FUNDAMENTALS

OF INDUSTRIAL
CONTROL
PREPARED BY :
ALVERO, MARIA CARLOTTA

DE TORRES, JIEZELL

JAVIER, MARIA LORALIE

JASTILLANA, LJ

MARASIGAN, ALLYCIA

RATIO, CHRISMAINE

TOLENTINO, MARIA TRISHA

INTRODUCTION OF
INDUSTRIAL CONTROL
SYSTEM
HISTORY

Often the controllers were behind the control room panels, and all automatic and manual
control outputs were individually transmitted back to plant in the form of pneumatic or
electrical signals. Whilst providing a central control focus, this arrangement was
inflexible as each control loop had its own controller hardware so system changes
required reconfiguration of signals by re-piping or re-wiring. The introduction of distributed
control allowed flexible interconnection and re-configuration of plant controls such as
cascaded loops and interlocks, and interfacing with other production computer systems.
For large control systems, the general commercial name distributed control system was
coined to refer to proprietary modular systems from many manufacturers which integrated
high speed networking and a full suite of displays and control racks. The old controls were
difficult to re-configure and fault-find, and PLC control enabled networking of signals to a
central control area with electronic displays. A SCADA system uses RTUs to send
supervisory data back to a control center. Many PLC platforms can now perform quite well
as a small DCS, using remote I/O and are sufficiently reliable that some SCADA systems
actually manage closed loop control over long distances.
DEFINITION

Industrial control system (ICS) is a general term that encompasses several types of
control systems and associated instrumentation which include:
• Devices
• Systems
• Networks
• Controls

• To operate and/or automate industrial processes.

• Such systems are extensively used in industries such as chemical processing, pulp and paper
manufacture, power generation, oil and gas processing and telecommunications.
• 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.
• Local operations are often controlled by so-called Field Devices that receive supervisory
commands from remote stations.
There are several types of ICSs
• Supervisory Control and Data Acquisition Systems (SCADA): a control system architecture that
uses computers, networked data communications and graphical user interfaces for high-level process
supervisory management
• Distributed Control Systems (DCS): a computerised control system for a process or plant usually with
a large number of control loops, in which autonomous controllers are distributed throughout the
system
• Programmable logic controllers (PLCs): an industrial digital computer which has been ruggedized
and adapted for the control of manufacturing processes

• Though SCADA and PLC systems are scalable down to small systems with few control loops.
INDUSTRIAL CONTROL
CLASSIFICATION

DE TORRES, JIEZEL U.
INDUSTRIAL CONTROL CLASSIFICATION

1. Motion Control – Automatic control system that controls

the physical motion or position of an object. It is a sub-
field of automation, encompassing the systems or sub-
systems involved in moving parts of machines in a
controlled manner.
 INDUSTRIAL CONTROL CLASSIFICATION

- Four basic parts

 Control – It is consider as the brains of the motion control system.
 Drive - The servo drive bridges the gap between the controller and
the motor
 Motor - The servo motor in a motion control system takes electrical
signals from the drive and converts them into motion
 Load - The load is the thing that is actually being moved by the
motor
INDUSTRIAL CONTROL CLASSIFICATION

2. Process Control – play an important role in how a plant

process upset can be controlled and subsequent emergency
actions executed. One or more variables are regulated during the
manufacturing of a product
- Two Categories
 Batch Processing
 Continuous Process
TWO CATEGORIES

 Batch Processing - Batch processing is a general term used for

frequently used programs that are executed with minimum human
interaction. Batch process jobs can run without any end-user
interaction or can be scheduled to start up on their own as resources
permit.
TWO CATEGORIES

 Continuous Process – as suggested by the name, the flow of

material or products is continuous. Processing the materials in
different equipment produces the products.
TYPE OF CONTINUOUS CONTROL
SYSTEM

1. Open Loop System - An open-loop control system takes

input under the consideration and doesn’t react on the
feedback to obtain the output.

Input Process Output

Block diagram of an open loop control system

2. Closed Loop System – A closed loop system is also
referred as a feedback control system. This system
record the output instead of input and modify it
according to the need.

