ELEC/MECH/PHEN 6th Semester

Industrial Automation & PLC Programming

ICS, DCS, SCADA Systems, and PLCs

Prof. Ashraf A. Zaher

German International University
Faculty of Engineering
Department of Electrical Engineering
 Layout
Introduction:
This lecture provides a brief survey to many different decentralized control structures that suit the need for
industrial automation. It emphasizes the concept of automation, and how it could be achieved, using a variety
of techniques and system architectures. The use of PLCs will pop up, naturally, as the most effective means,
currently used in the industry.

Objectives:
Establishing the necessary background and reasoning to appreciate the study of PLCs and how they relate to
control systems and automation. Different types of control systems that are currently available in the industry
will be reviewed to pave the way for introducing PLCs. A summary of main important concepts in automation
and a detailed list of terminology, acronyms, and jargon will be identified .

Outcomes:
By the end of this lecture, students should be able to:
 identify different industrial control systems (ICS),
 know how to automate industrial processes
 understand the structure of distributed control systems (DCS)
 build simple structures for supervisory control and data acquisition (SCADA) systems,
 recognize the differences between PLCs, DCs, and SCADA, and
Anticipate the future trends in automation, based on the current practices in different technologies
Prof. Ashraf Zaher 2
 Industrial Control Systems
Definition:
An industrial control systems (ICSs) is a collective term used to describe different types of control systems and
associated instrumentation, which include:
1. the devices,
2. systems,
3. networks, and
4. controls used to operate and/or automate industrial processes.
Depending on the industry, each ICS functions differently and are built to electronically manage tasks
efficiently. Today the devices and protocols used in an ICS are used in nearly every industrial sector and
critical infrastructure such as the manufacturing, transportation, energy, and water treatment industries.

The concept of integrated machine:

Every industrial production process consists of a series of simple or complicated machines that, through the
combination of raw materials, undergo a sequential transformation and integration in order to produce a final
product. The term “machine” denotes every kind of electromechanical device on the industrial floor, e.g., from
a simple motor (such as a drilling or a cutting machine) up to a complicated chemical machine (e.g., a chemical
combustion machine). The whole set of machines (namely non-homogeneous machines), which are being
integrated and combined in an industrial production process, will be referred to as an “integrated machine”.

Prof. Ashraf Zaher 3

 Industrial Control Systems – Example #1
Processing of paper machine
The following figure depicts the typical production line of an integrated paper machine, where
the initial raw pulp is undergoing the sequential processes of:
1. pretreatment and grinding,
2. refining,
3. pulp bleaching, and
4. pulp pressing and drying
until it is transformed into the final paper of predefined quality.

Prof. Ashraf Zaher 4

 Industrial Control Systems – Example #1

Prof. Ashraf Zaher 5

 Industrial Automation
Definition:
It is the use of control systems, such as computers or robots, and information technologies for
handling different processes and machineries in an industry to replace a human being. It is the
second step beyond mechanization in the scope of industrialization.

Advantages:
 High productivity
 Improved quality
 Increased flexibility
 High information accuracy
 Better safety
 Reduced energy consumption
 Better utilization of raw materials
 Less pollution

Disadvantages:
 High initial cost
 Social impact (layoffs and rapidly changing job market requirements)
Prof. Ashraf Zaher 6
 Automated Industrial Control Systems
 From the beginning of the industrial
era, the main aim of every production
process was the achievement of a
higher possible level of automation.

 Reducing the number of personnel

involved was also a common aim from
the factory owners.

 The transition of the production model,

from the initially multi-interrupted
form to the continuous form, required
the development of specific
methodologies and tools that would
allow the central coordination of all the
various procedures with minimal
human intervention in the overall
process.

