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DCS engineers are typically most effective using a “top-down” approach, which forces them to put significant effort into the upfront design. This focus on upfront design is a key to minimizing costs, compressing the project schedule, and creating an application that can be maintained by plant personnel over the long term. Since DCS applications are typically larger in scope, the ability to propagate libraries and templates throughout the application is important to minimize rework. The PLC is controlling a machine, while the DCS is controlling the plant. For example, a pencil manufacturer is producing an incredible amount of pencils at an extremely rapid speed using a PLC. By programming in machine code, engineers might be able to squeeze another 10 milliseconds out of the machine, which is now capable of punching out even more pencils and profits. The PLC engineer demands that kind of flexibility and open architecture. The process engineers controlling entire plants with a DCS require more intuitive programming platforms, which utilize predefined and pre-tested functions to save time and drive repeatability. Having the right tool for the job is also critical. Ladder logic is the ideal and preferred configuration language for many discrete control applications, such as high-speed interlocking or the control of motors and drives. Function block diagram, on the other hand, is preferred for continuous control and for implementation of alarming schemes. Determing whether your application is hybrid Now that we have reviewed the criteria for selection of a DCS or PLC, you may be thinking that your application requires capabilities from both. If this is TRUE, then you may need a process control system for hybrid applications. A hybrid can be defined as follows: • “The marriage of the discrete functions, which PLCs handled so simply and economically, with the sophisticated analog continuous control capabilities of the DCSs”* • “Defined based on the industries in which the systems work and serve, like pharmaceutical, fine chemicals, food and beverage, and others” • “The architectural marriage of the PLC simplicity and cost with the sophisticated operator displays, alarm management, and easy but sophisticated configuration capabilities of the DCS” * Reference – Intech, Sept 2007, “Hybrid Control Identity Crisis: What’s in a Name?”
ABB 3BHB002751R0106
Bently 3500/22-01-01-00
GE DS200ITXDG1ABA
GE 8521-LC-MT
ABB REF543KM127AAAA
BENTLY 3500/33-01-00
PROSOFT MVI46-MCM
PILZ PSS SB DI80Z4(301120)
B&W SQ-300I 8700700-004
POTTER & BRUMFIELD SDAS-01-7Y2S1024
ABB 07AI91
ABB 07AC91
AMCI 7264
ABB XVC722AE101 3BHB002751R0101
ICS TRIPLEX T8431
ICS TRIPLEX T8403
ICS TRIPLEX T8110B
BENTLY 125840-02
KOLLMORGEN E33NCHA-LNN-NS-00
ABB PM866 3BSE050200R1
TRICONEX 4351B
TRICONEX 3511
POTTER & BRUMFIELD SDAS-01-7Y2S1024
GE CT11T7F10PN1 PMC676RCTX V2.3 01 16 C1145 CR11 V2.x
GE 469-P1-HI-A20-E
ABB CI627A 3BSE017457R1
EPRO PR9376/010-011 9200-00097