The Beginning of SCADA

Before the emergence of SCADA systems in the mid 20th century, the factory staff manually controlled industrial units, plant floor operations, and remotely located sites. The equipment used to be monitored and controlled via push buttons and analog dials. Later, as complexities widened and remote sites began to expand, there was a need for supervisory systems to control and monitor equipment and machinery in remote locations. Moreover, it was problematic to reconfigure and detect faults. And hence, a need for a more efficient and automated control and monitoring system arose.

Later, in the 1950s, as the technological revolution began with the evolution of computers, many industries capitalized on it for enhancing industrial processes, and supervisory control became widespread. A decade later, in the 1960s, with the development of telemetry, a revolutionary transformation occurred in the way machines were monitored. Telemetry monitoring allowed for data transmission from remote locations through automated communications. The term SCADA or Supervisory Control and Data Acquisition originated in 1970. The concept of SCADA systems was fueled by the subsequent emergence of PLC technology during that decade, augmenting the capability of industries to monitor and control automated processes with greater efficiency.

Technological growth and networking protocols have skyrocketed down the lane to the present scenario. Today SCADA systems have become the standard for industries to gather real-time data from the plant floor and transfer it to the enterprise level, empowering businesses to make data-driven decisions.

What are SCADA Systems?

Supervisory Control and Data Acquisition (SCADA) is a system comprising software and hardware elements allowing facilities to control, monitor, collect real-time processing data, log events, and provide alerts from the equipment located remotely or on-premises. Devices such as sensors, valves, pumps, motors etc., are connected to PLCs/ RTUs, which continuously provide data to SCADA systems through a human-machine interface software. Later the SCADA system distributes and displays the information gathered to factory personnel. This enables operators and plant engineers to better manage and control the factory operations, quickly detect errors in real-time through alerts provided by the system, ultimately mitigating downtime and enhancing the production quality.

From water treatment, waste management, mining and metal to onshore and offshore gas & oil industries, SCADA systems are used in various industry verticals for industry-specific applications. The modern industrial units are expanded in large geographical locations. Developing a single command and monitoring center for overall equipment and process management has become possible with automated processing and SCADA systems. SCADA systems provide assistance in safety, maintenance, assembly line control, production monitoring to any industrial application.

Main Components of SCADA System

SCADA includes hardware and software elements that form the centralized control and monitoring system for all the information gathering and processing functions to work in synchronization. The following are some of the main components mentioned below in the line of operation to help understand the working mechanism of the SACAD system.

1. Field Devices: A SCADA architecture includes several devices like sensors, transmitters, switches, pumps, actuators, valves, etc., that interact with the equipment/machinery in remote locations. These field devices transmit the input received to RTUs or PLCs, from where the information is forwarded for further processing.
2. RTU or Remote Terminal Units: RTUs are microprocessors-based electronic devices that can be linked to field devices and automation systems like SCADA. RTUs collect the telemetry data and transmit it to SCADA servers for control and monitoring implementation from remote sites. They are easily configurable through programming languages like Basic, C++, etc., and can withstand harsh industrial environments.
3. PLC or Programmable Logic Controllers: PLCs, or Programmable Logic Controllers, are solid-state devices using microprocessors that gather input from field devices and trigger output based on pre-programmed parameters. Like RTUs, PLCs connect with field devices to control them; however, PLCs differ in programming flexibility, affordability, configuration and are better suited to modern automation systems.
4. Supervisory Computers/Servers: The supervisory system comprising computers, servers, and software is at SCADA architecture’s core. They are responsible for communicating with the field devices, gathering incoming sensor information, and sending control commands to the connected equipment. The servers interact with PLCs/RTUs to collect information about every procedure on the operation floor and present an integrated view of the industrial processes.
5. Human-machine Interface (HMI): An HMI is a software-based control system architecture that allows operators to monitor and manage equipment performance from a single centralized location using networked data. Its primary role is to display the status of the industrial processes using graphical interfaces. HMI processes all the data and showcases it into interactive interfaces for monitoring, analyzing, and visualizing the entire control process. HMIs continuously aggregate data for facilitating it for future use, allowing operators to visualize historical trends from the database and accordingly manage the operations.
6. Communication Infrastructure: For a seamless flow of information across the SCADA network and connected components, there’s a need for communication networks to manage the overall processing. Depending on the geographical area and operational requirements, a suitable communication framework can be developed. A variety of communication channels can be used, like radio links, modems, fiber optics, leased lines, routers, network topologies (bus, star, ring, etc.), ethernet, satellites, etc.
7. SCADA Software: A wide range of varieties of SCADA software is available in the market. Some popular SACDA software available are Rockwell Automation – FactoryTalk View Site Edition and Thin Manager, Siemens – WinCC RT Professional, Schneider Electric- Wonderware, etc. Each software has its own set of utilities and compatibility with different industrial applications. Efficiency, scalability, the flexibility of programming, easy management functionality, properly designed screens, etc., are some of the factors to be considered when selecting SCADA software.

