PLC Interview Questions with Answers Part 1

In this session we are gonna discuss about some PLC Interview Questions with Answers and this
part contains 15 questions

1. What is Programmable Logic Controllers (PLCs)?

Programmable L[ogic Controllers (PLCs) are the micro processor controller devices situated at
the remote sites of the plant or at the field of the process systems. PLCs purpose is to monitor the
process parameters located at the field and adjust the outputs based on the inputs received by the
PLCs. PLCs will operate on any systems which will have input field devices that are On-Off type
(discrete or digital ) or analog input devices. Similarly it will operate on the field devices which
will be discrete or analog output type.

In simple words, PLC acts as interface between the input and output devices at the process side
of the industries. It monitors the inputs receive from the input devices and takes necessary output
control functions by executing the programs stored in its memory.

The term Logic is used in Programmable Logic Controllers because all the program inside the
PLC will be of Logic programming (eg: Ladder diagrams).

In industrial applications hard wired relay logics were replaced by Programmable Logic
Controllers due to its reliability, simplicity, low cost, easier programming and many other
functions.

2. What are the applications of PLC?

Ans. PLC can be used in almost all industrial application solutions right from small machine to
large manufacturing plants. Even it caters applications of redundant systems at critical process
plants.

3. Explain what are different components in PLC?

Ans. Following are the different components in PLC:

1. Input Interface.
2. Memory Section.
3. Central Processing Unit (CPU).
4. Programmable Language.
5. Programming tool.
6. An output Interface.
4. What are the two basic sections of PLC?
Ans. The two basic sections of PLC are:

 CPU
 The Input/Output interface system

5. What are the three major components of CPU?

Ans. The three major components of CPU are:

 Processor
 Memory system
 System power supply

6. Explain what is the programmable language used in PLC?

Ans. The general language program consists of Ladder Diagrams. Relay logic control scheme is
represented in Ladder diagrams. Alternative languages uses Boolean representation of these
control schemes as base of the computer representation.

7. Explain what does Central Processing Unit (CPU) of PLC consists?

Ans. CPU is the brain of the system and consists of:

 Microprocessor: To carryout arithmetic and logical operations.

 Memory: The area in the CPU in which the information is stored and retrieved.
 Power Supply: The electrical supply that converts the ac voltage to various DC operating
voltages.

8. Explain what is SCAN in PLC ?

Ans. SCAN is the process in which a sequential operation of the controller that goes through the
ladder diagram from top to bottom of the ladder. In this process it updates all the outputs
corresponding to the inputs. SCAN takes place from left to right of each rung. Usually SCAN
time is in milliseconds and it is a continuous process.

9. What are the PLCs Advantages or Benefits?

Ans. Following are the PLCs Advantages or Benefits:
Higher Reliability: Once the program written and tested it can be easily downloaded into other
PLC’s memory. It requires lesser and simpler wiring compared to conventional hard wired
circuits employed. Hence reliability of the system increases significantly with PLCs.

More Flexibility: It is easier to create a new program module or change an existing program in
PLC compared to hard wired circuitry system. These software program modules can be changed
whenever required. Use can modify the programs in the field and if required, security can be
enhanced by hardware interlocks such as key locks and software features such as passwords.

Lower Cost: PLCs were originally designed to replace relay control logic which is not
economical and complex especially for large control circuits. With PLCs the cost savings have
been so significant that the relay control becomes uneconomical except for some power
applications. Generally if the application consists of more than half a dozen control relays, PLCs
are least expensive to install.

Low Cost PLC’s for beginners

Communication Capability: Communication capability of PLC with the other controllers and
computers in the system is one of the main advantages compared to relay control circuit.
Functions such as Supervisory control, data acquisition from the field, monitoring devices and
process parameters associated with the field and downloading and uploading of programs can be
easily possible with the PLC compared to hardwired circuits.

Faster Response: PLCs are designed for high speed and for the real time applications.Response
time for PLCs are much smaller compared to relay logic circuits. The programmable controllers
operates in real time i.e, an event taking carrying out at field will result in execution of operation
of output.

Easy to Troubleshoot: PLCs have inbuilt diagnostics and override functions that helps the user to
easily trance the software and hardware errors.

10. Explain Advantages of PLCs than Hard wired Relay?

Ans. PLCs are highly reliable, easily programmable, Small and Inexpensive, PLCs can be
designed with the communication capabilities so they can converse with the local or remote
computer. They can sustain in robust environment with less maintenance.

11. How to program PLCs ?

Ans. Every PLC manufacturer have their own software for programming the PLC. For example
Siemens uses Simantic S7 Manager, Allen Bradley uses RS Logix and Modicon uses PLC pro
programming software. The programming language used is Ladder Logic (LD), Statement List
(STL), Functional Block Diagram (FBD), Sequential Function Chart (SFC), Instruction List (IL)
etc.
12. What is the meaning of scan time in PLC?
Ans. Scan time is the Time required to read the I/P, Process the logic and update the output in
one cycle.

13. Why 4-20 ma and not 0-20 ma?

Ans. When you use a 4-20 ma signal, the PLC will be able to detect a cable break, because it
returns 0 ma.

When you use a 0-20 ma signal, the PLC won’t be able to detect a cable break, because it returns
0 ma and the PLC will think there is nothing wrong with the signal.

14. What Is SIL?

Ans. SIL stands for Safety Integrity Level. A SIL is a measure of safety system performance. It
has four levels. Higher the SIL level, lower the probability of failure for the safety systems. The
cost and complexity also increases as SIL level increases.

15. Name different types of timers used in PLC.

Ans. In PLC, timers may be On delay timer, Off delay timer, Retentive or accumulative timer &
Pulse timer.
The basis of every time is ON DELAY timer. Using only On delay we can arrange various other
types of times.

Difference between PLC & DCS

PLC:

PLC is electronic systems that operate digitally and are designed for use in
industrial environments, where the system uses programmable memory for
internal storage instructions that implement specific functions such as logic,
sequences, timing, enumeration and arithmetic operations to control machines
DCS:

A Distributed Control System (DCS) usually refers to a control system of a

manufacturing system, process or any type of dynamic system in which the
controller elements are not centrally located (such as the brain) but are
distributed throughout the system with one or more controllers controlling
each component sub-system.
Difference between PLC & DCS:

Majority of process plant has both the PLC & DCS. PLC employs as the
subsystem of DCS.

Core processes (food, pharmaceutical, refining, etc.) are usually controlled

and managed by DCS. PLCs are used to regulate non-core process tasks
including material handling, water treatment, engine control, plant equilibrium,
air compressor control, packaging and other features.
Architecture:

PLC architecture:

Architecture of PLC

DCS architecture:
DCS Architecture

Configuration vs. Programming:

DCS is designed to configure and PLC to program.

DCS configuration utilizes conventional control items which are automatically

connected to the corresponding faceplate, simplifying setup and resulting in
standardization.

PLC uses configured softwares to program process setpoints.

Skid & Packaged Systems:
Process plant PLCs on skid installed and packaged devices create control
and automation problems.
Skid mounted and packaged systems are factory-built units that provide a
particular plant-specific feature. Controls and automation on a skid are just as
much component of the plant as controls and automation installed on site.
Control Network Communications
DCSs have extremely sophisticated and embedded Foundation Fieldbus
and HART interfaces as well as appropriate interfaces to other networks of
industrial automation.
PLC systems tend to have fewer sophisticated Foundation Fieldbus and
HART interfaces. In many instances, they depend on hardware and software
from third parties with more intensive setup.
Interestingly, discrete network interfaces can pose a problem with PLC
systems, as there are many standards and bigger suppliers optimize the
interface and software setup to their flagship protocols.
Production Optimization:

Modeling and optimizing real-time software is an evolving feature supplied by

DCS providers to attain greater efficiencies. This optimization level is
elevated, multivariable control based on real-time business management
objectives, real feedstock data, demand for manufacturing and energy
expenses
Advanced Process Control:

PLC lacks in process optimization compared to DCS. Usually offering a

number of instruments to optimize control loops and more sophisticated
options to enhance PID control efficiency. PLCs add these features to
process control with their push.
DCS backbone network:

Typically, DCS backbone networks are conventional Ethernet hardware, but

they use their own closed, high-performance protocols and support
redundancy natively.