Characterization of Movements

Prof. Ashraf Zaher 7

 Automated Industrial Control Systems
Combined Tasks

Speed Control

Position Control

Direction Control

Prof. Ashraf Zaher 8

 Industrial Control Systems – Example #2

Prof. Ashraf Zaher 9

 Industrial Control Systems – Example #2

Continuous, discrete, and event-based operations

Define:
 Sensors
Automation
 Actuators
 Controllers
 Sequence of operation
 Logic-based operation
Prof. Ashraf Zaher 10
 Industrial Control Systems
Continuous Control:
 Level sensor
 PID controller
 Motorized valve
In the era of classical industrial
automation, this control scheme
would have been implemented
by analog circuits, whereas now
it is commonly implemented by
the utilization of computers and,
more specifically, programmable
logic controllers PLCs

Additional functions:
 Monitoring
 Alarming
 Data logging
Prof. Ashraf Zaher 11
 Computer-based ICS and Automation
Sequential Control:
 Rotary motion
 Liner motion
 Variable speeds
 No transfer functions
 Position sensors
 Boolean functions

Prof. Ashraf Zaher 12

 Industrial Control Systems
Through the evolution of multiple, related
technologies and through the developments in
the field of analog and discrete control in the era
of microprocessors and PLCs, a transition took
place from having small-scale, centralized,
industrial automation, to a decentralized and
large-scale one, fully controlled by numerous
distributed PLCs, able to synchronize multiple
industrial processes.

Through the sensors, the necessary signals and

measurements are collected from the controlled
process. Subsequently, this information is being
analyzed by the control logic, which is running in
a computational unit, and, in the final step, the
control actions are interacting with the controlled
process, through proper control of the provided The purpose of industrial automation
actuators.
Prof. Ashraf Zaher 13
 Industrial Control Systems
Prior to the introduction of solid-state electronics, the designer of an industrial production process was attempting
to make the automation operate as automatically as possible, based on the various instrumental tools. To enable
the vision of a full automation technology and after the appearance of various digital processors, a rapid increase
in process control computers and minicomputers took place, especially in small plants, which changed radically
the situation in the field of industrial process control and automation.

Types
 Industrial Personal Computers (I-PCs)
 Programmable Logic Controllers (PLCs)
 Embedded PLCs
 Programmable Automation Controllers (PACs)
 Distributed Control Systems (DCS)
 Supervisory Control and Data Acquisition (SCADA)

PCs, PLCs, and I-PCs

 Characteristics of each
 Crossing the gap between PCs and PLCs

Prof. Ashraf Zaher 14

 Industrial Control Systems
In parallel with the developments in computational power in the control and automation devices,
their ability to communicate, interact, and exchange information has also been developed in recent
decades, thus leading to the introduction of industrial networks. This topic will be covered later.

Hierarchical Levels in ICS

 Device Level
 Control Level
 Information Level

Commonly used Industrial Networks

 Serial Communication (RS485)
 HART
 DeviceNet
 ControlNet
 Modbus
 Profibus/Profinet
 Foundation Field Bus
Prof. Ashraf Zaher 15
 Distributed Control Systems
Definition
A distributed control system
(DCS) is a specially designed
automated control system that
consists of geographically
distributed control elements
over the plant or control area.

It differs from the centralized

control system wherein a single
controller at central location
handles the control function,
but in DCS each process
element or machine or group of
machines is controlled by a
dedicated controller. DCS local
controllers are connected via a
high-speed communication
network.
Prof. Ashraf Zaher 16
 Distributed Control Systems (DCS)

Decentralized Centralized
Prof. Ashraf Zaher 17
 Distributed Control Systems (DCS)
 Enterprise Resource Planning (ERP)
 Manufacturing Execution System (MES) Necessary Extra Information
 Historically, when PLCs were invented, they were really
good at handling single processes and were primarily
used for repetitive, discrete control.
 The advent of the DCS was for controlling many
autonomous controllers that handled many continuous
operations, mainly using analog control.
 The DCS has a number of predefined functions that come
ready to customize and deploy for various applications.
 Processing times are somewhat slower. Operators interact
with the control system via integrated graphical displays.

