TECHNICAL GUIDE

Differentiation
between
DCS and SCADA
This is an informational document about the differences between DCS and
SCADA and should be used as a bases for giving arguments for Siemens DCS
systems. This document is for internal use only!
 Index
Differentiation between DCS and SCADA
Objective of the Document 3
Content3
Comparison of DCS and SCADA
Main Concept 4
Industries and Practice 4
Starting Thesis 5
Key Characteristics 5
SIMATIC I/O lines for all kind of industries 7
Distinction9
Architecture10
Development towards Web-based Systems 10
Six questions and aspects for the customer
before choosing a system 11
Market Overview 13
Abbreviations14

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 Objective of the Document
In a number of industries there is considerable confusion over the differences between the
Distributed Control Systems (DCS) and Supervisory Control and Data Acquisition (SCADA)
systems. These two disparate technologies are often seen as competitors in similar application
environments, while DCS and SCADA systems seem to do essentially the same thing. With the
trend toward globalization and digitalization in industry, many of the applications within process
industries now share requirements thought to be exclusive only to either DCS or SCADA. These
hybrid applications typically require a solution that can deliver both DCS and SCADA capabilities.

This Technical Guide is meant to provide an overview of the main differences between DCS and
SCADA. The guide may be used as a starting point for discussing with the customer why a DCS is
the right solution for their needs when being confronted with SCADA competitor systems and
their supposed technological lead. For example, the newest generation of SCADA systems already
uses cloud technology, Web-based deployment or HTML5-based applications.

This supposed technological lead, however, should not be used as a counter argument to the
innovativeness of for example SIMATIC PCS neo. The SCADA systems were developed as a means
of remote access to control modules spread over large geographical distances for gathering
data and triggering alarms should an event occur. A SCADA system therefore always refers to a
system which coordinates but does not control processes in real time. A DCS scans the process
state sequentially and is usually applied to locally confined installations. The key benefit is its
reliability due to the distribution of the control processing around nodes in the system.

As a Web-based DCS, SIMATIC PCS neo ensures that users always have access to consistent,
reliable information to enable users to make correct decisions as quickly as possible.
Furthermore, SIMATIC PCS neo offers an intuitive user interface as well as an open and flexible
architecture. Attention should also focus on secure and reliable administration and operation.

The following pages will provide a detailed comparison of DCS and SCADA systems. The
Industries and Practice section provides numerous bullet points for supporting your reasons for
installing a DCS instead of a SCADA system, not to mention the innovativeness of a Web-based
DCS.

Content
First, we want to give you a short summary of what DCS and SCADA are and for which industries
they are used. The guide will then go into more detail on important differences between these
systems. In conclusion, we will provide you with a simple check list to help you determine what
type of system works best for your customer application and to substantiate your arguments for
DCS. Lastly, an overview is given of the available systems on the market.

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 DCS
Main Concept
A Distributed Control System (DCS) is a computerized
control system for a process or plant usually with a large
number of control loops in which autonomous controllers
are distributed throughout the system and there is central
operator supervisory control. This contrasts with systems
that use centralized controllers; either discrete controllers
located at a central control room or within a central
computer.
The DCS concept increases reliability and reduces installa-
tion costs by localizing control functions near the process
plant, with remote monitoring and supervision.
Industries and Practice
DCS systems are used in industrial and infrastructure
processes including:
• Chemical plants*
• Petrochemical (oil) and refineries*
• Pulp and paper mills*
• Boiler controls and power plant systems
• Nuclear power plants
• Environmental control systems
• Water management systems*
• Water treatment plants*
• Sewage treatment plants
• Food and food processing*
• Agrochemical and fertilizer
• Metal and mines*
• Automobile manufacturing
• Metallurgical process plants
• Pharmaceutical manufacturing*
• Sugar refineries
• Agriculture applications
• Cement and glass*
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VS SCADA
Supervisory Control and Data Acquisition (SCADA) is a
control system architecture that uses computers, networked
data communications and graphical user interfaces (HMI) for
high-level process supervisory management. SCADA uses
other peripheral devices such as Remote Terminal Units
(RTU) and Programmable Logic Controller (PLC) to inter-
face with the process plant or machinery. These systems can
range from just tens to thousands of control loops depending
on the application.
It is also important to understand that the term SCADA itself
can be understood in very different ways: in the sense of
SCADA / PLC (Factory Automation) which addresses local
plants and OEMs, and in the sense of SCADA / RTU (Process
Automation) which addressed widely distributed plants
and end-customers. The following differentiation therefore
mainly applies to SCADA / RTU.
SCADA Systems are used in industrial, infrastructure, and
facility-based processes including:
• Manufacturing
• Process control*
• Power generation
• Fabrication
• Refining
• Water treatment and distribution*
• Wastewater collection and treatment*
• Oil and gas pipelines*
• Electric power transmission and distribution
• Wind farms
• Buildings, airports, ships, and space stations
• heating, ventilation, and air-conditioning systems
(HVAC)
• Access
• Energy consumption
*(relevant for DI PA AE)
 Starting Thesis
1. Process industry means that first there is the process, then the automation. The process usually runs continuously.
2. Manufacturing industry means that the manufacturing process and the associated automation arise simultaneously. The
manufacturing process runs in steps.

