The Big List of DCS Offerings from Major Automation Contractors (Updated for 2024)
The landscape of Distributed Control System (DCS) products is constantly evolving as suppliers introduce new offerings and features each year. DCS is an extremely popular type of automation technology, particularly in the process and pharmaceutical industries.
End-users in these sectors favour single supplier solutions that optimize for quick integrations that can be easily duplicated to other facilities.
One of the emerging themes is the development of industry specialized DCS versions optimized for specific industrial applications, providing end-users with a choice of DCS “flavours” to suit their process.
Another emerging trend is the creation of “light” DCS versions, designed for small and medium sized plants, optimized for flexibility, scalability and lower cost.
Additionally, major DCS manufacturers continue to expand through strategic acquisitions, with larger automation contractors maintaining their appetite for acquiring specialized companies and integrating their expertise and products into existing DCS offerings.
This article provides a comprehensive overview of major market leading DCS products. While avoiding detailed comparisons, we try to emphasize the distinguishing features, along with reporting on feedback from industry professionals that worked on the systems.
Disclaimer: Unlike other online automation blogs that have covered this topic, we have refrained from simply regurgitating the marketing literature or using generative AI. The comments and remarks are based on analysis by industry-experienced engineers on our editorial team. Feel free to make a comment if you feel we have made an error or want to contribute.
Rockwell Automation
Rockwell’s approach to DCS design differs from that of larger industry leaders. Drawing from their background as a leading PLC supplier, they have offered a DCS that is essentially a repackaging of their existing PLC products by including plantwide software and a large library of AOI.
While some may consider Rockwell’s PlantPAx to be inferior to the offerings of major suppliers, it’s important to recognize that Rockwell has distinguished itself by using non-proprietary protocols for its plant network infrastructure, in contrast to many competitors.
Rockwell has embraced open automation and developed a model known as CPwE (Converged Plantwide Ethernet) that facilitates the use of standard Ethernet protocols and technologies, such as Ethernet/IP and IEEE 802.3, for communication within the industrial environment.
This standardization promotes interoperability between various devices and systems from different vendors. CPwE should make it easier and less costly to integrate third-party subsystems and remove the need for costly gateways, subnets, and additional software needed for application layer translation.
However, many system integrators have noted a major issue with PlantPAx. It uses ControlLogix as its processor core and therefore cannot perform partial downloads. This means it is not suitable for plants that require high availability, such as continuous process types like oil and gas and chemicals, as making a download will shut down the process.
This has led many in the industry to argue that PlantPAx is not a true DCS, as partial downloads are a key component of a DCS.
PlantPAx
- PlantPAx has evolved from traditional PLC-based systems, essentially acting as a DCS wrapper to their PLC platform by adding a plantwide operating software with an extensive library of pre-programmed blocks (AOIs)
- Unlike DeltaV and other mainline products, PlantPAx is not a standalone system but a suite of products integrated into a cohesive platform.
- It comprises ControlLogix and CompactLogix processors as its core, housing a variety of process object libraries. These libraries include control modules, equipment modules, and sequencers, enabling comprehensive control and monitoring capabilities.
- PlantPAx 5.0 system architectures are TUV certified to the international standard ISA-99/IEC 62443.
- PlantPAx uses open communication standards ( Ethernet/IP protocol) unlike many DCS systems. This allows off-the-shelf products to easily integrate into the system and share real-time data up to the enterprise level.
- Through integration with motor control devices such as the Allen-Bradley PowerFlex 520-Series of AC drives and Allen-Bradley motor starters and electronic overload relays, the PlantPAx system helps ease motor control configuration and delivers diagnostic information directly to the operator at the HMI level.
ABB
ABB specializes in four domains of automation; electrification (PMS), process automation, motion, robotics, and discrete automation. In December 2023, the company announced that its distributed control system (DCS) continues to lead a market worth more than $14 billion.
Freelance Distributed Control System
- This is the budget offering DCS from ABB and is particularly optimised for scalability.
- The installation can be made on any standard windows machine and does not require a windows server with a workgroup.
- ABB claims the system is particularly easy to commission and use compared to larger DCS packages.
- The architecture is a combination of PLC and DCS with small footprint controllers, which can be located in the field in the enclosure.
- As expected, this minimalist system has no functional safety capabilities.
- Freelance can be used in conjunction with 800xa and may share the same control network at the terminal level.