The process networks (Foundation Fieldbus, HART) and PLC-oriented

networks (DeviceNet, Profibus, Modbus, etc.) are linked in DCS systems to
controllers linked to the DCS backbone process.
PLC systems use open published protocols to cover a broad variety of apps
including easy discrete, synchronized movement control, engine control, and
process control.
Value of the product being manufactured:

The PLC is the probable option if the price of each autonomous item being
produced is comparatively small and/or downtime results in loss of
manufacturing, but with little extra expense or harm to the process.
The choice should be DCS if the price of a batch is large, either in the price of
raw material or market value, and downtime outcomes not only in lost
production but possibly hazardous and harmful circumstances.
System speed, PLC vs. DCS

The PLC has been designed to satisfy the requirements of high-speed apps
requiring scanning rates of 10 milliseconds or less, including movement
control, high-speed interlocking, or motor and drive control activities.
Most of the time, the DCS doesn’t have to be that fast. The regulatory control
loops usually scan within the range of 100 to 500 milliseconds. In some
instances, executing control logic any quicker could be harmful–potentially
causing excessive wear on final control components such as valves, leading
to early maintenance and process problems.
PLC vs. DCS:

 DCS (Distributed Control System) is a CONTROL SYSTEM that operates with

multiple controllers and coordinates all controller’s job. A distinct plant is handled by
each controller. The PLC is linked to this controller.
 The PLC (Programmable Logic Controller) is a CONTROLLER that can be
rescheduled. If the PLC is a stand-alone and not combined with other PLCs, it will be
called DDC. It implies that PLC is a big system of sub-system called DCS.
 All system checks are performed in the central processor in DCS so that the entire
power plant will also fail if it fails. Mostly DCS is used as a regulatory check.
 DCS is not a large PLC. Because system architecture of DCS and PLC are different.
 DCS is not an integrating PLC into a single big system. “Controller” is more intended
for “Logic Controller” in the PLC, while “Controller” is more intended for “Process
Controller” in the DCS.
 Both DCS and PLC is a configurable and reconfigurable.
Quick Look: PLC vs. DCS

[table id=4 /]

1. What is SCADA?
SCADA stands for Supervisory Control And Data Acquisition is a
system that refers to a combination of telemetry and data acquisition.
SCADA is a real-time supervision, monitoring and information
handling scheme. Components of SCADA include Master Station,
Remote Station / Remote Terminal Unit and Telecommunications
Media.
2. What are Features of SCADA software ?
SCADA’s popular characteristics include Dynamic Mimic Process,
Trends, Alarm, Hardware Connection, Recipe Management, etc.
3. Who are the leading SCADA manufacturers?
 Invensys Wonderware InTouch
 Siemens WinCC (Earlier COROS)
 Allen Bradley RS View (Earlier Control View)
 Intellution iFix (Earlier Fix DMACS)
 GE Fanuc Simplicity
4. List various EXE files used in InTouch Software and there role
 InTouch : It’s a manager of the application. You can use this to build a fresh request.
Moving between different apps.
 View: Windowviewer. This will start Runtime application. From this you can monitor
and control the plant.
 WM: WM.XE is the manufacturer of windows. This will launch the InTouch
development package. You can use this to create the application
5. What are the advantages of SCADA over other protocols?
SCADA enables users to generate object-oriented graphs, offering
trending graphs for real-time information analysis.

SCADA also handles big data, allowing you to create a database

system that shows trends over several years. This allows users to
access important data that can be used for future growth.
6. What is DDE?
DDE is the acronym for dynamic data exchange. DDE provides a
communication protocol that enables communication signals to be
sent and received by machines. Microsoft created this protocol
7. What is RTU?
RTU is a remote terminal device in full form. The remote terminal
devices connect the sensor to the process control and transform the
sensor to digital data
8. How does SCADA handle data?
SCADA system collects information and sends it to a data processing
central computer. Using the SCADA software, information is managed
and displayed to the user. Also, SCADA logs information on who is
running reports and the data being used.
9. At what voltage does an RTU operates?
110V/240V.
10. What are Trends?
Trends implies information graphic representation. To show graphical
depictions of various tagnames over time, you can configure both
trend items.

Real-time trends enable you to chart up to four pens (information

values), while historical trends enable you to chart up to eight pens.

Trends in real time are dynamic. They are continually updated with
whatever time span in setup during runtime. In order to see previous
data, you can not scroll the real-time trends.
11. What types of Licensing patterns used in SCADA software?

There are two types of licenses are used, it is a hardware lock that
can be placed on the PC’s communication port. Software lock: this is
the licence for the software code. You can typically placed the code
during setup or move the code from the floppy to the hard drive
12. What happens to alarm monitoring if the primary alarms serve fails?
The servers are mirrored and all functions are transparently
transferred to the users or ongoing functions.
13. What happens to monitoring if the primary server fails?

No transmission to users is transparent and all functions are as usual

14. How to backup critical tasks such as plant floor I/O alarm and trends?
The redundant server mirrors all server functions. The system offers
local information backups or storage with backup systems on a
network client.
15. What is CIMPLICITY?
CIMPLICITY is a SCADA package. it is based on a client
server architecture consisting of servers and viewers.
Data collection and distribution is the responsibility of servers.
sCSDAVewers connect to servers and have complete access to the
information gathered to view and monitor actions

1.What are the major functions of a supervisory control system?

A. There are three major functions for a supervisory control systems and they are

Set point generation

Process monitoring

Operator interface

2.Explain automation ?
A. Automation is a process that can reduce human efforts, we can see the use of
automation in many industrial applications. The machines in a factory can be controlled by
using automation.

3.What are the functions of a production control system?

A. The product control system does the scheduling of the process, and it also does the
inventory and maintenance management.

4.What are the types of control systems that is used in automation?

A. In automation, there are different kinds of the control system and they are

PLC control system

DCS control system

PID control system

PC based automation system

5. What are the major components that is required for automation?

A. There are many components in an automation system like sensors, transmitters, control
systems, and output devices. The sensors are used to sense the input, and transmitters are
used to transmit electrical signal. The control system is composed of PLC, DCS etc. The
actuators and control valves are the output devices.

6.How is a PLC different from relay?

A. A relay cannot be programmed but the PLC can be programmed, relay is not advanced
like PLC. PLC can work with analog I/O’s whereas the relay cannot do this.

7.What is test automation?

A. In test automation it uses software to do the testing so there won’t be any errors like that
can be seen in manual testing.

8.What is the need for automation testing?

A. Automation testing will provide an accurate result, this testing is done by using the
software so it can reduce cost and efforts. We can improve the testing efficiency by using
automation testing.

9. Name some of the automation testing tools?

A. Rational robot, QA run, silk performer, Load runner

10. In automation do we need manual testing?

A. There are some functions that cannot be tested by using automation, so we need to do it
automatically. So the automation cannot completely replace the manual testing

11. What are the major problems of test automation?

A. The major problem that could affect the test automation is the maintenance of the old
script if there is an enhancement. The old scripts are affected by the change in the
technology of the application.

12. What are the different types of sensors used in automation?

A. There are many types of sensors used in automation they are temperature sensors,
pressure sensors, flow sensors, and there are sensors to detect the level, conductivity, and
density.