Comprehensive Automation portfolio

Suits any architecture and requirement with perfect interaction

DCS Plant control/ DCS Plant control/ Line Plant control Line control SCADA
SIMATIC PCS neo / SIMATIC PCS 7

SIMATIC PCS neo / SIMATIC PCS 7

DCS DCS Control
SIMATIC PCS 7 SIMATIC PCS neo WinCC Unified WinCC V7 S7-1500
SIMATIC PCS neo SIMATIC Batch WinCC Unified (F/R/H)
MTP MTP
Control level Process modules CNC

Process Machine Machine

modules control control PLC

S7-410 SINUMERIK ONE

S7-1500

S7-1200

Field level Equipment control / Equipment control

TIA Portal
TIA Portal
SIMATIC ET 200SP HA
SIMATIC CFU SIMATIC ET 200SP
Field level
SIMATIC ET 200 iSP
DCS PLC PLC

Process industries Hybrid industries Discrete industries

Oil & Gas Refining& Pharma Food and Automotive Machine

Petrochemicals … Beverage … Building

Figure 1: Siemens comprehensive

automation portfolio

DCS VS SCADA

Key Characteristics
General Idea

Local processes Widely distributed processes*

The DCS refers to a control system or a process where the The SCADA concept was developed as a universal means of
controller unit is not centrally located but is distributed remote access to a variety of local control modules, which
throughout the system. Every component in the system is could be from different manufacturers allowing access
controlled by one or more controller elements. through standard automation protocols.

Key Attribute

Reliability Supervisory operation over a variety of devices

The key attribute of the DCS is its reliability due to the The SCADA system’s key attribute is its ability to perform a
distribution of the control processing around nodes in the supervisory operation over a variety of other proprietary
system. This mitigates a single processor failure. If a devices.
processor fails, it will only affect one section of the plant
process.
*mainly for SCADA / RTU

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 DCS VS SCADA

Focus

Automation of operation sites Communication over large distances*

DCS focuses on the automation of operation site, e.g., SCADA focuses on communication over large distances,
chemical plants, creating a direct operator-process interface. e.g., distribution networks; therefore, it has an indirect
process interface.
Driving Factor

Process state driven Event driven*

A DCS is process-state driven. It scans the process on a A SCADA system is event driven. It does not scan the process
regular basis and displays the results to the operator on sequentially but waits for an event that causes the process
demand. parameter to trigger certain actions.

Data source

Permanent connection to data source

Database*
A real-time database of process parameter values is not
SCADA maintains a real-time database to log the parameter
necessary because the DCS is always connected to its data
values which can be further retrieved for operator display and
source. Redundancy is usually handled by parallel equip-
allows trending and analytical auditing. Redundancy is
ment, e.g., controllers, not by diffusion of information
synchronized by distributed servers.
around a distributed database.
*mainly for SCADA / RTU

Controllers and IOs

SIEMENS DCS SIEMENS PLC / SCADA

Programming software SIMATIC PCS 7 / PCS neo TIA Portal / WinCC Professional

CPU type S7-410 / S7-410H S7-1200 / S7-1500 / S7-1500H

Redundant controller / IO option yes partly

Change SW in run yes yes

Change HW in run yes no

IO hot swapping yes yes

yes yes
Backup memory
(without battery) (without battery)