Block diagram of an open loop control system

TYPES OF INDUSTRIAL
CONTROL

Jastillana, LJ
DISTRIBUTED CONTROL SYSTEMS

• a digital processor control system for a process or plant, wherein

controller functions and field connection modules are distributed
throughout the system.
• as the number of control loops grows, DCS becomes more cost
effective than discrete controllers.
• provides supervisory viewing and management over large industrial
processes.
• A DCS enables easy configuration of plant controls such as
cascaded loops and interlocks and easy interfacing with other
computer systems such as production control.
• A DCS typically uses custom-designed processors as
controllers, and uses either proprietary interconnections or
standard protocols for communication. Input and output
modules form the peripheral components of the system.
Distributed control systems (DCS) are
dedicated systems used in manufacturing
processes that are continuous or batch-
oriented
 Processes where a DCS might be used include:
 Chemical Plants Petrochemical (oil) and refineries
 Pulp and Paper Mills
 Boiler controls and power plant systems
 Nuclear power plants
 Environmental control systems
 Water management systems
 Water treatment plants
 Sewage treatment plants
 Food and food processing
 Agro chemical and fertilizer
 Metal and mines
 Automobile manufacturing
 Metallurgical process plants
 Pharmaceutical manufacturing
 Sugar refining plants
 Agriculture Applications
 SCADA SYSTEM
(Supervisory Control and Data Acquisition)

JAVIER, MARIA LORALIE

HISTORY

• In 1950’s, computers were first developed and used for industrial control
purposes.
• In 1960 telemetry was established for monitoring, which allowed for
automated communications to transmit measurements and other data from
remotes sites to monitoring equipment.
• SCADA is rooted in distribution application, such as power, natural gas,
and water pipelines, where there is a need to gather remote data through
potentially unreliable or intermittent low-bandwidth and high-latency links.
SCADA

• A system of software and hardware elements that allows industrial

organizations to:
Control industrial processes locally or at remote location
Monitor, gather, and process real time data.
Directly interact with devices such as sensors, valves, pumps, motors
and more through HMI software
Record events into log file
SCADA

Supervisory Control and Data Acquisition

 SUPERVISORY
 Operator/s, engineer/s, supervisor/s, etc.
 CONTROL
 Monitoring
 Telemetry
 DATA ACQUISITION
 Access and acquire information or data from the equipment
 Sends it to different sites through telemetry
 Analog/digital
SCADA
ADVANTAGES
Saves Time and Money
 Less travelling for workers
 Reduces man-power needs
 Increase production efficiency of a company
Reliable
Supervisory control over particular system

DISADVANTAGES
Cyber warfare /cyber terrorism
WHERE IS SCADA USED?
Main SCADA application :
 Water and waste water
 Power
 Oil and gas
 Research facilities
 Transportation
 Security system
 Siren system
 Irrigation
 Communication control
SCADA EXAMPLES?

GAS CONTROL SYSTEMS

WHAT IS INDUSTRIAL CONTROL?

WATER CONTROL SYSTEMS

POWER SYSTEMS
 COMMON THREATS IN
INDUSTRIAL CONTROL SYSTEM

MARASIGAN, ALLYCIA MAE

 As the technology changes there are threats
that arise in the part of the industrial control
system. ICS are converted to digital platform
without the layered security approach to the
safeguard of the system. Follow are the threats
that overlooked on ICS.
HARDWARE BASED

The proprietary nature and lack of upgrade support of

the hardware exposes systems to increased security
risks. Executing hardware upgrades requires total
replacement of systems from the same vendor, which is
costly and often postponed or not executed at all.
WEAK AUTHENTICATION/ENCRYPTION

• Hardware-based systems were not designed to support

advanced encryption standards or complex authentication. Many
hardware-based systems do not even have an authentication
mechanism or, if they do, it consists of just a few numbers typed
into a keypad or easily decipherable passcodes. Encryption in
hardware systems is rarely strong due to the processing power
that is required to support encryption.
UNSUPPORTED SOFTWARE/FIRMWARE

• Due to the use of closed architectures and

software, any modifications to the ICS requires
using the vendor and may be limited if the
software/firmware is no longer supported by the
vendor.
SLOW RESPONSE TIME TO
PATCHING/UPDATING

• Vendors often provide customers with

approved/tested patches or updates to address
identified vulnerabilities months after the security
risk is identified.
POOR PHYSICAL SECURITY

• Many ICSs have a small form factor design, meaning

that they are physically small in size and have very
little computing power. This means that they can be
easily stolen and then reconfigured. In addition, with
the distributed nature of some ICSs, physical security
that prevents theft can prove to be difficult to ensure
without extensive costs.
WIRELESS CONNECTIVITY