13. Why do we 4-20mA signal instead of 0-10V?

A. The 4-20mA signal has the advantage that it won’t drop signal value during long-distance
travel, but in the case of the 0-10V, it is different the signal will drop due to the line
resistance.

14. What is the use of capacitive sensors?

A. It can sense metallic and non-metallic objects

15. What is the use of inductive sensors?

A. Inductive sensors can sense metallic body without touching it

16. What is industrial automation?

A. We can see most of the industries uses automation and it is used to reduce manpower.
Many manufacturing industries have replaced manpower with automation nowadays we can
see automated machines, automated monitoring systems. So most of the industrial
machines are automated and they also have automated control systems.

17. What are the benefits of industrial automation?

A. Increased quality and production, industrial automation, and process control have widely
reduced the need for human sensory and mental requirements. The manufacturing flexibility
is increased and the manufacturing process can be easily converted with the same
production line.

18. Explain derating factor?

A. It is the factor in which the ratings of the parts of the components are decreased so that it
will be safe for to use it in critical applications and also it can be used for extreme
environmental conditions.

19. What does PID stands for?

A. Proportional integral derivative

20. What is PID based control system?

A. In closed-loop control system an algorithm is used which is PID, and the PID controllers
are used to control the closed-loop control in plants. PID controllers are mostly used for
independent loops.

21. Explain smart transmitter?

A. In a smart transmitter it would have a microprocessor in its electronic section and
because of this, it can do remote digital communications and also we can set the device
from a remote position.

22. Explain the difference between the two wire, three wire and four wire transmitter?
A. The power signal transmission is done in a single cable for a two-wire transmitter. The
data signal and power are related to common ground in a three-wire transmitter, while in the
case of four-wire transmitter two wires are used for supply power, and for signals, two wires
are used.

23. Explain fieldbus?

A. A field bus is a communication protocol and it is digital, in-fact it is a high speed
communication protocol. With the help of the field bus higher speed communication is
possible and it can communicate with multiple transmitters in the same filed wiring.

24. What are the required features for a good automation tool?
A. It should support multiple frame work

It should be able to identify the object

It should be able to test the image and object

It must need better debugging facility

25. Explain the cold junction compensation?

A. The instrument will not be set to 0 degree Celsius because of the industry standards
instead of that it will be set to room temperature. Because of this the EMF must be changed
and this is called cold junction compensation.

26. What is a pneumatic system?

A. It is a system that uses air to operate the control valves and actuators
27. What are the factors that must be considered while selecting a sensor?
A. Accuracy

Environmental conditions

We must consider the sensor measurement limit

Repeatability

The sensor should be capable to detect the smallest change

28. What are the types of temperature sensors?

A. Thermocouple, resistance temperature detectors, thermistors,

29. What are the required elements for an automation system?

A. The required elements of automated systems are, they should have the power to
accomplish the process and operate the system, in order to direct the process it would need
a program of instructions, and actuate the instructions it would need a control system.

30. What are the output devices that is used in industrial automation?
A. The output devices such as actuator, drives, control valves, solenoid valves, coils,
indicating lamps, etc can be seen in industrial automation.

31. What is the purpose of sensors and transmitters in automation?

A. The sensors can sense the input parameters and the transmitter is used to transmit the
electrical signal or it can transmit the out.

32. What is the importance of PLC in industrial automation?

A. A PLC is a computerized industrial computer that is capable to do discreet or sequential
logic in a factory environment. It replaces timers, relays, counters, etc.

33. Explain the positive and negative feedback system?

A. In a negative feedback system the output will be removed from the controller while in a
positive feedback system the output will be added to the controller.

34. What are the types of pressure sensors that is used for pressure measurement?
A. Manometers, DP transmitter, Bellows, bourdon tubes and diaphragm elements.

35. Explain open loop and closed loop control system?

A. The out-put of open-loop control system doesn’t make any effect on the output of the
controller and the controller would have high gain in this type of control system. In a closed-
loop system, the system output would affect the controller output.

36. Explain the function of smart regulator of the PID controller?

A. Most of the PID’s are loaded with self-tuning parameters and this feature is known as a
smart regulator. With the help of the smart regulator, the PID can vary the parameters
automatically using intelligent adjustment.

37. Name the types of control valves that is used in industries and their functions?
A. The control valves such as gate, ball, diaphragm, butterfly, and plug valves are used for
ON-OFF services. While certain control valves such as the globe and pinch valves are used
for throttling services and the check valves are used to do the throttling services.

38. What is active and passive sensor?

A. Active sensors are sensors that needs the power supply, photoconductive cell is an
example for this. While the passive sensors doesn’t need a power supply an example for
this would be radiometer.

39. What are the types of sensors used for industrial automation?
A. There are different types of sensors used in industrial automation and these sensors can
be calssified according to their properties.

Classification of sensors based on properties

Temperature – RTD, thermistors etc

Pressure – LVDT, Fiber optic etc
Level sensors – Thermal, differential pressure etc
Flow – Differential pressure, positional displacement etc
Proximity & displacement – Ultrasonic, LVDT etc
Certain other sensors are also used for industrial automation like speed sensor, moisture
humidity sensor.

40. What is an actuator, and what does it do?

A. Actuator is a major part of the control system, which is capable to change the output of a
microprocessor or control system into a control action.

41. Explain pneumatic actuators?

A. The pneumatic actuator will use the air to do certain functions, these actuators use the
air to do the control action in a machine.

42. What is hydraulic actuators?

A. This type of actuator uses the fluid power to do the control action in a machine

43. Explain the infinite position valve and finite position valve?
A. The control valves could be either finite position or infinite position valves, the infinite
position valve can be set in between the fully opened to the fully closed position. The finite
position valve cannot be set like the infinite position valve it could either be completely open
or completely closed

44. How to check the zero of a DP level transmitter while it is in line?

A. At, first close the isolation valves then open the vent valve on the LP leg and HP leg
drain and then check and adjust zero if needed.

45. Explain the difference between the two wire and three wire RTD system?
A. The two wire RTD’s are used for small distance while the three wire RTD is used for long
distance.

46. Is there any limitation for level troll?

A. The major limitation of the level troll is that it can’t be used for lengths that is more than
70 inches.

47. What is the purpose of suppression and elevation?

A. Suppression and elevation is used for level measurement if the transmitter couldn’t be
installed to the zero levels of the tank

48. If a displacer has hole in it while in line what could happen?

A. There would be only minimum output

49. If the displacer has fallen down while in line then what could happen?
A. Then the output will be maximum

50. Explain the interface level and how can we calculate it?
A. If a tank is filled with two liquids that have two different specific gravities and this level
measurement is the interface level.

It can be calculated by the formulae DP= H (D-d)

H=height D= specific gravity of the liquid that is below in the tank

d= is the specific gravity of the liquid with is above the tank or it has less specific gravity
when compared to the other liquid in the tank.
51. What is plant automation?
A. in industrial automation systems, the technical process would contain many multiple sub
processes and it can be seen in the entire plan
 What is transducer?

The non-electrical quantity is converted into an electrical form for using electrical methods
and techniques for measurement, manipulation and control. The device which when
actuated, transforms energy from one form to another is called a transducer.

Transducers are classified into:

1. Active and Passive
2. On the basis of principle used as Capacitive, Resistive, Inductive.
3. Primary and Secondary
4. Analog and Digital
5. Transducers and Inverse Transducers.
What is sensor?

A sensor is a device which senses the presence or absence of energy; it measures a

physical quantity and converts into a signal which can be measured by an instrument or an
observer.Sensor is a device which responds with a change in physical phenomenon. The
classification of sensor is based on conversion principle, based on quantity being measured
and the technology used. The types of energy that can be sensed is classified as
Mechanical, electrical, gravitational, thermal etc. Resolution in sensor defines its ability to
detect a change in sensed element during measurement.

The sensing of any quantity is liable to errors. The two types of errors are Static error and
Dynamic error.