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 SIMATIC I/O lines
SIMATIC IO lines have been successfully designed
for all kind of industries
to meet requirements of all industries

DCS PLC/SCADA

Food & Beverage

Pharmaceuticals
Pulp & Paper

Metal/Mining

Automotive

Electronics
Chemicals

Oil & Gas

Refinery
Power

Water

Glass
Process Industries Hybrid-Industries Discrete Industries
ET 200eco PN
ET 200SP HA
ET 200M ET 200SP ET 200MP ET 200pro
ET 200iSP
CFU

ET 200AL

DCS
VS SCADA

HMI

Static, hierarchically structured plant displays World maps*

Visualization is based on static, hierarchically structured Visualization of large areas is achieved with world maps,
plant displays. Online function plans, e.g., SFC and CFC including topological and geospatial information according
according to IEC61131 are integrated. to IEC60870 control model.

Orientation

Process-oriented Data-gathering oriented

DCS is process oriented. DCS emphasizes more on control of
the process and it consists of a supervisory control level. In
doing so, it presents the information to the operator.
SCADA systems are data-gathering oriented. SCADA
concentrates more on acquisition of process data and
presenting it to the operators and control center. This
encompasses the collecting of information, transferring it
back to the central site, carrying out analysis and control and
then displaying it on several displays. The required control
actions are then conveyed back to the process.

*mainly for SCADA / RTU

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 DCS VS SCADA

Main Criteria

Process variable’s present state Changes of state

DCS systems consider the process variable's present state
to be the main criteria driving the DCS and tasks are gener-
ally run sequentially rather than event driven. Therefore,
alarms and events are not generated when a point changes
state, but when the process runs. Timestamps are only
applied for alarms.
A SCADA considers changes of state as the main criteria for
data gathering. SCADA systems often provide special 'event'
processing mechanisms to handle conditions that occur
between data acquisition periods. The buffered transmis-
sion is time stamped.

Engineering

Top-down Bottom-up

Engineering is homogeneous, i.e., the complete solution is Engineering is based on the work of different OEMs (inho-
typically contained in one automation multi-project which is mogeneous), who may use products from different automa-
engineered under the responsibility of one company. tion suppliers and who work in separate and independent
automation projects, e.g., up to 100 engineers in parallel to
In addition, the solution is derived from the process design
maintain a grid model. This time-based engineering model-
and is aimed at a cost-optimized initial engineering
ling approach results in inhomogeneous automation solu-
approach.
tions for the plant.
As the name “Distributed Control System” implies, the auto-
mation is distributed to several controllers. This distribution,
since it is based on the process design, must not be fixed
from the beginning. In this way it is possible to start the
engineering based on sample solutions without having the
controllers already defined and makes the allocation at a
later stage.

Function

Monitoring, control and automation Monitoring, control and analysis

Communication

High-speed Potentially slow and unreliable

Via a local area network (LAN), the DCS carries out high- SCADA needs to receive secure data and control over a
speed (GBits/s) bus communication between various distrib- potentially slow, unreliable communications medium (WAN,
uted control units. Wide Area Network), and needs to maintain a database of
'last-known good values' for prompt operator display.

Scope of application

Confined Large

In DCS, data acquisition and control modules or controllers The SCADA system covers larger geographical areas such
are usually located within a more confined area, such as as water management systems, power transmission and
single plant or factory. distribution control.

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 DCS VS SCADA

System design requirements

Process-control functionality Database and data-gathering system

DCS systems typically have more complexity in their SCADA systems require a great deal more complexity in the
process-control functionality but are transparent. database system and data-gathering of its various media
sources.
Closed-Loop Control

Closed loop control No closed loop control

DCS employs a closed-loop control at process control stations As for SCADA, there is no closed-loop control.
and at remote terminal units.

Distinction
Today the functionality of SCADA and DCS systems are very The control room is not geographically remote.
similar; however, DCS tends to be used on large continuous
In practice, large SCADA systems have grown to become very
process plants where high reliability and security is
similar to DCS in function but use multiple means of inter-
important. Depending on the criticality of the process, all
facing with the plant.
components can be designed redundantly to provide
maximum availability. Different approach to DCS

Since the process continues to run independently of the auto- “SCADA (and SCADA system) is just a software that runs on
mation, a controller cannot be stopped for change opera- any PC to provide operator interface (monitoring, buttons)
tions. Therefore, it must be possible to make all changes to and historian (data collection). SCADA is used with both DCS
DCS components at runtime. and PLC systems.”