Automation Pyramid
Prof. Ashraf Zaher 18
 Basic Components of a DCS

 A typical plant starts with a centralized operator control center typically called
Operator Stations.
 Operator Stations, in a DCS, are the heart of the system.
 This is where the operator can observe the operations of the plant, view process
warnings and alarms, monitor production, and more.

Prof. Ashraf Zaher 19

 Basic Components of a DCS

 The next level of components may contain servers for the collection of data,
archiving computers, and engineering stations that include hardware
configurations, logic of tasks, and HMIs.
 Communications with the Operator Station level is typically Industrial Ethernet.
Prof. Ashraf Zaher 20
 Basic Components of a DCS

 Next level is the master controllers that are responsible for providing the data to
the servers, which in turn, supply the data for the graphical interface.
 The processor executes the logic and control the processes. Communications is
done using either Industrial Ethernet or fiber optics, depending on the distance.
Prof. Ashraf Zaher 21
 Basic Components of a DCS

Field Devices

 Components at this level would be devices such as transmitters, switches, valves,

motors, remote or distributed I/O, etc.
Prof. Ashraf Zaher 22
 SCADA Systems

Prof. Ashraf Zaher 23

 SCADA Systems
In general, by allowing the connection of digital industrial controllers, the industrial network offers
mainly the possibility of sensing messages and control commands through a decentralized approach,
which can be geographically spanned. Thus, today the controller of a specific production process
could sample the information from another part of the factory automation or control the operation of
a machine in a remote part of the industrial field. Since this concept can be fully generalized on the
full automation floor, the ability to control the whole industrial process and to have a complete
overview of the ongoing sub-processes has been made more achievable than ever before, and thus
the concept of supervisory control and data acquisition (SCADA) has been introduced. Furthermore,
today’s industrial networks can interconnect industrial controllers from different producers,
converging in a similar way as the well-known “open communications” demand.

The SCADA concept has been introduced from the real need to gather data and super vision like
control subsystems on a large industrial process plant in real time. SCADA today represents a
combined hardware and software system, including the remote field devices, the network, the
central station equipment and the software platform. This software platform, in the case of SCADA,
offers the user all the functionality required to receive or send data, represent data graphically,
manage alarm signals, perform statistic calculations, communicate with other databases or software
applications, schedule control actions, print various reports, and many other user facilities.

Prof. Ashraf Zaher 24

 SCADA Systems
Objectives of SCADA
1. Monitor: SCADA systems continuously
monitor the physical parameters
2. Measure: It measures the parameter for
processing
3. Data Acquisition: It acquires data from
RTUs (Remote Terminal Units), data
loggers, etc.
4. Data Communication: It helps to
communicate and transmit a large amount
of data between MTU and RTU units
5. Controlling: Online real-time monitoring
and controlling of the process
6. Automation: It helps for automatic
transmission and functionality

Prof. Ashraf Zaher 25

 SCADA Systems (A Project Idea)
Decide on
Sensors and
Actuators

Establish
Wireless
Communication

Perform
Monitoring and
Alarming

Add Supervisor
Functions

Prof. Ashraf Zaher 26

 DCS vs. SCADA
1. DCS is process oriented, whereas SCADA is data-gathering oriented. DCS emphasizes more on control of the
process, and it also consists of supervisory control level. And as a part of doing so, it presents the information to the
operator. On the other hand, SCADA concentrates more on acquisition process data and presenting it to the
operators and control center.
2. In DCS, data acquisition and control modules or controllers are usually located within a more confined area and
the communication between various distributed control units carried via a local area network. SCADA generally
covers larger geographical areas that use different communication systems which are generally less reliable than a
local area network.
3. DCS employs a closed loop control at process control station and at remote terminal units. But in case of SCADA
there is no such closed loop control.
4. DCS is process state driven where it scans the process in regular basis and displays the results to the operator, even
on demand. On the other hand, SCADA is event driven where it does not scan the process sequentially, but it waits
for an event that cause process parameter to trigger certain actions. Hence, DCS does not keep a database of
process parameter values as it always in connection with its data source, whereas SCADA maintains a database to
log the parameter values which can be further retrieved for operator display and this makes the SCADA to present
the last recorded values if the base station unable to get the new values from a remote location.
5. In terms of applications, DCS is used for installations within a confined area, like a single plant or factory and for
a complex control processes. Some of the application areas of DCS include chemical plants, power generating
stations, pharmaceutical manufacturing, oil and gas industries, etc. On the other hand, SCADA is used for much
larger geographical locations such as water management systems, power transmission and distribution control,
transport applications and small manufacturing and process industries.
Prof. Ashraf Zaher 27
 Computer Integrated Manufacturing (CIM)
Based on the technology of industrial networks and the
powerful computational automation units, the optimal
implementation of the concept of computer integrated
manufacturing (CIM), which was initially introduced in
the 1970s, has been achieved.