1. Static error: It is a type of error caused while sensing due to reading problems. The
parallax of needle in meter scale is an example of this type of error. One major
advantage of digital readouts is parallax error doesn’t exist.
2. Dynamic error: This error is caused due to the difference in quantity as it really is
and the amount to be measured, caused by the loading of measuring instrument itself.
 A typical example is a false voltage reading across a high- resistance potential divider
with a voltmeter whose resistance is not high enough.
What are types of sensors?
Sensors are mainly classified into two as Active sensors and Passive sensors.

 Active sensor : These type of sensors self generating and it does not require any
external power supply. Photovoltaic cell, piezoelectric devices thermocouples are
examples of Active sensors.
 Passive sensor: These type of sensors requires an external power supply and are
not self generating. A diaphragm used to convert the pressure is an example of
passive sensor.
What is the difference between transducer and sensor?

The following are the differences between transducer and sensor or how is a transducer
differ from a sensor.

 A transducer is a device which convert one form of energy into some other useful
form. While a sensor is a device which detects one form of energy and convert that
data to electrical energy. So we can say that the sensors are, a type of transducer.
 Sensor produces output based on the strength of the input physical quantity.
 In sensors, the sensing element is the sensor itself. In transducers, other than the
sensing element , a circuitry will be there; a signal conditioning element.
 A sensor itself cannot give feedback to the system. While transducers can convert
between any form of energy, it can give feedback to the system.
 A sensor senses the changes in physical quantity in surrounding whereas
Transducer converts the physical quantity into another form.
 Is transducer a detector?
 Sensors or detectors are a type of electrical transducers which can sense and
convert energy (heat energy, light energy etc) from one form to another. Thus we can
conclude that all sensors are transducers but all transducers are not sensors in all
cases. Almost input transducers are sensors and output transducers are Actuators or
Effectors.
 Is Thermocouple a transducer or a sensor?
 Peltier effect is the working principle of Thermocouple. The structure of
thermocouple consists of two metallic ends joined together to form two junctions of
different temperature. Peltier emf is generated due to the temperature difference in two
junctions. A reference temperature is connected to one end for reference and unknown
is connected to other end. Since it senses the temperature it is a sensor and it
converts temperature into emf, hence it is a Transducer. Thermocouple acts as
an active transducer.
These are the comparison between sensors and transducers.
what is PLC?

PLC is a Programmable Logic Controller is used for automation of electromechanical

processes. The PLC is designed for multiple inputs and output arrangements, extended
temperature ranges and it have the ability to resist electrical noise and resistance to
vibration and impact. Programs to control machine operation are usually stored in battery
backed up or persistent storage.
PLC can be described as an electronic system which is operated digitally and designed for
use in an industrial environment. It uses a programmable memory for internal storage of
user oriented instructions. Those instructions are used for implementing special functions
such as logic, sequencing, timing, counting and arithmetic to control, through digital or
analog inputs and outputs, various types of machines or processors.

A programmable logic controller is almost same as a small computer with built-in operating
system (OS). The OS is highly skilled to handle incoming events at the time of their
occurrence. Sensors are connected to the PLC input lines to notify upon events. For
example temperature above or below a certain level, liquid level reached etc. and for any
reaction to the incoming events it has output lines to signal. For example start an engine,
open or close a valve etc. The system is user programmable and it uses a language called
‘Relay Ladder’ or RLL (Relay Ladder Logic) for this purpose.
What is the architecture of PLC?
A PLC is a solid state user programmable control system with the following functions as to
control logic, sequencing, timing, arithmetic data manipulation and counting capabilities.
PLC can be viewed as an industrial computer that has a central processing unit, memory,
input output interface and a programming device.

Every PLC needs:-

• A CPU module
 • A power supply module

• At least one I/O module

An integrated PLC contains all of those components in a single unit. Some integrated PLC’s
can be expanded by having additional I/O modules PLCs must contain a CPU module, a
power supply and I/O modules plugged into the same rack.

What is CPU module in PLC? What are the functions of CPU module in PLC?


The CPU module consists of two main parts as the central processing unit and its memory.
The memory includes PROM (Programmable read only memory) containing the PLCs
operating system, driver programs and application programs; and also RAM, where the user
written programs and working data are stored. PLC manufacturers offer different types of
retentive memory to save user programs and data while power is removed, so that the PLC
can resume execution of the user-written control program as soon as power is restored. If
the PLC has one of the following tentative memory options, it doesn’t have to be
reprogrammed each time it is turned on, so a keyboard and monitor not necessary to be
included as a part of every PLC.

In most PLCs, at least, part of the RAM memory’s contents is protected by a long-life
battery, for years of use. Other PLCs have only capacitor –based power back-up. So RAM
memory is saved only for short periods of power outages (measured in hours).Many PLCs
also offer removable memory modules, which are plugged into the CPU module. A copy of
the user-program and data on EEPROM (electrically erasable programmable read-only
memory) chips in the removable memory modules can be possible to the user. An
EEPROM module can be connected into any PLC of the same make, so they are also
useful in copying programs and data from one PLC to the next.

Now a days, PLC have started to include flash memory, which is like EEPROM memory
except that it can be written without the need of special circuitry. Flash memory is used on
some removable memory modules as an alternative of using the older EEPROM memory
chips, but flash memory is also sometimes built into the CPU module, where it automatically
backs up parts of Random access memory even as the PLC runs. And also if the power
fails while a PLC with flash memory is running, the PLC will resume running without having
lost any important working data after power is restored. Modern CPU modules often contain
more than one microprocessor. The main microprocessor chip’s job is to execute the scan
cycle while slave microprocessors handle the communication functions required to
exchange data with increasingly powerful I/O modules remotely located sensors and
actuators, and with other controllers via local area network.

What is the function of power supply module in PLC?

The power supply module of PLC converts available power to dc power at the level required
by the CPU and I/O module internal circuitry. Generally, available power is in the range of
60Hz/120V ac or 50Hz/220V ac, although power supply modules are available for other
input power characteristics. Output must drive the circuitry at 5Vdc. The Power supply
modules may be plugged into the bus or may have to be wired to the CPU module in
modular PLC systems. If the PLC based control system needs significant power to drive
sensors and actuators, or needs dc levels other than 5 or 24V dc, or needs other electrical
signal characteristics, the user should give additional power supplies and (for the high
power applications typical of some actuators) may need to supply relays, optical isolators or
other circuit- isolation devices.
what is the function of I/O modules in PLC?
Input and Output modules allow the PLC to be connected to sensors and actuators. The low
voltage, low current-signals that the PLC uses internally from the higher- power electrical
circuits required by most sensors and actuators are isolated by the I/O modules. The
modules offered by PLC manufacturers are designed to work with that manufacturer’s CPU
module and so the compatibility is assured. Most manufacturers have extensive range of
I/O modules.
• What is Digital I/O modules?
These kind of modules are used to connect the PLC to sensors and actuators that can only
be switch on and off. Modules are available for a variety of dc and ac voltage and currents.
Each module typically can be connected to several digital sensors or to several digital
actuators of similar electrical characteristics.

• What is Analog I/O modules?

These kind of modules are used to connect the PLC to sensors that can provide electrical
signals which are proportional to a measured value or to actuators that differ their output
proportional with the electrical signals they receive from an output analog module. A signal
analog module can typically only be connected to a few sensors or actuators of similar
electrical characteristics.

Miscellaneous intelligent I/O modules, each with its own built in microprocessors and
memory. Intelligent I/O modules are designed for special purposes such as counting high-
frequency signals or providing servo control of motors.

What is Process Scanning in PLC?