In addition, due to environmental conditions components

must be robust, have a high diagnostic quality, and be flex-
ible enough to be used in explosion-proof areas.

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 Architecture
DCS OS Single Station
Client OS SCADA SCADA clients SCADA clients
(max. 40 en mode multi-client)

Terminal bus LAN WinCC Server WinCC SCADA-Server

SCADA-Server + PerformanceMonitor
OS Server
(max. 18 redundant) (max. 17)

PROFINET

Industrial Ethernet PROFIBUS

S7-300

S7-1500
AS-410S S7-410F/H/FH/E S7-400

At first glance, the system architectures pictured look very similar. Both systems share the following components:
• Field devices
• Input/output modules
• Controllers
• Human machine interface (HMI)
• DCS and SCADA systems provide basic services for the management level (Manufacturing Execution/Operation).

As you look at the following system architectures, it should be noted that the technologies used in each system are in fact very
similar; the difference becomes more apparent when considering the nature and requirements of the application:
• Automation and I/Os are an integrated part of a DCS. The automation does not need to support the communication func-
tion in parallel.
• RTUs are not integrated into the SCADA system. They are typically connected via standard protocols, e.g., TeleControl to
the SCADA thus combining both automation and communication functions.

Development towards
Web-based Systems
The latest developments in DCS include the following new technologies:

• Wireless systems and protocols

• Remote transmission, logging and data historian

• Mobile interfaces and controls

• Embedded webservers

Increasingly and ironically, DCS is becoming centralized at the plant level with the ability to log into remote equipment. This
enables the operator to control both at the enterprise (macro) and at the equipment level (micro) both within and outside the
plant as physical location due to interconnectivity primarily due to wireless and remote access has shrunk.

As wireless protocols are developed and refined, DCS increasingly includes wireless communication. DCS controllers are now
often equipped with embedded servers and provide on-the-go Web access. Whether DCS will lead IIoT or borrow key elements
from it remains to be seen.

Fourth generation: "Web-based"

The growth of the Internet has led SCADA systems to implement Web technologies allowing users to view data, exchange
information and control processes from anywhere in the world. The early 2000s saw the proliferation of Web SCADA systems.

Web SCADA systems use Internet browsers such as Google Chrome and Mozilla Firefox as the graphical user-interface (GUI) for
the operators HMI. This simplifies installation for the client and enables users to access the system from various platforms with
Web browsers such as servers, personal computers, laptops, tablets and mobile phones.

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 Six questions and aspects
for the customer before
choosing a system
Now we will get to the last chapter of this Technical Guide – the six questions and aspects you should place when being
confronted with SCADA competitor systems. The six questions are designed to make your customer think about their compa-
ny's operating philosophy and application requirements, while considering the view of all major stakeholders regarding their
plant: engineering, operations, maintenance, etc. Please consider that this document uses broad generalizations and that
every individual application will have its exceptions to these aspects; however, the logic is still sound.

The method for gauging whether you should be using a SCADA or DCS is to go through this survey form and to check all the
responses that apply. If all responses are in one column, then the application clearly calls for this one type of system. If you
have multiple selections from both the DCS and SCADA columns, then maybe you have a “hybrid” application which requires a
solution capable of delivering both DCS and SCADA functionality.

Note: Since Siemens delivers both DCS and SCADA solutions to the market, we are in a unique
position to deliver both sides of the story.

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 1 What is your focus of your application?

