
Differential pressure flow meter introduces a constriction in the pipe that creates a pressure drop across the flow. When the
flow increases more pressure drop is created. The DP transmitter measures the difference between upstream pressure and
downstream pressure of the constriction.

P=P1-P2

The velocity(V), Volumetric flow(Q) and the Mass flow(W) can be calculated using the following formulas,
V = k (h/D)0.5
Q = kA(h/D)0.5
W = kA(hD)0.5

Where,
A=Cross sectional area of pipe,
h=Differential pressure,
D=Density of flowing fluid,
k= Discharge coefficient of the element.
Bernoullis equation states that the pressure drop across the constriction is proportional to the square of flow rate. using this
relationship, the 10% of the full scale flow produces only 1% of the full scale differential pressure. At 10% of full scale flow,
the differential pressure flow meter accuracy is dependent upon the transmitter being accurate over a 100:1 range of
differential pressure.
Different geometrics are used in the differential pressure flow meter. Some of them are,
1) Orifice plate,
2) Flow Nozzle,
3) Venturi Tube, Etc
ORIFICE PLATE:

Orifice plates are the most widely used type of flow meter in the world. They
offer significant cost benefits over other types of flow meter, especially in larger line sizes, and have proved to be rugged,
effective and reliable over many years. Where a need exists for a rugged, cost effective flow meter which has a low
installation cost and a turn down of not more than 4:1, The orifice plate continues to offer a very competitive solutions.

An orifice plate installed in a line creates a differential pressure as the fluid flows
through it. This differential pressure is measured via impulse lines by a differential pressure transmitter which converts it into
an Analog or Digital signal which can be processed to provide a display of the instantaneous rate of flow. The relationship
between the rate of flow and the differential pressure produced is very well understood and is fully covered by
comprehensive national standards. The relevant standards are BS1042 and ISO5167.
Advantages:
1) Use on Liquid, Gas & Steam.
2) Suitable for extreme temperature & pressure.
3) High pressure loss.
4) No moving parts.
5) Low material costs.
6) Inexpensive, When compared to other flow meter.
Disadvantages:
1) Limited rangeability.
2) Affected by changes in Density, Pressure & Viscosity.
3) Expensive to install.
4) Low accuracy
5) Pressure drops can be large.
6) Contraction of flow reduces accuracy of downstream pressure measurement.
FLOW NOZZLE:

Flow nozzles have a smooth elliptical inlet leading to a throat section with a sharp outlet. This restriction in the fluid flow
causes a pressure drop which relates to the flow rate by applying Bernoulli's Equation.
Due to its rigidity the flow nozzle is more stable at higher temperature and flow rate than Orifice.
The flow nozzle is generally used for measuring the flow of steam, non-viscous, erosive and high velocity media. Flow nozzles
are typically used to measure steam, air, gas, vapour and chemical substances and liquids with a small degree of suspended
solids.
The design and manufacture of the flow nozzle complies with the requirement of ISO5167 standard. Thus an accuracy of "+
(or) -1.0%" is assured. By means of a calibration a higher accuracy of upto "+(or) - 0.25%" can be achieved.
Advantages:
1) For same flow rate, It has significantly lower pressure drop than an orifice plate.
2) May be mounted Horizontally and Vertically.
3) Less suspectible to erosion and corrosion than an orifice plate.
Disadvantages:
1) Unsuitable for Viscous flow and Sticky materials.
2) Requires consistently smooth flow rate, Cna't handle Eddies and Vortices.
VENTURI TUBE:

Venturi tube consists of a convergent cone section, cylindrical bore and divergent cone section. The cylindrical bore restricts
the fluid flow and results in the pressure drop. This differential pressure relates to the flow rate using Bernoullis Equation.
Due to its simplicity and dependability, The venturi tube is used in applications where its necessary with higher Turndown
rates, Lower pressure drops than the orifice plates can provide.
In the venturi tube, The fluid flow rate is measured by reducing the cross sectional flow area in the flow path and generating
a pressure difference. The design and manufacture of the Venturi Tube is complies with the ISO5167 standard.

.The angled inlet and outlet cones help control the pressure recovery, making venturi the most efficient of all the differential
meters available. This results in lower permanent pressure loss and greater capacity than other differential meters of the
same size. Permanent pressure loss is typically 5% to 15% of the differential pressure depending on the bore size selected.
Advantages:
1) Handle large flow volumes at lower pressure drops.
2) Accommodate liquids with high solid content.
3) May be mounted horizontally or vertically.
4) No moving parts, Low maintainance.

Disadvantages:
1) Require four or more pressure taps to accurately measure pressure differential.
2) Accuracy depends on consistent flow rate.
3) Less accurate at low flow rate.

In my next post i will go through Vortex & Ultrasonic Flow Meters.

if i skipped any main points in this post, Then please let me know through ur valuable comments.
Thanks For Reading,
Have a good day :)

Ultrasonic Flow Meter:

Ultrasonic Flow meter is a type of flow meter, Which uses ultrasonic sound waves to determine the velocity of fluid flowing in
a pipe. There are two different types of ultrasonic flow meters which include, Doppler flow meter and another one is Transit
time flow meter.