The processor in PLC is designed to perform various duties in a special sequence and the
sequence is repeated continuously. The operating sequence is also called the processor
scan or sweep. A scan is composed of a series of sequential operation includes input data,
execution of program,output data, servicing or updating the programming device, system
communications and diagnostics. This scan cycle is performed sequentially and repeatedly
in when the processes is in run mode. The processor could be in run mode for hours, weeks
or even months. The user program will execute when the top or rung zero, straight through
to the last rung, continuously, unless altered by an instruction specifically designed to after
the flow of the program. Program flow instructions, direct the flow of instructions and
execution instructions within a ladder program.

What are the types of process scanning in PLC?

There are 3 types of process scanning in plc as,
1. Input scan:During the input scan the CPU scans each input module for the ON or
OFF states of each of the associated input point and these states are stored in the input
status file.
2. Program scan:After the input reading process, it is stored in the input status file, the
processor then uses this information to solve the user ladder program. The processor then
scans the user program, starting at the rung zero at the left power rail, working left to right
and evaluating one instruction at the time until the output instruction is reached. The output
status is the resultant of the solution of input logic for that rung. The logical 1 or 0 output
status is placed in the output status file. When the rung zero is completed, immediately the
processor goes on to rung one, rung two, rung three and so on, sequentially to the last
rung. After the last rung of the ladder logic is executed, there is one additional rung in the
program. This last rung is automatically inserted by software. The end rung alters the CPU
that it has reached the end of the program. The time taken by the CPU to scan the user
program varies depending on which instructions are used and the ON or OFF status of the
instructions.
3. Output scan:Here the CPU writes the ON or OFF status, one word at a time, to the
associated Output module. Each output status is comprised of ON or OFF electrical signals;
there is one ON or OFF signals for each output point. In each module the output point
latches its ON or OFF signals into electronic hardware to keep the output in the proper
status until the next output scan sends the update. The time it takes to read an input, solve
the user program, and turn ON or OFF the corresponding outputs, is called the system
throughput.
What is DCS?

DCS (Distributed Control System) refers to a control system usually of a manufacturing

System, process in which the controller elements are not central in location but are
distributed throughout the system with each component sub-system controlled by one or
more controllers. It also controls the safety of whole plant operation. This concept increases
reliability and reduces installation cost by localising control functions near the process plant
with remote monitoring and supervision. DCS was introduced in 1975 by:

 Honeywell-TDC 2000
 Yokogawa
DCS operates with multiple controllers and it coordinates all job and also it uses
conventional control items which are automatically connected.
What is the structure of DCS?

The main attribute of a DCS is its reliability due to the control system in distributed nodes.
The above diagram shows the structure of DCS. Field level or level zero in the diagram
contains the field devices such as sensors and final control elements as control valve.
Industrialised input and output modules are included in level one and their respective
distributed electronic processors.The supervisory computers which collect information from
the nodes and provide operator control screens are included in level two. Level one and two
are the functions of traditional DCS level. The monitoring process is done in level three.
Level 4 is the production scheduling level.
The application of DCS is in wide range as it is dedicated systems in manufacturing plants
like Chemical plant operation, Water treatment plants, Nuclear power plants etc.DCS
reduces design integration risk.

PLC vs DCS
The comparison between PLC and DCS are as follows:

1. PLCs are less expensive as compared to DCS system.

 2. Response Time: When comparing the response time of both, the response time of
PLCs are 1/10 and which makes it an ideal controller for near real-time actions.While
DCS take long time to respond, not a right solution when response time is critical.
3. Scalability : When compared with DCS system, the scalability of PLC is less. PLC
can able to process with a few thousand i/o points while DCS can handle with several
thousands i/o points. Hence for an advanced control system spread over a wide area
DCS is the best option.
4. Redundancy: When we need power or fault tolerant I/O, the redundancy of PLC is a
problem. DCS is better than PLC in this case. The DCS systems are also in higher
level in three programming library, in advanced or optimizing control in self-tuning
algorithms and particularly in their total plant architecture and information management
capabilities.
5. Complexity: For complex operations like oil and gas, power plant, chemical plant
operation DCS is the suitable one as it requires advanced process control operations
and for small scale PLCs are suitable.
6. Vendor Support: DCS vendors generally requires user to employ them to give
integration services and implement process variations. For PLC based systems, the
system integrators perform the same function. When the quality of support factor in
vendor selection become an important factor, most manufacturers reduced the factory
staff and a generation of experienced process control personnel has begun to retire.
7. Frequent process change: For dedicated processes that does not change often,
PLCs are applied. For frequent adjustments and analyse large amount of data in a
complex process, DCS is preferred.
8. Safety :In PLCs, when something is broken, diagnostics will tell you. In DCS, the
asset management will informs you to what might break before it does.
9. PLCs were developed by manufactures that had been making relay for logic and
inter-lock applications, while DCS systems were developed by process control
manufacturers, having experience in PID-type analog control. Therefore, in the past it
made good sense to use each type of controller in its area of superior experiences.
10. If the I/O was digital, the logical choice is to use a PLC, whereas if the I/O was
mostly analog, a DCS system was selected. This logic while still valid to some extent,
end- user familiarity has become a decisive factor in system selection.
11. PLC I/O is likely to be more rugged and PLCs are likely to handle detached logic
faster than DCS system.
12. PLCs are also more desirable. Their language, such as ladder logic are more familiar
to plant personnel and therefore these are less, resistance in using them. Ladder logic
type languages can be undesirable in some situations because they are not well suited
for analog process control
13. Some users have overcome the limitations of PLCs by integrating them with
personal computers using custom-coded programming. The disadvantage to this
approach is that such a non-standardised system is generally understood fully only by
its designer, and when the person leaves the company, the system can be ruined.
The above mentioned are the differences between PLC and DCS system.
What are the components of a PLC?
by AshlinApril 19, 2021095
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A PLC is a digitally operating electronic apparatus and it has a program memory to

store the instructions. These instructions are for certain functions in order to do certain
functions such as logic, sequencing, arithmetic, etc. So basically a PLC is an industrial
computer that would monitor inputs and depending upon their state it would make
decisions based on its program or logic to control its output to automate machine or
process.
Major components of PLC
 Power supply
 Processor module – CPU, memory
 Communication interface
 I/O modules
 O/P modules
 Software
POWER SUPPLY
The power supply is required to run the primary PLC components, most of the PLC
controller would work either at 24 VDC or 240 VAC, certain PLC controllers would have
electrical supply as a separate module. The system power supply not only provides the
power it also monitor and regulate the supplied voltages and warns the CPU if there is
anything wrong. The power supply would provide a well-regulated power and protection
for other system components. Most of the industrial facilities would have fluctuations in
line voltage and frequency and because of this, the PLC power supply must be able to
handle a 10 to 15 % variation in the line voltage condition.

CPU
The central processing unit is the major part of the PLC and it performs the tasks which
are needed to complete the functions of the PLC. The CPU would have a program that
would tell the PLC how to execute the control instructions. The CPU controls and
processes all the operations within the PLC and because of this, it is called the PLC
brain. The CPU would communicate with other PLCs, programming devices, and I/O
devices. The CPU is a microprocessor-based circuitry, the CPU consist of an arithmetic
logic unit, program memory, process image memory, internal timers, and counters.

Arithmetic logic unit – The major function of an ALU is to do the arithmetic and logic
operations with the data transmitted. The accumulator is a part of the ALU and this
would store both the data to be processed as well as the result of an operation. The
instruction register stores the command from the program memory until it is decoded
and executed. A command would have an operation part and an address part. The
operation part would indicate which logic operation must be carried out. The address
part would define the operands with which a logic operation is to be executed. The
program counter would have the address of the next command to be processed. The
counter unit would regulate and control the entire logic sequence of the operation which
is needed for the execution of the command.
Functions of the CPU
 It receives inputs from various sensing device and switches
 It executes the user program
 It is capable to make various decisions in order to control the operation of the
equipment or the process
 It can do many arithmetic and data manipulation functions
 It is capable to deliver the output to various load control devices such as relay
coils and solenoids
INPUT MODULE
The input devices are pushbuttons, sensors, potentiometers, pressure switches. The
input module would change the high voltages to low-level voltages which the CPU can
use for processing. The input module is capable to process both the analog input and
the digital input, mostly digital inputs are used in industries. The analog input module
would convert analog signals from analog devices such as temperature sensors,
pressure sensors. The analog signals from these devices would be converted to digital
with the help of an ADC. Analog signal would be varying voltage and it would be in the
range of 0-12V or current in the range of 5-20ma and these values will be converted into
integer values.