Functions of SCADA Systems

Many facilities utilize SCADA systems for simplified management. SCADA systems are designed to gather field data and transmit it to the operator’s workstation. It empowers them to access actionable insights and control hundreds of assets without manually inspecting each field device. The fundamental function of SCADA systems is to acquire sensor data and make it available to operators in comprehensible measurements like temperature, vibration, capacity levels, power usage, etc. This allows operators to feed instructions based on input, like turning machines on/off, increasing or decreasing speed, etc. SCADA systems also trigger alarms in case of any abnormalities found in the functioning of any operation or connected device based on pre-programs fed into it. Apart from providing notifications, SCADA systems can be programmed to handle entire operations by providing commands based on inputs without operators’ involvement. And if any issue requires human intervention, the system automatically sends SMS, emails or notifies the operator.

Advantages of Deploying SCADA System

SCADA systems significantly ease industrial control and monitoring processes by supporting supervisory tasks and simplifying processes. From maximizing overall efficiency, reducing overhead costs, decreasing lead times, enhancing factory management, and analyzing and efficiently monitoring overall industrial processes, SCADA systems have proved immensely advantageous for industries. Below are some of the main advantages of deploying SCADA systems.

1. Prevents Downtime: Unplanned outages can cost businesses hefty amounts, leading to unsatisfied customers. Uptime Institute surveyed facility executives and the results reveal that outages have become way more expensive. Over 60% of the respondents reported losing more than $100,000 to downtime. Of that 60%, 15% lost over $1 million. By deploying SCADA automation solutions, operators can identify any discrepancies and inefficiencies in the system before they occur and cause downtime. Moreover, with the help of historical databases stored in the SCADA system, operators can conduct trend analysis and identify any potential issues in the operations.
2. Increased Efficiencies: A SCADA system allows real-time monitoring with real-time data gathering, which operators can utilize for optimization of processes by identifying areas of improvement. Another valuable advantage of SCADA is that it supports predicitive maintenance, meaning the system anticipates whenever maintenance of equipment is required. This enhances equipment’s life expectancy, increases uptime, and avoids any chances of mishandling of equipment. Moreover, with real-time control, operators can also check the quality of the end products, with no compromise on customer experience.
3. Ease of Reporting: Industrial units have scaled up significantly, comprising hundreds of assets, and therefore manually collecting data and drafting a report for performance/health checks can be a herculean task. SCADA systems can store large amounts of data and provide flexibility in creating customized and detailed reports in a single user-friendly format, saving time and simplifying reporting procedures. Moreover, these reports enable better decision-making and empower stakeholders to find new opportunities for expanding their business.

Modern SCADA Systems Powered by IIoT

The advent of the Industrial Internet of Things empowers industrial control and monitoring systems with more flexibility, virtualization, and decentralized control architectures. IIoT has fueled the use of cloud-based SCADA systems, allowing for enhanced visibility and managing a large amount of data virtually. Moreover, SCADA systems are becoming highly intelligent with the application of IIoT technology like Machine Learning, Data Analytics, and paving the way for more sophisticated, automated, optimized functioning. Nevertheless, IIoT cannot completely replace SCADA systems, but these two technologies together will develop hybrid control architecture for upscaling industrial control systems.