ABB Ability Symphony Plus
- ABB claim Symphony Plus is intended for small to mid-size plants with no requirement for functional safety.
- The Symphony Plus product and service offerings are focused towards power generation and water industries.
- Unlike the Ability 800xA the Symphony Plus is not designed to execute as a power management system in addition to industrial plant automation.
- Ability Symphony Plus ICS advisory for a vulnerability in March 2023
ABB Ability System 800xA
- 800xA is ABB’s flagship DCS offering and is the most widely used DCS in the automation industry.
- ABB also holds a leading position in power management systems (PMS) and motor control center (MCC) technology. With 800xA, ABB has fully integrated its PMS, allowing the system to function as a DCS, PMS, and ICSS with functional safety capability.
ABB claim the latest revision of 800xA product can “seamlessly” import Modular Type Packages (MTPs), regardless of vendor’s automation platform used using what they call “ancillary coordinated control logic”.
This functionality appears to be an initiative pioneered by NAMUR WG 1.12 and other partners in the German chemical industry to develop “Plug and Produce” plant modules to reduce engineering time and cost.
The seamless import of modular packages can only be done with package suppliers which have developed the necessary vendor neutral language defined by NAMUR NE 148 to allow control and monitoring between DCS and package skid control system.
At the time of writing it’s not apparent how successful this type of rollout will be or if it shall be taken up in other process industries that are also characterised by significant use of vendor skids and packages such as in oil and gas production.
Emerson Electric
In 1993, Emerson made its market debut through an acquisition when it purchased Fisher-Rosemount. The next year, in 1994, Emerson started the beta testing of DeltaV Version 01 at the Monsanto Decatur Plant, building upon the foundation laid by PROVOX.
Emerson has maintained a proactive approach in terms of market presence by consistently, expanding its market share through strategic acquisitions.
DeltaV
- DelatV is Emerson’s leading flagship DCS platform, providing PAS (BPCS) and SIS capability.
- DeltaV was traditionally the market leader for complex batch-type pharmaceutical processes, providing services to many North American pharmaceutical giants.
- In recent years and after the introduction of SIS products it has made established gains in the process industry practically upstream oil and gas.
- Emerson has also entered into the PLC market with the introduction of the DeltaV PK Controller, which is essentially a Emerson branded PLC that connects directly to the Detlav Area Control Network (ACN). This provides some options for end-users that need the performance of PLC scan rates without cost of PLC/DCS integration.
Ovation – Power and Water Industries
- Ovation is Emerson’s automation offering focused on power generation and wastewater treatment industries.
- Ovation suit includes some specific tools such as fuzzy logic, MPC for power generation and waste/water treatment.
- Also included are some tools related to environmental compliance such as combustion optimization, SO2, and CO2 reduction, etc.
- Ovation is originally derived from Westinghouse’s WDPF, which Emerson acquired in 1993.
- Emerson introduced the Ovation product as a single platform solution for automating Turbine Control and plant DCS or sometimes called balance of plant (BOP). Traditionally, gas or Steam turbine control would be undertaken by separate specialist providers with their own PLC or automation system dedicated to controlling turbines and auxiliary components.
Ovation Green – Renewable Industries
- Based on Ovation but combined with Mita-Teknik, software is used for wind turbine control systems, pitch control, and condition monitoring (Emerson acquired Mita-Teknik in Jan 2022).
- Mita-Teknik’s proprietary controls manage wind turbine operation to maximize energy production, while their control software optimizes wind farm output to provide the lowest-cost source of energy.
General Electric
General Electric’s (GE) primary DCS offering is the Mark VIe, which has established itself as a leading automation solution for GE combined cycle power plants since at least 2008.
Primarily designed to control and safeguard turbines and their auxiliaries, the Mark VIe has transitioned into a dual role as both a turbine control system and a general use DCS for balance of plant (BOP) control applications.
Mark VIe Distributed Control System
- Traditionally developed for turbine controllers, it can also be deployed for entire plants, or Balance of Plant (BOP) as it is referred to in power industries.
- Mark VIeS is a stand-alone safety control system for safety-critical applications that conforms to the domain of IEC-6150 standards.
Honeywell
Honeywell entered the DCS market in 1975 with the release of the TDC 2000. In the 2000s, Honeywell transitioned from the TDC 3000 to their open system “Experion”.
Experion PKS
- PKS is a full DCS solution sold directly by Honeywell, typically as a complete, wired, and programmed system with a service contract.