The input and output modules would allow the PLC to check and control a process, the
input section is composed of I/O rack and individual I/O modules. The input interface
module would receive a signal from the machine or process device and converts it into
signals which can be used by the controller. The input interface would enable details
regarding the process that is to be communicated to the CPU. In the input section, the
status signals are filtered to remove noise. Many I/O modules can be inserted into the
rack of the PLC, and this section provides a connection to the machine and the process.
The input to PLCs is discreet signals from the input device. The I/O modules can be
located near the I/O devices with the help of remote I/O and by doing this the wiring
connection can be reduced.
Functions of the input module
 It can sense when the signal is received from a sensor
 It would also convert the signal to the proper voltage for the PLC
 It would also isolate the PLC from the fluctuations in the input signals voltage or
current
 It would also send a signal to the processor indicating which sensor originated
the signal.
The input module would respond to the input signal in this manner
 The voltage transients are reduced or removed by the input filtering and by this
there won’t be any false data
 The optical isolation will protect the backplane circuits and module logic circuits
from the damage which could happen from the electrical transients.
Types of I/O circuits
Discreet I/P
This type of circuit can sense the status of limit switches, pushbuttons, and other
discreet sensors. It will also do the noise suppression and by that, it will prevent false
indication of Inputs.

General purpose outputs

Mostly this is a low voltage and low current and it is used to indicate lights and other
non-inductive loads

Pilot duty outputs

This type of output is mostly used to drive the high current electromagnetic loads such
as valves, motor starter, etc. it can withstand high inrush currents and this load is highly
inductive.

Analog I/O
This type of circuits can sense or drive the analog signals, the analog inputs comes
from devices such as strain gauges, thermocouples, or pressure sensors, and it will
provide a signal voltage or current which is derived from the process variable. The
standard analog I/P signal is 4-20 ma, 0-10v

DC I/P module
AC I/P module

OUTPUT MODULE
The output device is composed of controller coils, solenoid coils, lamps, etc. The output
module would amplify the low-level logical signal which is generated by the CPU and
then it would transmit these modified signals to the final control elements to operate the
output devices. This module would convert the controller signals to external signals
which can be used to control the machine or process. The output interface would allow
the CPU to communicate operating signals to the processing device under its control.
The output module is capable to convert the signals from the CPU into analog or digital
values which can be used to control different output devices.

Memory
Memory is the part of the PLC which stores data, programs, and information. The
process of adding new information into memory is called writing, and the process of
retrieving information from a memory location is called reading. The major types of
memory which are used in the PLC are read-only memory and random access memory.
We can only read Rom location but it can’t be written, the ROM would have programs
and data which should not be edited like the operating programs. The RAM location can
be used to do the reading and writing and by this, we can edit or change the information
which is stored in the RAM.

System buses
This is the internal path through which the digital signals flow within the PLC. Mostly the
system would have four buses, the data bus is to send data between different elements,
the address bus is to send the address of the locations in order to access the stored
data, the control bus is for the internal control, and the system bus is for the
communication between the I/O ports and I/O units.

SOFTWARE
The PLC has two parts the operating system and the user program. The operating
system of the PLC provides proper support from the starting of the project to the
creation of the user program. The major window would have all the functions which are
needed to set up a project, and also to configure the hardware, write, and set up a
program. During the processing of the PLC program, the CPU would scan and execute
the main program cyclically. A program scan cycle consists of sequential operations
which include input scan, program scan, and output scan. In the input and output scan
of the PLC, the CPU updates the process image of the input and output. So after the
completion of each scan cycle, the CPU would return to the next cycle and repeats the
cycle and the required to scan one program is scan cycle time.

What is industrial automation?

Automation is the use of machines, control systems, and information technologies to
optimize productivity in the manufacturing processes with little human involvement.

Industrial automation helps us to process the plant operation in more optimized conditions
by using various control systems such as Programmable Logic Circuit (PLC), Human-
machine Interface (HMIs), and robotics.

Automation employs logic and programming to provide information to machines on how to

accomplish a function; these machines provide great control, which enhances
manufacturing performance.

In a manufacturing environment, industrial automation may consist of various types of

equipment. In industrial automation control, multiple process variables such as temperature,
flow, pressure, distance, and liquid levels can be recorded at the same time. All these
variables are recorded, processed, and controlled by complex microprocessor systems or
PC-based data processing controllers.

Advantages of Industrial Automation

The main advantages of industrial automation are

 High reliability
  Increased productivity
 Quality enhancement and
 Reduced labor expenses
Block diagram of Industrial Automation

What are the types of Industrial Automation?

There are different types of industrial automation available in the market based on their use.
They are:

 Fixed (Hard) Automation

 Programmable Automation
 Flexible (Soft) Automation
 Totally Integrated Automation (TIA)
Fixed (Hard) Automation
This type of automation is used in high-volume production settings with dedicated
equipment. To perform well there is a pre-installed operating set are available with the
equipment

Fixed (Hard) Automation Advantages:

 High production rates
 Low unit cost
Fixed (Hard) Automation Disadvantages:
 The initial investment is high
 High chance for failure
Programmable Automation
The production equipment in this method is built to be able to modify the operation
sequence to meet different product configurations.

It is mainly used when manufacturing products in batches because we can customize and
make adequate changes throughout the manufacturing process.

A program of instruction always controls the manufacturing process in programmable

automation. In this case, we can just load the program into the hardware system and begin
producing new products at any moment.

Advantages of Programmable Automation :

 Very flexible
 Able to deal with design variations
 Appropriate for batch production
Disadvantages of Programmable Automation:
 High investment.
 Production rate is low than fixed automation.
Flexible (Soft) Automation
The material-handling system connects several machine tools in flexible automation, and all
components of the system are controlled or controlled by a central computer.

Flexible (Soft) Automation Advantages:

 Continuous production of variable mixtures of products
 Flexible to deal with product design variation
 The production rate is medium
Flexible (Soft) Automation Disadvantages:
 High investment
 Cost is high compared to fixed automation
Totally Integrated Automation (TIA)
Integrated industrial automation refers to the comprehensive automation of production
operations, in which all processes are coordinated digitally and controlled by computers. It
includes technology such as:

 Computer-aided process design

 Machine systems that are adaptable
 Machine tools for computer numerical control
 Material-handling robots are examples of automated material-handling systems.
 Systems for automatic storage and retrieval
  Control of production and scheduling by computer
 Conveyors and cranes that are automated
Main Components ofIndustrial Automation
 PLC – Programmable Logic Controller
 DCS- Distributed control system
 SCADA
 Advance Solutions
 Cyber Security
 OT
PLC
A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial control system that
continuously analyses the status of input devices and makes choices to control the state of
output devices based on a custom program. To automate a process or machine, a PLC
monitors inputs, makes choices based on its program, and controls outputs.

PLC has composed of three main parts:

 Input,
 CPU and
 Output.
Architecture of PLC

Basic PLC Operation :

A PLC consists of Input modules, a central processing unit (CPU), and output modules. An
input device collects digital or analog signals from various field devices known as sensors
and converts them into a logic signal that the CPU may use. Depending on the program
instructions stored in the system memory, the CPU makes decisions and executes control
instructions. A programming tool provides the appropriate instructions, which specify what
the PLC will do in response to the presented input. An operator interface allows the device
to show process information and add new control settings.