• Many ICS products are located in remote locations

where network connectivity is only possible through
wireless and/or cellular networks. These ICSs come
preconfigured with standard configurations for
encryption such as the encryption key and
network/cellular passwords, which introduce a risk to
the infrastructure if compromised.
NO ANTIVIRUS OR
MALWARE PROTECTION

• The nature of ICS requires real-time, low-latency operating

systems/environment. This requirement does not allow for
traditional antiviruses or malware protection commonly seen in
standard IT systems. The inability to add this protection to an
ICS leaves systems prone to virus and/or malware infections,
which can lead to loss of information, degradation in service
and physical destruction.
LACK OF CONFIGURATION
MANAGEMENT

• ICS programmers write control logic for their systems, which is

a workflow for how a system is supposed to work. Many times
control logic program files are not version controlled and
configuration files are not monitored against an approved
baseline to ensure integrity. This is a common problem with
configurations and is an easy way for an attacker to add
backdoors or malicious configurations onto systems without
being detected.
CURRENT THREATS

• According to Industrial Data Communication, the BSI has compiled the latest threats
with highest criticality to which ICS systems are exposed at the moment during their
cyber security analyses.
• The threat priority results from an aspect examination like circle of offenders,
distribution and exploitability of the weak points, as well as possible technical and
economical consequences of an attack for example. Well-established incident databases
are evaluated for this amongst others.
TOP 10 THREATS ACCORDING TO BSI

1.Unauthorised use of remote maintenance 6. Introduction of malicious code via

accesse removable media and external hardware
2.Online attacks via office / enterprise 7. Reading and writing messages in the ICS
networks
network
3.Attacks on used standard components in
8. Unauthorised access to resources
the ICS network
4.(D)DoS attacks 9. Attacks to network components

5.Human misbehaviour and sabotage 10.Technical misbehaviour and force majeure

 COMMUNICATION
WITHIN ICS SYSTEMS

RATIO, CHRISMAINE JOY

COMMUNICATION WITHIN ICS SYSTEMS

• Devices and control modules in ICS systems relay information

through communication protocols.
• Most of these protocols are designed for specific purposes such
as process automation, building automation, power systems
automation, and many more.
• However, there are some protocols that only work if the
protocols and equipment come from the same manufacturer.
The ICS protocols that are commonly found include:
• Process Field Bus (PROFIBUS)
PROFIBUS uses RTU to MTU, MTU to MTU, and RTU to RTU
communications in the field.
There are two available variants:
*Profibus DP (decentralized peripherals) - which is used to operate
sensors and actuators through a central controller
*Profibus PA (process automation) – which is used to monitor
measuring equipment through a process control system.
DISTRIBUTED NETWORK
PROTOCOL (DNP3)

• This is a protocol with three layers operating at the data

link, application, and transport layers. Also, it is widely used in
electricity and/or water and wastewater treatment plants.
MODBUS

Since its introduction in 1979, the Modbus is considered one of the oldest
ICS protocols. Modbus uses serial communications with the PLCs and has
been the de facto communications protocol in an ICS environment.
There are two types of Modbus implementations:
*Serial Modbus – which uses the high-level data link control (HDLC)
standard for data transmission
 Modbus-TCP – which uses the
TCP/IP protocol stack to transmit data.
OPEN PLATFORM
COMMUNICATION (OPC)

Developed in 1996. The OPC is a series of standards and

specifications for industrial communications. The OPC
specification is based on technologies developed by Microsoft®
for the Windows® operating system family (OLE, COM, and
DCOM).
BUILDING AUTOMATION AND CONTROL
NETWORKS (BACNET)

• Founded in 1987. This is a communication protocol that is

designed to control heating, ventilating, and air-conditioning
control (HVAC); lighting; building access; and fire detection.
COMMON INDUSTRIAL PROTOCOL (CIP)

• Supported by ODVA. A CIP is a set of services

and messages for control, security, synchronization,
configuration, information, and so forth.
It can be integrated into Ethernet networks
and the internet. CIP has a number of
adaptations providing intercommunication
and integration for different types of networks.
ETHERNET FOR CONTROL AUTOMATION
TECHNOLOGY (ETHERCAT)