Selecting the Right SCADA Solution for your Facility

Industrial processes are complex, demanding the highest level of precise control and coordination among all the components. It’s important to deploy the SCADA system that matches your factory requirements, best suited to your industrial applications, and aggregates required data to enable key stakeholders to make intelligent decisions.

With an experience of more than two decades, ENWPS has been providing automation solutions to varied industries, from process to discrete manufacturing. Our professionals can help you develop all types of SCADA and HMI systems, including scripting in C, VB, SQL database system, both regular and Web Reporting Systems. We ensure quality services extending to SCADA programming, device integration, testing and simulation, and working with SCADA and HMI software like Factory Talk View, Ignition SCADA, Wonderware, WinCC, etc. To get a detailed view of our services, Click here. And if you need direct assistance, feel free to leave your requirements at rfq@enwps.com and we will connect with you shortly!

Since its inception in the 20th century, PLC systems have evolved radically to become the keystone of modern automation control systems. Programmable Logic Controllers are used to communicate, monitor, and control various automated processes in manufacturing units, marine connoisseurs, the oil and gas industry, or any automated environments. PLCs play a quintessential role in automated factories by helping establish a physical interface between industrial devices or machinery, Human-Machine Interfaces (HMIs), and Supervisory Control and Data Acquisition (SCADA) systems. With the help of sensors and actuators, PLCs continuously gather real-time inputs from plant-floor operations, implement user-created program logic to provide instructions or output data to run applications. As industrial applications become more complex and sophisticated, various changes in design, hardware, and software upgrades are being made in PLCs to support modern factory operations. Enhanced programming flexibility, scalability, agility to meet industrial control needs, higher processing speeds, compatibility with IoT networks, built-in wireless connectivity, etc., are the driving factors for greater use of PLCs in factory automation. The reliability of PLCs will continue in the near future as various automation advancements will require PLCs for managing industrial control systems.

PLCs will Become Smaller, Faster, and More Powerful

PLCs will continue to become smaller, emanating from the trend that the components become smaller in size as technology evolves. However, with shrinking sizes, PLCs have already become more powerful with increased processing speed and higher memory storage space. PLCs leverage USB technology, allowing more flexibility for online programming and monitoring control systems. With the availability of micro and mini USB connectors, the communication features will be available for smaller and compact PLCs. This will improve cycle times, faster troubleshooting, and enhance performance.

Unification of PLCs and PACs

Compared to PLCs, PACs or Programmable Automation Controllers can manage more complex automation applications and extensive process control requirements. The merging of PLC technology with PAC technology will broaden the capabilities of PLC for improved performance and additional features. This merger will result in the advanced communication potential of PLCs with hardware and software as both the technologies will continue to evolve with time. As PLCs become more memory efficient with higher-speed processors, the merger will result in additional features like vision systems, motion controllers, and extending support for multiple communication protocols while maintaining the ease of PLC usability. In the future, there will be more advancements in both technologies, working collaboratively to meet the demands of complex process control of applications. At the same time, improving processing speed, memory space, and maintaining lower production costs will remain a challenge for suppliers.

PLCs and Wireless Communication Technology

The future will involve increasing the number of new wireless communication technologies. Some examples of these include Wi-Fi and Zigbee. Additionally, mesh technology is predicted to be a rising trend in the future, along with near-field communication (NFC). The adoption of many newer, more effective wireless technologies will expand from remote terminal units (RTU) to other more critical applications where real-time control is mandatory. Further, with the advent of 5G networks, the PLC function will be accessed easily from anywhere in the plant without opening electrical cabinets.