What are the advantages of PLCs?

The advantages of PLCs are

 Smaller in size compared to Relay logic solutions.

  Easy to handle
 Faster response
 Less maintenance
 Easier to troubleshoot.
 Better reliability
 Remote control and communication capability.
Major PLC manufacturers list
1. Siemens.
2. Rockwell Automation / Allen Bradley.
3. Mitsubishi Electric
4. Schneider Electric.
5. ABB.
6. Honeywell Process.
7. Omron.
8. Hitachi Industrial Equipment Systems.
Distributed Control System (DCS)
A distributed control system, or DCS for short, is a manufacturing plant control system with
autonomous controllers scattered throughout the system.

The distribution of control system architecture throughout the plant has resulted in more
efficient methods of improving control stability, process quality, and plant efficiency.

DCS are commonly used in the following processes,

 Oil and Gas

 Petrochemicals
 Chemical plants
 Nuclear power plants
 Water treatment plants
 Sewage treatment plants
 Food processing
 Automobile manufacturing
 Pharmaceutical manufacturing
A DCS is made up of both software and hardware. The simplicity of local installation with
most controllers reduces installation expenses. On-site, low-latency automated control
improves reliability, while central control functions and remote control alternatives allow for
human oversight. Unlike a central controller system, individual processes have their own
controllers with separate CPUs, allowing other processes to continue in the event of a
breakdown.

What is the Function of a DCS?

While DCS are used in a variety of industries to manage complicated production processes,
they are most commonly seen in large, continuous manufacturing plants like Oil and
Gas, petrochemical industry. Individual controllers receive instructions from the DCS, which
are then distributed throughout the plant. When properly set, the DCS can increase safety
while simultaneously increasing production efficiency.

Major DCS manufacturers list

 1. Honeywell
2. Yokogawa
3. Emerson Electric
4. Invensys Limited
5. Siemens
6. Metso
7. ABB
8. General Electric
9. Mitsubishi
10. Rockwell
SCADA
Supervisory control and data acquisition is a control system architecture that consists of
computers, networked data transfers, and graphical user interfaces for high-level monitoring
of equipment and processes. This process can be industrial, infrastructure, or facility-based:
Manufacturing, power generation, manufacturing processes, and refining are all examples
of industrial processes that can run in continuous, batch, repetitive, or discrete modes.
Water treatment and distribution, wastewater collection and treatment, oil and gas pipelines,
electricity transmission and distribution, and other infrastructure activities are examples of
public or private infrastructure activities.

Subsystems of SCADA
The SCADA System is made up of subsystems. They are as follows:

a) A human-machine interface, or HMI, is a device that displays process data to a human

operator and allows the human operator to monitor and control the process.

b) A supervisory (computer) system that collects (acquires) process data and sends
commands (controls) to the process.

C) Remote terminal units (RTUs) link to process sensors, transform sensor signals to digital
data, and transmit the digital data to the supervisory system.

Major SCADA manufacturers list

1. Honeywell
2. Schneider Electric
3. ABB
4. Siemens Energy
5. General Electric
Cyber Security in Industrial Automation
Organizations are more interconnected in digital networks. Access to industrial automation
and process control systems is possible through the company’s internal and external
networks.

The transfer of data between different systems and networks makes them more vulnerable
to attacks and subsequent system failures. Ensuring the availability and integrity of these
systems requires precautions against unauthorized internal and external access to industrial
control systems.
Importance of Cyber Security:
First, we have to know there are many reasons why digital or cyberattacks occur, in some
cases, it is just for the fun to the hackers and in some cases, people use it as a money-
making way.

The significance of cybersecurity is highlighted here.

In any of the above circumstances, the impact of these attacks can be devastating, causing
immense financial and reputational harm to the people or industry. For these reasons, IT
and OT security are more important than ever before, even if most companies are
unprepared or unaware from even the basic security perspective. Unless an effort is made
to safeguard this next phase of IT/OT fusion, many existing frameworks will be vulnerable to
these assaults. IT/OT combo not only lets businesses build future-proof enhancements, but
it also allows them to do it safely.

Solutions available in Cyber Security for Industrial Automation

Various methods to Prevent Cyber Attacks
The Various types of Cyber security solutions are

Cyber & Malware attack

Anti-malware software is recommended to prevent malware attacks. Installing this software
on a computer help us to find and remove the malware’s if there is any on our machine and
it also prevents malware attack in future.

What is DOS and how to prevent it?

DoS or Denial of Service attacks is one of the best offensive attacks since they take down a
target’s servers, making it difficult to access their locations or use their online services.
Having more bandwidth capacity is the simplest approach for countering DoS attacks. If
you’re concerned that your company might be a target for DoS attacks, simply having
enough server capacity to handle the increased traffic activity can keep the attacks at bay.
There are also third-party administrations that can help your firm stay online during a DoS
attack.

Phishing and the prevention for Phishing assaults

In a phishing attack, a cybercriminal tries to get personal information from you by tricking
you into giving it to them. Scammers who are more adventurous may attempt to steal a
victim’s government-managed ledger data. A recent phishing scheme used Google Docs to
trick users into entering their Google login credentials.

The easiest and efficient way to prevent phishing attacks is to make sure the workers are
aware of both how normal and harmful an attack can be; remind them to keep extra care
while checking emails and to report any email they find suspicious. Apart from this, make
sure workers are using security features like two-factor authentication for their email
accounts.

Cyber security in Industrial Automation and Industrial Control Systems :

Cybersecurity is a word that describes how industrial automation and control systems
(IACS) protect themselves from unforeseen events, actions, opportunities, or attacks.
Accidents can happen anywhere, including the Internet, company systems, program
evaluations, and unauthorized access, and they can have a major impact on health, safety,
and the environment.

OT Networks
Operational technology (OT) is a combination of hardware and software that detects and/or
modifies industrial equipment, resources, processes, and events through direct monitoring
and/or control. The term was coined to describe the technical and functional differences
between standard IT systems and industrial control system environments. Here are some
examples of technologies that work:

 Programmable Logic Controllers (PLCs)

 Supervision and Data Acquisition Systems (SCADA)
 Distribution Control Systems (DCS)
 Computer Numerical Control Systems (CNC)
 Scientific Instruments (eg digital oscilloscopes)
 Building Management and Building Automation Systems (BMS) / (BAS)
 Controlling lighting for indoor and outdoor applications
 Integrated energy, safety, and security monitoring systems
 Transportation systems for the built environment
Advance Solutions
Historian
It is a time base data system or tool designed to collect the data from an automation
system. The saved data can subsequently be utilized to illustrate process data trends on
charts, generate reports, or perform data analysis.

Standard Elements of a Historian System

A Historian system is made up of three basic components:

Data collectors collect data from various sources such as PLC, OPC servers, files, and
network devices.
Server Software: It processes the data which was collected by the data collector and
serves it to the client applications.
It also provides some other services like alarm management, calculation, and data context
subsystems.

Client applications for data reporting, charting, and analysis.

Alarm Management
The main role of the alarm management system is to alert the operator if any abnormal
operating situations occur in the industry. The alarm occurs due to the following reasons:

 A manmade or natural issue

 Equipment problem,
 Product Quality Control.
Emergency Shut Down (ESD) systems are also used to halt the process when if the alarm
occurred due to danger of serious safety, environmental, or financial issues.

Advance Process control

Advanced Process Control, or APC, is model-based software used to control the operation
of a process and is commonly called multivariate predictive control (MPC).