Remote access to a variety of local control

Automation of a local process running 24/7/365
modules (e.g., PLC, DCS)
Handle simple to complex analog control (i.e., OR Communication over large distances
PID or close loop control)
Complex Batch Control

2 What is the cost of downtime?

The value of a “batch” is high, either in raw-ma- The value of the individual component being
terial cost or market value manufactured is relatively low
Downtime results in lost production, but with little
Downtime not only results in lost production,
additional cost or damage to the process
but can result in dangerous conditions
equipment
OR
Downtime can result in process equipment Return to steady state production after an outage
damage is short and relatively straightforward
Return to steady state production after an
unplanned outage can be long, expensive, and
difficult
3 What do you view as the “heart” of the system?
Typically, the heart of the system is the
Typically, the heart of the system is the HMI for
OR Supervisory Computer (SCADA Server) for data
operator interactions
collection, data fusion and data analytics
4 What does the operator need to be successful?
The operator’s interaction is typically required
to keep the process in its target performance The operator’s primary role is to handle exceptions
range

Faceplates and analog trends are critical to see Status information is critical information for the
what is happening to the process operator
OR
Alarm management is key to safe operation of
Exception-based alarms are key information for
the process and for responding effectively
the operator
during plant upset conditions

Failure of the HMI could force the shutdown of

Manufacturing might be able to run “lights-out”
the process
5 What system performance is required?

Reliable and secure communication between
various distributed control units
OR
Online configuration changes are often
required
6 What are your engineering expectations?
Capability of managing enormous volumes of data
and archiving for the long term
Devices can be taken offline to make configuration
changes

Up-front design of complete system before Program/configure individual components,

implementation begins (top-down) integrate later (bottom-up)

Homogeneous solution in the responsibility of “Inhomogeneous” solution based on different

OR
a company OEMs

System designed to make it easy to engineer

System designed to be flexible
process application

DCS TOTAL SCADA TOTAL

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 DCS VS SCADA

Market Overview
Siemens

SIMATIC PCS neo SIMATIC WinCC Professional

for process and hybrid industries
SIMATIC PCS 7
for process and hybrid industries
Add-on »SIMATIC PCS 7 TeleControl«
addressing SCADA / RTU for process industries
SCADA / PLC, integrated in TIA Portal
SIMATIC WinCC V7
SCADA / PLC, scalable and open
SIMATIC WinCC Open Architecture (OA)
SCADA / RTU for process industries,
vendor- and platform-independent

Siemens Energy
SPPA-T3000
for power and water industries
ABB
AbilityTM 800xA AbilityTM Symphony Plus
for process and power industries for power and water industries
AbilityTM Symphony Plus SCADAvantageTM
for power and water industries for oil and gas industries (upstream and midstream)
Freelance DCS Compact HMI
for process industries based on 800xA DCS platform and for process industries
B&R APROL
SCADA / PLC
Emerson

DeltaV TM OpenEnterprise™
for process industries for oil and gas, distribution and transmission industries
OvationTM Ovation™ SCADA Server
for power and water/wastewater industries for power and water/wastewater industries

Honeywell
Experion® SCADA
Experion® PKS (Orion)
for process industries with focus on oil and gas
for all industries
Experion® HS
PlantCruise by Experion®
comprises a subset of PKS components for small to
for process industries
medium automation projects
Experion® LX
Experion® Elevate
for continuous and batch process control applications
cloud-enabled solution
Rockwell Automation
PlantPAx FactoryTalk
for all industries SCADA / PLC
Schneider Electric

Wonderware by Aveva
SCADA / PLC
Foxboro® SCADA
EcoStruxureTM Foxboro DCS
supports EcoStructure DCS process automation system
for all industries
Foxboro® IASCADA
EcoStruxureTM Hybrid DCS
for process industries, vendor-independent on UNIX®
for hybrid industries
platforms
StruxureWare ClearSCADA
for oil & gas (upstream and midstream) and water

Yokogawa

Centum VP
SCADA Software (FAST/TOOLS)
for process industries
for all industries supporting operating systems incl.
Centum CS
Linux, UNIX® and Windows
for all industries

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 Abbreviations
CFC Continuous Function Chart
DCS Distributed Control System
GUI Graphical user interface
HMI Human machine interface
HVAC Heating, ventilation, and air conditioning
IIoT Industrial internet of things
I/O Input/Output
LAN Local Area Network
OS Operating system
PID Proportional–integral–derivative controller
PLC Programmable logic controller
RTU Remote terminal units
SCADA Supervisory Control and Data Acquisition
WAN Wide Area Network

Published by Siemens AG
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Germany
Phone: +49 9131 17-35501
Mobile: +49 172 479 1300
E-mail: darawan.muecke@siemens.com
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