- Normally delivered as part of a PO and service agreement directly with Honeywell.
- Has full SIS capability for functional safety applications.
Experion LX
- LX is a “DCS Lite” version lacking some of the capacity of PKS and is sold by licensed distributors.
- LX can be linked to PKS using Experion Local Control Network (LCN)
- It is designed to be a compact version of PKS, and Honeywell claims it is intended for small—and mid-sized companies.
- One of the main differences between LX DCS systems and PKS is that they are delivered exclusively through Honeywell channel partners and system integrators.
PlantCruise
- A lighter version of Experion with reduced redundancy marketing for none mission-critical applications.
- It was released in 2013 with the intention of making the Experion PKS DCS technology more scaleable and flexible, making it available to a more diverse group of manufacturing plants.
- The components are not SIL capable and cannot be used for functional safety applications.
- It is generally cheaper as most components are made in China and it is sold through channel partners. It is deployed extensively in manufacturing plants in developing countries.
Mitsubishi Power
Developed by Mitsubishi Heavy Industries (MHI) the DIASYS series originating as a thermal power plant control system in the early 1980s and has since evolved into a globally accepted DCS solution.
According to MHI, the DIASYS DCS has been installed in over 2,700 facilities across 60 countries as of June 2023.
DIASYS Series
- DIASYS series, developed as a control system for thermal power plants in the 1980s
- Originally developed for thermal power plants, nuclear power stations, and hydroelectric power plants.
- According to Mitsubishi, DIASYS has also found good applications for other balance of plant, rocket launch facilities, LNG carriers, and office building automation.
- Most of the installation bases exist are in Japan according to Mitsubishi’s press release
- Outside of Japan, there are many install bases in the Middle East, Asia, and Southeast Asia.
Siemens
Siemens DCS are widely used in European manufacturing industries due to the excellent availability of spare parts and good expertise in the region.
Siemens launched PCS 7 (Process Control System 7) in 1996, marking its initial DCS offering. This system was designed to compete with other leading DCSs by offering better scalability, flexibility, and easier integration capabilities.
SIMATIC PCS 7
Siemens is a PCS 7 similar to Rockwells PlantPAx’s DCS solution in that it uses the existing PLC product base as its processing core. It is extremely popular in mainland Europe for manufacturing and automotive plants.
- The processing core of PCS7 is composed of S7-400 PLC but is also compatible with Siemens TDC and IPC technologies.
- Communication at the control level is through open standard PROFIBUS protocol.
- There is some debate among integrator professionals about whether PCS 7 is a true “out-of-the-box” DCS or just a high-performance PLC with WinCC Scada HMI. However, it appears suitable for the same applications and competes in the same market as other major DCS products.
- Additionally, it does not suffer the same limitation about partial downloads and availability as Rockwells PlantPAx. S7-400 generally supports incremental and partial downloads, allowing for online modification without plant disruption.
- Some users criticize the documentation for PCS7, describing it as challenging and poorly structured, making it difficult to navigate without prior experience or guidance.
SIMATIC PCS Neo
Neo is a newer, browser-based iteration of PCS7 that is intended to replace PCS7 fully in the near future. Despite being in a developmental phase, PCS7 Neo is noted for its user-friendly interface.
- A web-based system software architecture that company officials say will set new standards for distributed control systems (DCS).
- Simatic PCS neo’s web-based collaboration platform makes it easy for manufacturing teams to securely share information globally and easily change between the engineering and the monitoring and control views at any time.
- Simatic PCS neo’s web-based collaboration platform makes it easy for manufacturing teams to securely share information globally and easily change between the engineering and the monitoring and control views at any time.
- PCS neo is web-based and uses the HTML5 environment. No DCS software is needed to run locally. Typically, only one engineering server and one monitoring and control server are needed to support multiple engineers and operators who can access the HMI through a web browser, preferably Google Chrome.
Schneider Electric
Schneider Electric has been actively expanding its market share in the DCS domain by acquiring other automation providers, such as Invensys in 2014 along with taking a significant ownership stake in AVEVA in 2018.
Foxboro is owned by Schneider Electric, with the software aspect managed by AVEVA and the hardware managed by Schneider. This arrangement can cause confusion for system owners in terms of support and sales.
Schneider’s flagship DCS offering, EcoStruxure, has a development history similar to DeltaV, involving the integration of acquired technologies under EcoStruxure wrapper.