With respect to the CIM model, an industrial

process can be organized in a three-layer
hierarchical structure:
1. The lowest layer is comprised of
sensors, actuators, and embedded
micro-controllers.
2. The middle layer is the control layer
where the industrial controllers,
industrial PCs, and industrial PACs
are connected.
3. The highest layer is the management
level, where the mainframe
computers for SCADA and resources
planning functionalities are located.
Prof. Ashraf Zaher 28
 Programmable Logic Controllers (PLCs)
Definition
A PLC is a computer specially designed to operate reliably under harsh industrial environments,
such as extreme temperatures, wet, dry, and/or dusty conditions. PLCs are used to automate
industrial processes such as a manufacturing plant’s assembly line, an ore processing plant, or a
wastewater treatment plant.
 A PLC continuously monitors the state
of input devices and makes decisions
upon custom program to control the
states of output devices.
 PLCs emerged in the late 1960s in the
automotive industry in the US. Its main
motivation was to replace the existing
relay hard-wired circuits.
 The evolved rapidly due to the advances
in programing and technology.
 PLCs could be interfaced to a wide range
of sensors and actuators.
 Most famous brands are Siemens, ABB,
Alan Bradley, Omron, and Mitsubishi.
Prof. Ashraf Zaher 29
 Exercise

Compare
Prof. Ashraf Zaher 30
 Review Questions
1. Define the term “industrial system” from the automation point of view. Give important considerations
concerning either the industrial equipment or its characteristics.
2. What is the “dominant variable” of an industrial production procedure? Give some examples of the
dominant variable in concrete industrial applications.
3. In your opinion, what is an automation system? Indicate the difference between an automation system
and an automatic control system.
4. What is the purpose of using sensors in an industrial system? Explain the difference between the
information derived by sensors and that provided by indication devices.
5. What is the role of handling devices in an industrial system when this system has been automated?
6. The control terms utilized in the operation of an automated industrial system may include the following:
a. Sequential control
b. ON-OFF control
c. Logic control
d. Digital control
Indicate which of these terms primarily refer to control based on Boolean theory.
1. Explain the differences between an automation circuit and a wiring diagram. Which of them expresses
better the “logic” of system operation?
2. In your opinion, does the automation of an industrial production process increase or decrease
unemployment? Explain substantially.
Prof. Ashraf Zaher 31
 Summary
By the end of this introduction, students are now familiar with:
 The structure of industrial control systems (ICS),
 Different components and accessories connected to a typical ICS,
 Centralized vs. decentralized control systems,
 The concept of sequential control,
 Automation requirements,
 Different types of ICS, including I-PCS, PLCs, DCS and SCADA,
 Computer Integrated Manufacturing (CIM), and
 PLCs, as replacements to hard-wired relay logic.

What is next?
 Hardware components for automation and process control,
 Industrial automation synthesis,
 Logical design of automation circuits,
 Basic operating and programming principles of PLCs
 Introducing Siemens S7-1200 series and TIA-Portal software package, and
 Applications (analytical, numerical, and practical) – Know How and Do How!
Prof. Ashraf Zaher 32