PLCs, DCSs & Controllers


The convergence of intelligence: DCS, SCADA and TLC

October 2024 PLCs, DCSs & Controllers

In the early days of industrialisation, control systems were primarily mechanical, and relied on manual intervention and simple feedback loops to manage processes. And whilst it sounds positively medieval compared to today’s technologies, these systems played a very important role in man and machine’s industrial evolution.


Kobus Vermeulen, direct sales executive, Process Automation at Schneider Electric.

Fast forward to the middle of the 20th century, and electronics and computing technologies had advanced to a point where industries could leverage automated systems that required minimal human intervention. These early digital control systems were centralised, with a single controller managing multiple processes. However, they had limitations like single points of failure and scalability challenges. Now in the 21st century, industrial process automation systems are mind-blowingly intelligent, and provide almost unparalleled control and monitoring capabilities, making them integral to modern industrial systems.

Intelligence like no other

At the forefront of these intelligent systems are distributed control systems (DCS), supervisory control and data acquisition (scada), and total load control (TLC) systems, which have significantly transformed the industrial automation landscape.

Each system plays a distinct yet complementary role, enhancing the efficiency and sustainability of industrial processes. DCS centrally manages complex processes, while scada focuses on remote monitoring and control, and TLC optimises energy management by regulating electrical loads − the industrial trifecta.

It is the convergence of these three systems into unified solutions that is driving the next wave of industrial automation, marked by enhanced efficiency, resiliency and intelligence.

Trifecta of intelligence

The integration of DCS, scada and TLC into unified systems leads to fundamental benefits such as:

• Streamlining operations: Unified systems consolidate various control functions, reducing complexity and improving overall efficiency. By integrating different automation and control layers into a cohesive platform, businesses can eliminate redundancy, simplify maintenance, and enhance system interoperability.

• Comprehensive data utilisation: This leverages data synergies across different streams, enabling more comprehensive monitoring, control and analysis. The complete view provides operators with actionable insights, supporting predictive analytics and better operational decision making.

• Cost effectiveness and resource optimisation: Integration minimises redundancy, optimises resource allocation, and enhances energy efficiency, leading to more sustainable and productive outcomes. Standardised interfaces and protocols reduce the costs associated with system integration, expansion and maintenance.

From the above, it is clear that the integration of DCS, scada and TLC systems empowers companies to make data-driven decisions while optimising operations. If one adds AI analytics and IoT into the mix, these systems become even more optimised:

• AI enables real-time data processing and pattern recognition, allowing quick responses to changes and anomalies.

• AI predicts equipment failures by analysing sensor data, reducing downtime through proactive maintenance.

• AI and IoT drive systems towards autonomous control, enhancing efficiency and reducing human intervention.

• AI dynamically adjusts parameters for optimal performance and energy efficiency.

• AI and IoT process data at the network edge, minimising latency for faster responses.

Ultimately, the industrial automation marketplace is set to become even more intelligent, providing fundamental benefits to organisations and industry alike. At the current growth rate, today’s systems might even sound slightly outdated in the next few years.


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Why turbomachinery should break free from vendor lock-in
Schneider Electric South Africa Motion Control & Drives
Today’s modern turbomachinery control systems form an important of operational efficiency, be it in heavy industries, traditional power generation or renewables such as hydroelectric facilities. Independence is the name of the game, and turbomachinery stands to gain lot from this newfound freedom.

Read more...
The evolving landscape of data centres in the age of AI
Schneider Electric South Africa IT in Manufacturing
The data centre industry is undergoing a period of rapid transformation, driven primarily by the explosive growth of AI. It’s clear that the demands of AI are reshaping the very foundations of data infrastructure. This isn’t merely about incremental upgrades; it’s a fundamental shift in how we design, power and operate these critical facilities.

Read more...
Monitoring partial discharge on medium voltage switchgear
Schneider Electric South Africa Electrical Power & Protection
Schneider Electric South Africa has launched its EcoStruxure Service Plan (ESP) in the Anglophone African region for medium voltage (MV) switchgear

Read more...
Buildings in Africa’s urban evolution
Schneider Electric South Africa IT in Manufacturing
Africa is now an urban continent. How does the continent mobilise to accommodate urban dwellers and maintain and implement critical infrastructure that allows for this expansion? Building management systems provide a tangible solution to optimise resource use, lower operations costs and ultimately contribute to a growing continent that also employs green practices.

Read more...
Innovating control and display solutions
PLCs, DCSs & Controllers
Mimic Group, founded in 1971, started with electronic and mimic displays before expanding into control desks, software and display electronics.

Read more...
Compact, high density power protection system for AI, data centre and large-scale electrical workloads
Schneider Electric South Africa Electrical Power & Protection
Schneider Electric has launched its new Galaxy VXL – a highly efficient, compact, modular, scalable and redundant 500-1250 kW (400 V) 3-phase uninterruptible power supply (UPS), complete with enhanced cybersecurity, software and safety features.

Read more...
Duct and plant room air quality (PRAQ) sensors
Schneider Electric South Africa Sensors & Transducers
Schneider Electric South Africa offers a comprehensive range of SpaceLogic duct and plant room air quality sensors. These cutting-edge sensors are designed to enhance building air quality and energy efficiency by combining multiple sensing capabilities into a single unit.

Read more...
The sensory reaction of the BMS
Schneider Electric South Africa Sensors & Transducers
Today’s building management systems cannot function properly without sensors. Like our senses, they are an integral part of operations that run silently in the background, almost taken for granted.

Read more...
ABB technology for greater circularity in metals and mining industries
PLCs, DCSs & Controllers
ABB has been selected by GreenIron, an innovative Swedish company working in the mining and metals industries with its patented materials reduction technology, to provide automation and control system solutions for a first commercial facility in Sandviken, Sweden.

Read more...
Schneider Electric relaunches legacy access control systems
Schneider Electric South Africa IT in Manufacturing
Schneider Electric South Africa has relaunched its comprehensive access control platform to help customers upgrade from ageing and obsolete systems.

Read more...