Developed by Beckhoff. It is an open-source communications

protocol used to incorporate Ethernet into industrial
environments. EtherCAT is used in automation applications with
short updating cycles (≤ 100μs) and with jitter ≤ 1μs.
COMPONENTS OF AN INDUSTRIAL
CONTROL SYSTEM (ICS)
ENVIRONMENT

TOLENTINO, MARIA TRISHA

 IT AND OT
• Operational Technology (OT) variables include the hardware and software systems
that monitors and controls physical devices in the field. OT tasks vary with every
industry. Devices that monitor temperature in industrial environments are examples of
OT devices
• The convergence of IT and OT provides enterprises greater integration and visibility
of the supply chain– which include their critical assets, logistics, plans, and operation
processes. Having a good view of the supply chain helps organizations remain
competitive. On the flip side, however, the convergence of OT and IT allows easier
access to these two components that are targets of cybercriminals. In many
organizations OT infrastructure is at best poorly protected against cyber attacks.
 PROGRAMMABLE LOGIC
CONTROLLER (PLC)

• This is a type of hardware that is used in both DCS and SCADA

systems as a control component of an overall system. It also
provides local management of processes being run through feedback
control devices such as sensors and actuators.
• In SCADA, a PLC provides the same functionality as Remote
Terminal Units (RTU). In DCS, PLCs are used as local controllers
within a supervisory control scheme. PLCs are also implemented as
primary components in smaller control system configurations.
REMOTE TERMINAL UNIT (RTU)

• An RTU is a microprocessor-controlled field device

that receives commands and sends information back
to the MTU.
CONTROL LOOP

• Every control loop consists of hardware such as PLCs and

actuators. The control loop interprets signals from sensors,
control valves, breakers, switches, motors, and other similar
devices. The variables measured by these sensors are then
transmitted to the controller to carry out a task and/or complete a
process.
HUMAN MACHINE INTERFACE (HMI)

• A graphical user interface (GUI) application that allows

interaction between the human operator and the controller
hardware. It can also display status information and historical
data gathered by the devices in the ICS environment. It is also
used to monitor and configure setpoints, control algorithms, and
adjust and establish parameters in the controllers.
REMOTE DIAGNOSTICS AND
MAINTENANCE

• This is a term used to identify, prevent, and

recover from abnormal operations or failures.
CONTROL SERVER

• A control server hosts the DCS or PLC

supervisory control software and communicates
with lower-level control devices.
SCADA SERVER OR MASTER
TERMINAL UNIT (MTU)

• This is a device that issues commands to

RTUs in the field.
INTELLIGENT ELECTRONIC
DEVICE (IED)

• A smart device capable of acquiring data,

communicating with other devices, and performing
local processing and control. The use of IEDs in control
systems like SCADA and DCS allows for controls at
the local level to be done automatically.
DATA HISTORIAN

• A data historian is a centralized database for logging all

process information within an ICS environment and then
exporting data to the corporate IS. The data gathered is
then used for process analysis, statistical process control,
and enterprise level planning.
TRIVIA
PROGRAMMING LOGIC CONTROLLER
- HEART OF INDUSTRIAL CONTROL
10 FACTS YOU SHOULD KNOW

1. PLC stands for Programmable Logic Controller – a special computer device used for industrial
control systems.
2. It is essentially an industrial computer, built to withstand harsh conditions.
3. Used to control devices, the PLC ‘software's’ components together by monitoring a series of
different inputs and manipulating the output for the desired control/effect.
4. It contains a programmable (changeable) memory in which a sequence of instructions is stored.
Those instructions enable the PLC to perform various useful control functions like relay logic,
counting, timing, sequencing, and arithmetic computation.
5. Its key advantage is that it is highly flexible in how it can be programmed while still being reliable –
meaning no program crashes or mechanical failures (as is the case with some traditional control
systems).
6. PLCs come in many shapes and sizes. They can be small enough to fit in your shirt pocket while more
involved controls systems require large PLC racks.
7. Modern day PLCs are programmed with specialized software. A common form of programming is Ladder
Logic and involves the use of symbols rather than words.
8. A single PLC can be programmed to replace thousands of relays and timers with one programme.
9. It can be designed to run its one program at a very fast speed, responding very quickly to any of the events
under its control. For example, controlling a machine’s production running at 30 000 units an hour!
10.You will find PLCs across a wide range of industries, including manufacturing, travel, aerospace, printing,
textiles, agriculture, and film. Where there’s automation, there’s bound to be a PLC (or quite a few) at work!
THANK YOU !