The integration includes the Modicon and Telemecanique brands, contributing to the diverse lineup of controllers and programming platforms.
EcoStruxure Foxboro DCS Control Software 7.1
- Many users report that Foxboro DCS has user-friendly documentation, which covers hardware, programming, and system configuration extensively, compared with some competitors such as Siemens.
- According to Schneider, EcoStruxure Automation Expert is Based on the controversial standard IEC 61499, which emphasizes event-driven and distributed control systems. The IEC authors claim it allows for modular programming and is designed to handle complex automation tasks with high flexibility. IEC 61499 is a standard for DCS and was released to build upon IEC 61131-3, but industry uptake is small.
Did you know that IEC 61499 was proposed to address the limitations of IEC 61131 for industrial applications? Despite claims of better reusability, portability, interoperability, and distribution, recent studies argue that IEC 61499 falls short and has not been widely adopted by the industry.- Users have reported that working with HMI can be cumbersome; for example, working with graphics involves multiple interfaces (editor, binding editor, live graphic), which can be cumbersome compared to a single platform on other DCS such as DeltaV Live.
- Some users claim that development in EcoStruxure can be complex and present a difficult learning curve for developers who are new to the product.
- Many users report that Schnieder imposes a much less rigid licensing regime than competitors like Emerson. The hardware works seamlessly without restriction, and licensing cleanup can be done after the deployment.
- EcoStruxure DCS Control Software 7.1 runs on Windows 10 and Windows Server 2016, to provide flexibility while ensuring cybersecurity. When planning upgrades, Schneider Electric customers can mix Windows XP, Windows 7 and Windows 10 on the same system, allowing flexibility in scheduling and timing for upgrades.
- EcoStruxure is particularly well used in oil and gas and chemical industries. According to some users EcoStruxure offers excellent function blocks for continuous controls but lacks some standard blocks for discrete controls.
- Unlike other DCS providers, it does not provide any light offerings for small and mid-size plants. Although Foxoboro has been used in the automation of the power industry, Schnieder has not offered a dedicated product such as Emerson Ovation.
EcoStruxure offers excellent interfacing solutions for a wide range of PLC products and continues to support some of its very old legacy PLCs.
- EcoStruxure Control Expert: Supports M340, M580, MC80, and older PLCs with IEC 61131 programming and 984 ladder logic for legacy support.MC80 is a non-expandable brick type PLC, while M340 and M580 are classic rack/slot systems with IO cards and expansions.
- EcoStruxure Machine Expert: CodeSys-based for M241, M251, and M262 PLCs, targeting low to mid-range PLCs with IEC language support.Includes Machine Expert Basic for M221 PLCs (ladder logic and IL with a Grafcet sequencer) and Machine Expert HVAC for M172 PLCs (focused on HVAC applications with IEC language support).
Yokogawa
Yokogawa entered the Distributed Control System (DCS) market in 1975 with the introduction of its CENTUM series, marking a significant milestone in the company’s history. The CENTUM series was one of the world’s first DCS platforms, revolutionizing industrial control by offering centralized control with distributed processing capabilities.
Over the decades, Yokogawa has continued to innovate and expand its offerings, maintaining a strong presence in the industry with advanced solutions for process automation, safety systems, and industrial IoT.
Yokogawa has a significant market presence in the Asia-Pacific region, with a strong base in Japan and substantial installations in China, India, and Southeast Asia. The region’s rapid industrial growth and investment in automation contribute to this high concentration.
The Middle East is another critical region for Yokogawa, particularly in the oil and gas industry. Countries like Saudi Arabia, the United Arab Emirates, and Qatar have numerous Yokogawa DCS install bases in their oil refineries, petrochemical plants, and other industrial facilities.
Centum VP
- The Centum YP offering is strong in the area of alarm management. Yokogawa has actively supported the development of industry standards and best practices for alarm management.
Did you know that Yokogawa is a contributing member of ISA18 Working Group 7 (WG7) for Alarm Management in Plants Incorporating Packaged Systems?
- Yokogawa ProSafe RS R4 is IEC/TÜV certified to meet the SIL 3 classification requirements. ProSafe RS is a fail-safe, standalone system that does not rely on any other systems to fulfil its function.
- Yokogawa also offer solid-state SIS, allowing up to SIL4 for high-integrity applications such as HIPPS.