Doppler Flow Meter:

Doppler ultrasonic flow meter operate on the doppler effect. In Doppler effect, One transducer transmits an ultrasonic beam
of 0.5Mhz into the flow stream. Liquid flowing through the pipe must contain sonically reflected materials such as solid
particles or air bubbles. the movement of these materials alters the frequency of the wave reflected onto a second receiving
transducer. The frequency shift is linearly proportional to the rate of flow of materials flowing in the pipe.
The basic equations defining the doppler flow meter are,

Equation(3) clearly shows that the Flow velocity is equal to the Doppler frequency shift. Now, because the diameter(D) of the
pipe is known, Volumetric flow rate(e.g Galloons per minute) can be measured using the following expressions,

Where, K= a constant dependent on the units of Flow velocity and D.

One Doppler meter design mounts both the transmitting and receiving transducers in the same case attached to one side of
the pipe. Reflectors in the flowing liquid return the transmitting signal to the receiver with a frequency shift proportional to
the flow velocity.
Advantages Of Doppler Flow Meter:
The main advantage of doppler flow meter is its non-intrusive design. An acoustic-coupling compound is used on the surface
of the pipe and the sensors are simply held in place to take a measurement or, for a more permanent installation, they are
strapped around the pipe. Some manufacturers offer a special clamp-on probe which allows connection to smaller pipe sizes.
Other advantages include:
1) Easy installation and removal.
2) No process downtime during installation.
3) No moving parts to wear out.
4) No process contamination.
5) Works well with dirty or corrosive fluids.
6) No leakage potential.
7) Insensitive to liquid temperature, viscosity, density or pressure variations.
Disadvantages Of Doppler Flow Meter:
The main disadvantage of the doppler flow meter is the fact that the liquid stream must have particulates, bubbles, or other
types of solids in order to reflect the ultrasonic signal. This means that the doppler flow meter is not a good choice for the
water and very clean fluids.
The another disadvantage is that the accuracy can depend on particle-size distribution and concentration and also on any
relative velocity that may exist between the particulates and the fluid. if there are not enough particulates available, the
repeatability will degrade.
The other potential problem of this technology is that it can have trouble operating at very low flow velocities.
Applications Of Doppler Flow Meter:
Being an non-intrusive, Doppler flow meters have a wide variety of applications. Some of them include:
1) Influent and effluent water flow.
2) Digester feed control.
3) Waste water.
4) Crude oil flow.
5) Mining slurries.

6) Acids.
7) Liquified gases.
Transit Time Flow Meter:

Transmit time flow meter sends and receives the ultrasonic waves between transducers in both the upstream and
downstream directions in the pipe. At no flow conditions, It takes the same time to travel upstream and downstream
between the transducers. Under flowing conditions, The upstream wave will travel slower and take more time than the
downstream wave. When the fluid moves faster, The difference between the upstream and downstream time increases. The
difference in transit times in the upstream and downstream directions(Tu-Td) measured over the same path can be used to
calculate the flow passing through a pipe.
Transmit time ultrasonic flow meters are more accurate and economical than the doppler ultrasonic flow meters.
Advantages Of Transit Time Flow Meter:
The main advantage of the transit time flow meter is, that it works non-invasively with clean and ultrapure fluids. This allows
the user to maintain the integrity of the fluid while still measuring the flow. Some of the other advantages include:
1) Easy installation-transducer set clamps onto pipe.
2) No moving parts to wear out.
3) Zero pressure drop.
4) Works well with clean and ultrapure fluids.
5) No leakage potential.
6) Insensitive to liquid temperature, viscosity, density or pressure variations.
Disadvantages Of Transit Time Flow Meters:
The transit time flow meter perfomance can suffer from pipe-wall interference, accuracy and repeatability problems can
result if there is any Space Gap between the fluid and pipe wall.
The transit time flow meters will not operate on dirty, bubbly, particulate-ladden fluids. Sometimes, the purity of a fluid may
fluctuate so as to effect the accuracy of the flow measurement. For such cases, there are Hybrid meters onthe market that
will access the fluid conditions within the pipeand automatically choose doppler or transit time meter operations where
needed.
Applications Of Transit Time Flow Meter:
Transit time flow meter have wide applicability for flow measurement of clean or ultrapure streams. Some of the applications
include:
1) Clean water flowrate in water treatment plants.
2) Hot or cold water in power plants.

3) Pure and ultrapure fluids in pharmaceutical, food and beverage industries.

4) Liquid to medium crude oils in the petroleum refining industry.
5) Water distribution systems used in agriculture and irrigation.

In my next post i will go through Vortex & Electromagnetic flow meter.

If i skipped any main points in this post, Then please let me know through your valuable comments.
Thanks for reading,
Have a gud day :)