PLCs and Connected Factory

Process Data is one of the essential requirements of the connected factories. It empowers operators, engineers, and the management to make data-driven decisions based on factory floor conditions. Many manufacturers have persistently faced the challenge of feeding process data upstream for integration with enterprise resource planning (ERP) and other computing systems. However, PLCs have included many features, hooks, and functions to simplify this integration. In the future, availability for upstream data integration will become more common, and suppliers will have to use various integration technologies to cater to the industry-specific requirements. Future PLCs will have the ability to control applications and provide required data, manipulate that data for effective use, and allow interacting with the data easily like through mobile applications, etc. Many manufacturers are leveraging the power of PLCs for connected factories; however, soon, it will become more readily available and highly used.  

The Role of PLCs in IIoT Implementation and Modern Technologies

IIoT applications, industrial machine learning, cloud computing, robotics automation, artificial intelligence, big data and analytics, sophisticated devices, smart sensors, etc., are changing the manufacturing landscape. Programmable Logic Controllers have become an inevitable part of the successful implementation and working of these breakthrough technologies as they play a vital role in processing real-time manufacturing data and control applications. The connected sensors and other integrated devices working alongside PLCs help collect data and provide it to the machine’s learning procedure. Later, plant managers can analyze and use this data to improve manufacturing procedures, schedule production, shorten cycle times, prevent downtime, implement predictive maintenance, enhance the quality of production, etc., to maintain optimal performance. In the long term, as the adaptability of modern technologies becomes widespread, the functionality and use of PLCs will also intensify.

More Advancements for the Future PLCs

Future PLCs will be primarily used for software-based solutions rather than as a piece of robust hardware capable of controlling applications in harsh industrial environments. Virtualized PLCs will become more common performing software functions that can run on the cloud, on-premises, or a server. Another major transformation in the usability of PLCs will be their capability to help gather edge-of-network data working alongside edge computing technology. This technology is intended to overcome the challenge of data-gathering in challenging industrial environments or with restricted infrastructure expansion possibilities like in oil and gas industries, etc. The edge computing technology aims to increase reliability by moving PLC polling close to the source and reducing latency, maintaining unrestricted data flow. Talking about programming tools for PLCs, it will remain the same so that plant floor staff can quickly identify any loopholes in logic functions. The associated digital services with PLC installation, commissioning, and supply will demand technical agility from the suppliers while opening aftersales revenue streams.

Conclusion

Regardless to say, PLCs are here to stay; it is maturing well to adapt to the changing landscape of manufacturing technology. The purpose and role of PLCs will be industry-specific, and more relevant transformations will be made. Revolutionary changes in its hardware technology, integration compatibility, compactness, and other advancements will be continuously made and adapted as part of industry requirements.

About ENWPS

With over two decades of experience in various industry verticals, ENWPS has successfully provided bespoke and turnkey solutions for control system integration. We deal in supply, installation, and integration of control systems, PLC/MCC/PDP panels, and HMI stations; ENWPS has a skilled Electrical and Automation team experienced in meeting global standards. Our service areas also include PLC, HMI, and SCADA programming, robot integration and programming, automation solutions, data analytics, and IoT services for industrial units. Email us your requirements at rfq@enwps.com, and we shall be happy to assist you!

Introduction: Evolution of PLC Based Automation

The concept of industrial automation came into being in the early 20th century, long before the invention of Programmable Logic Control Systems. In the early 20th century, factories were usually controlled using electromechanical relays, wherein a switch connected to a device could be turned on or off based on input from an operator. This system was inflexible because it required thousands of relays for simple processes, and if one relay was affected by an error, it could cause that corresponding device to go out of service. Later in 1968, the relay-based system was replaced by PLC, or Programmable Logic Controllers. They were introduced to help industrial plants simplify some of their relay circuitry, which had been difficult to program in the past. The first model was designed with a clear digital display that made programming easy for engineers and technicians already familiar with relay logic and control schematics. The first PLCs were built with limited speed capabilities and storage space. However, modern PLCs have evolved to be extremely powerful with accelerated processing capacity, real-time monitoring, and other features. This blog focuses on PLC automation in today’s industrial world along with advantages, use cases, and the future of PLCs. Continue reading!