Improved operational economics or production improvements are common inspirations for

implementing these applications. The advanced process control software may offer the
following features:

 Tools for offline and online model creation, model verification, and data analysis that
ensure model accuracy
 Driver program for obtaining historical data from control systems or online process
historian systems.
 Operator direction to inform the operator of where the APC is taking the process.
 Controlled variable prediction based on future projected motions of managed
variables
 APC adjustment at runtime to account for changes in process dynamics without the
need to recompile the model
 Not the PID or process controller tuning and related performance, but the APC
controller monitoring and performance analysis software
Asset Management System (AMS)
An Asset Management Solution focused on reducing the downtime of an Automation
System.

Industrial automation has a large number of smart machines like PLCs, HMIs, VFDs, etc,
and these devices are either configured or programmed based on the industry. Smart
machines are usually connected to an Ethernet network. Sometimes, some disruptions will
occur in the industry, and quick recovery from these disruptions is very important to reduce
downtime and product loss. These disruptions occur due to man-made or natural issues
and an Asset Management System can solve these problems.

Capabilities of AMS
The capabilities of AMS software are listed below:

 Archive critical files and documents

 Automatic disaster recovery
 Track or audit all changes to operating settings:
Archive critical files and documents: When changes are made to any of the resources, a
version history records the user name and the date of the change. The most recent revision
is stored, and the number of backup versions kept is determined by the user. So if any error
happens, the user can revert back to previous versions and can run the industry without
much delay or downtime.
Automatic disaster recovery: By using AMS software, we can schedule the backups of
files. If any differences that are detected are assembled into a report that can be
automatically emailed to a list of users.
Track or audit all changes to operating settings: For example, When a user modifies a
parameter value or a setpoint in a controller, the event is automatically recorded in a
centralized audit log, which includes the device, user, time, and action executed.
Other benefits of AMS. You may automatically scan the running network and add new
assets to AMS. Workstation software packages may be tracked and readily uploaded.
Security scans can be performed on several devices at the same time. Assets can also be
tracked using a mobile device.
Data Collection Software and Change Management System
A data collection is a computerized system for collecting and storing data from various input
and output devices in an electronic format. The advantages of employing data collection
technologies include the elimination of paper surveys and the ability to instantly export data
for data analysis and reporting.

Function and Components of DCS

by SivaranjithOctober 25, 20180965

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Functions of DCS:
Based on its function, DCS has functions:
  DCS functions as a tool to control a loop system where one loop can perform several
control processes.
 Serves as a substitute for manual and automatic control devices that are separated into
a unit so that it is easier to maintain and use
 Data collection and processing facilities to obtain the right process output
Components of DCS:
In general, the components of DCS consist of 3 basic components, namely: Operator
Station, Control Module, and I/O module.

Operator station:

A station operator is a place where the user monitors or monitors the running process.
The station operator is used as the interface of the system as a whole or commonly also
known as a collection of several HIS (Human Interface Station). The HIS form is an
ordinary computer that can retrieve data from the control station. Station operators can
bring up process variables, control parameters, and alarms that the user uses to
retrieve operating status. Station operators can also be used to display trend data,
messages, and process data.
Control Module:

The control module is the main part of DCS. The control module is the control centre or
as the brain of all process control. The control module performs the computational
process of algorithms and runs logical expressions. In general, the control module is in
the form of a black box located in a cabinet or cabinet and can be found in the control
room. Control modules usually use redundant mode to improve control reliability.

The function of the control module is to take an input variable that will be controlled. The
variable value will be calculated. The results of this calculation will be compared with the
set point. This set point is the value expected of a process. If the calculation results are
different from the set point, the value must be manipulated so that it reaches the set
point. Value manipulation results will be sent to the input module output and to be
delivered to the actuator.
I/O Module:

I / O Module is the interface between the control module and the field instrument. I / O
module functions to handle input and output of a process value, convert signals from
digital to analog and vice versa. The input module gets the value from the transmitter
and provides the process value to FCU for processing, while FCU sends the
manipulated value to the output module to be sent to the actuator. Each instrument
field must have an alias on the I / O module. Each field instrument has a unique name
on the I / O Module.

Components of PLC
by Editorial Staff

The recommended controller for SCADA systems is

the programmable logic controller (PLC). PLCs are general-purpose
microprocessor based controllers that provide logic, timing, counting,
and analog control with network communications capability.

Components of PLC
A PLC consists of the required quantities of the following types of
modules or cards, mounted on a common physical support and
electrical interconnection structure known as a rack.

A typical PLC rack configuration is shown in below figure.

(1) Power supply :

The power supply converts facility electrical distribution voltage, such
as 230 VAC, 120 VAC or 125 VDC to signal level voltage used by the
plc processor and other modules.
(2) Processor:
The processor module contains the microprocessor that performs
control functions and computations, as well as the memory required
to store the program.

(3) Input/Output (I/O) :

These modules provide the means of connecting the processor to the
field devices. Examples of these modules are Analog Input Module,
Analog output module, Digital input module, Digital output module
etc.

These are used to connect devices between plc and field devices like
flow transmitters, pressure transmitters, control valves, analyzers,
substation feeders for motor control etc.

(4) Communication:
Communications modules are available for a wide range of industry-
standard communication network connections. These allow digital
data transfer between PLCs and to other systems within the facility.

Most commonly used modules are Modbus communication cards or

Serial communication.

Some PLCs have communications capability built-in to the processor,

rather than using separate modules.
(5) Communication Media and Protocols:
The most common communication media used are copper-wire,
coaxial, fiber-optics, and wireless. The most common “open”
communication protocols are Ethernet, Ethernet/IP, and DeviceNet.

“Open” systems generally provide “plug and play” features in which

the system software automatically recognizes and communicates to
any compatible device that is connected to it.

Other widely accepted open protocols are Modbus, Profibus, and

ControlNet.

(6) Redundancy:
Many PLCs are capable of being configured for redundant operation in
which one processor backs up another.

This arrangement often requires the addition of a redundancy module,

which provides status confirmation and control assertion between the
processors. In addition, signal wiring to redundant racks is an option.
PLC Software and Programming
All software and programming required for the PLC to operate as a
standalone controller is maintained on-board in the processor.

PLCs are programmed with one of the following

standard programming languages:

(1) Ladder Diagrams:

Used primarily for logic (Boolean) operations and is easily understood
by electricians and control technicians. This is the most commonly
used language in the United States and is supported by all PLC
suppliers.

(2) Function Block Diagrams:

Used primarily for intensive analog control (PID) operations and is
available only in “high-end” PLC’s. It is more commonly used outside
the United States.

(3) Sequential Function Chart:

It Used primarily for batch control operations and is available only in
“high-end” PLC’s.

(4) Structured Text:

It is Used primarily by PLC programmers with a computer language
background and is supported only in “high-end” PLC’s.

SCADA
SCADA PLCs should be specified to be programmed using ladder
diagrams. This language is very common, and duplicates in format
traditional electrical schematics, making it largely understandable by
electricians and technicians without specific PLC training.

The ladder logic functions the same as equivalent hard-wired relays.

The PLCs in a SCADA system will be networked to one or more central
personal computer (PC) workstations, which provide the normal means
of human machine interface (HMI) to the system.

These PCs will be provided with Windows-based HMI software that

provides a graphical user interface (GUI) to the control system in which
information is presented to the operator on graphic screens that are
custom-configured to match the facility systems.

For example, the electrical system status may be shown on a one-line

diagram graphic in which open circuit breakers are colored green,
closed breakers are colored red, and voltage and current values are
displayed adjacent to each bus or circuit breaker.

PLCs are recommended for the following reasons:

(1) They were developed for the factory floor and have demonstrated
high reliability and tolerance for heat, vibration, and electromagnetic
interference.

(2) Their widespread market penetration means that parts are readily
available and programming and technical support services are
available from a large number of control system integrators.

(3) They provide high speed processing, which is important

in generator and switchgear control applications.

(4) They support hot standby and triple-redundant configurations for

high reliability applications.