What is a PLC and Why is it so Important?

A Programmable logic controller (PLC) is an industrial computer used to perform control functions in manufacturing units. This miniature computer contains hardware and software which enables automated control of electromechanical processes. It includes machinery automation on factory assembly lines like the automotive industry, food processing, etc. PLC continuously monitors inter-connected input devices like sensing devices, switches/pushbuttons and makes decisions based upon pre-feed programs to control the state of output devices/machines like valves, pumps, control relays, etc. Further, the compatibility of PLC to withstand harsh industrial environments like extended temperature ranges, electrical interference, dirt, vibration, and other factory conditions make PLC a trustworthy choice among manufacturers.

The increasing usability of PLC in manufacturing industries, machinery automation, handling systems, marine, and various other sectors is rising at a higher pace due to its prominent features like reliable controlling efficiency, sequential control, user-friendly hardware system, ease of programming etc. These unique features of PLC have gained pivotal importance and are ideally suited to the needs of modern automation.

Overview: PLC Based automation

The global Programmable Logic Controller (PLC) market was valued at USD 11.21 billion in 2020 and is expected to reach USD 15.15 billion by 2026, at a CAGR of 4.7% over the forecast period (2021 – 2026). PLC is the foundational stone for rapidly growing industrial automation trends as it is vital for industrial control systems. Increased adoption of automation systems is driving the market share of PLC. With AI and IIoT proliferating across every industry, robots have become integral in achieving efficiency in almost every sector. PLC deployment is expected to benefit significantly from the continuous installation of new automated machines worldwide since robots use PLCs for their control system technologies.

Another driving factor of PLC-based automation is its ability to remove human errors during decision-making processes in manufacturing. PLC technology positively impacts the cost of control applications by eliminating the need for hard-wired relays and increasing operational efficiencies. Market studies have observed that the PLC automation system reduces downtime by almost 20% to 4%, driving unparalleled productivity and substantial growth for businesses. There is also a need for real-time process control and speedy application with improved production efficiency, which is made possible through modern automated PLC systems. The processing/scan time of a PLC is around one thousand times per second or 0.001 seconds. PLC Automation is imperative for industrial automation with a broad range of features and ease of use and integration in the industrial setup.

Advantages of Using PLC

PLCs offer a wide array of benefits and are the most reliable choice among manufacturers for managing industrial control systems. Below are some of those advantages.

• Ease of Use/Programming: Today, PLCs are becoming more powerful and versatile with increased computing flexibility, built-in wireless capabilities, and greater capacity for delivery. The latest evolution in PLCs directly benefits from USB technology, which makes it extremely easy to program, operate online, and monitor control systems. Moreover, PLCs use simple programming methods like Ladder Logic, Boolean Type, etc. Further, various feature modules can be added to increase the performance of the PLC system or as per the requirement.
• Flexibility with Advanced PLC Technology: PLC software offers a straightforward framework to feed instructions or change instructions as per requirements compared to a relay-based system. Rewiring a whole relay circuit to create a new one is a daunting task, while in the case of PLCs, the logic changes are made inside the controller rather than hardware or wiring changes. The input/output ports can be connected to input and output components to create logic and write a program according to the need of the application. Later the program is downloaded onto PLC software.
• Enhanced Reliability: Once a program is written and tested, it can be downloaded to multiple PLCs to secure the connection in other places with similar needs. The program is stored inside the PLC’s memory, so there is no chance for an error to occur, like in the case of rewiring relays from scratch. It takes a lot of pressure off when it comes down to controlling the overall functionality of the plant with hundreds of machinery/equipment.
• Multiple Points of Contact: PLCs contain a wide range of contact points for each coil available for programming for different applications.
• Effortless Troubleshooting: PLCs have built-in diagnostics and can easily override any software or hardware issues. To find and fix problems, users can view the display of control systems on a monitor and check its execution in real-time. PLC control systems contain many troubleshooting features that immediately inform operators/engineers what’s causing an issue. Fault indicators are displayed, and messages notify the operator of the problem. PLCs are designed to provide easier access, allowing engineers to connect with the components easily.
• Lower Power Consumption: On average, a PLC system approximately consumes only 1/10^th of the power compared to the relay-based control system.
• Simulation Feature: PLC programming software entails simulation features to help programmers test the logic development early and check the integration with other devices. With the PLC simulation feature, installation and commissioning can be expedited and a considerable chunk of costs can be saved as errors in development and programming can be detected and rectified at the early stage. Any discrepancies at the execution stage can affect the entire functionality of the factory operation and can cause unnecessary downtime.
• Communication Capacity: PLCs comprise communication capabilities to easily connect with other equipment to conduct various functions such as data gathering, monitoring process parameters, supervisory control, download, and upload programs etc.

PLC: Use Cases

The usability of PLC automation systems is dependent on the nature and requirements of the industry. Various sectors use PLC systems to standardize the processes, control operations, and other functions. PLCs have use cases in verticals like- paper manufacturing, aerospace, cement manufacturing, textiles, HVAC, etc. Likewise, in the Glass industry, PLCs combined with Bus technology are used for data recording, maintaining quality control, and positioning control during glass production. Similarly, Oil and Gas industry PLCs on well pads allow technicians to analyze the condition of well pads in different locations based on input and output devices. Later, engineers are sent out to specified well pads that require repairs, maintenance, inspection, etc., without sorting the well pads data manually.

The Future of PLC Automation

Programmable Logic Controllers will continue to evolve according to the needs of industrial automation applications. With advancements in technology, PLCs are becoming faster with wireless capabilities and high-speed ethernet, gaining enhanced programming flexibility, scalability, memory space, etc. The future PLCs are likely to get more hardware improvements and upgrades resulting in expanded functionality, continuing to fasten computing capabilities, integration with enterprise resource planning (ERP), and other higher-level computing systems to the factory floor. Data collection from processes and machines has become easier with sorting abilities. The modern PLCs will be manufactured with varied materials like fiber signals for increased durability compared to electronic signals. Combined with IIoT technology, many enhancements in PLC technology have occurred, like compatibility with smart factory environments, remote monitoring, high processing speed with solid-state drives, etc. However, PLCs will also continue to be more optimized and sophisticated as IIoT advancements unfold.

Get PLCs for your facility!

Selecting the best fit for your industrial automation needs and adaptability with plant operations is inevitable. Cost, processing speed, communication capabilities, integration with other devices, etc., are some considerations that manufacturers track while making a buying decision for PLCs. However, PLCs come with a wide range of functionality, upgrading capabilities, and other features.

Our engineers at ENWPS can help you with complete PLC supply, installation, commissioning, and programming solutions. Our professionals have qualified knowledge and experience with selection, networking, interfacing, logic development, programming, execution & proving, training & documentation, and other related services. AT ENWPS, our engineers have hands-on experience with different PLC systems like Allen-Bradley, Siemens, Schneider Electric, among others. Leave your requirements at rfq@enwps.com, and over team shall be happy to connect with you!

Significance of IIoT Adoption

Adopting IIoT can benefit a manufacturing business owner in innumerable ways driven by a widespread increase in digital transformation and ever-increasing competition in today’s technology-driven world. Through the complete digitalization of the manufacturing process, one can improve operations, limit potential losses, gain visibility into shop floor operations, effectively manage supply chains and empower innovation.

Related Blog: Powerful Advantages of Industrial Internet of Things (IIoT) with Industrial Applications

Why ENWPS Is a Reliable Choice?

With over two decades of experience providing automation solutions to businesses globally, our engineers have developed a vivid understanding of the company’s challenges during the transition. Our team has worked as an Implementation partner for various projects and provided bespoke solutions per industry-specific needs. Our services range from design & engineering, programming services, supply, installation & commissioning, and IIoT related jobs.

Are you looking for a trustworthy Implementation partner? Your search ends here! Email your requirements to us at: rfq@enwps.com.