An industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and interactive distributed control systems (DCSs) with many thousands of field connections. Control systems receive data from remote sensors measuring process variables (PVs), compare the collected data with desired setpoints (SPs), and derive command functions that are used to control a process through the final control elements (FCEs), such as control valves. Larger systems are usually implemented by supervisory control and data acquisition (SCADA) systems, or DCSs, and programmable logic controllers (PLCs), though SCADA and PLC systems are scalable down to small systems with few control loops. Such systems are extensively used in industries such as chemical processing, pulp and paper manufacture, power generation, oil and gas processing, and telecommunications.
History
Process control of large industrial plants has evolved through many stages. Initially, control was from panels local to the process plant. However, this required personnel to attend to these dispersed panels, and there was no overall view of the process. The next logical development was the transmission of all plant measurements to a permanently staffed central control room. Often, the controllers were behind the control room panels, and all automatic and manual control outputs were individually transmitted back to the plant in the form of pneumatic or electrical signals. Effectively, this was the centralisation of all the localised panels, with the advantages of reduced manpower requirements and a consolidated overview of the process. However, 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. It also required continual operator movement within a large control room in order to monitor the whole process. With the coming of electronic processors, high-speed electronic signalling networks and electronic graphic displays, it became possible to replace these discrete controllers with computer-based algorithms, hosted on a network of input/output racks with their own control processors. These could be distributed around the plant and would communicate with the graphic displays in the control room. The concept of distributed control was realised. 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. It enabled sophisticated alarm handling, introduced automatic event logging, removed the need for physical records such as chart recorders, allowed the control racks to be networked and thereby located locally to the plant to reduce cabling runs, and provided high-level overviews of plant status and production levels. For large control systems, the general commercial name distributed control system (DCS) was coined to refer to proprietary modular systems from many manufacturers that integrated high-speed networking and a full suite of displays and control racks. While the DCS was tailored to meet the needs of large continuous industrial processes, in industries where combinatorial and sequential logic was the primary requirement, the PLC evolved out of a need to replace racks of relays and timers used for event-driven control. The old controls were difficult to reconfigure and debug, and PLC control enabled networking of signals to a central control area with electronic displays. PLCs were first developed for the automotive industry on vehicle production lines, where sequential logic was becoming very complex. It was soon adopted in a large number of other event-driven applications as varied as printing presses and water treatment plants. SCADA's history is rooted in distribution applications, 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 systems use open-loop control with sites that are widely separated geographically. A SCADA system uses remote terminal units (RTUs) to send supervisory data back to a control centre. Most RTU systems always had some capacity to handle local control while the master station is not available. However, over the years, RTU systems have grown more and more capable of handling local control. The boundaries between DCS and SCADA/PLC systems are blurring as time goes on. The technical limits that drove the designs of these various systems are no longer as much of an issue. 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. With the increasing speed of today's processors, many DCS products have a full line of PLC-like subsystems that weren't offered when they were initially developed. In 1993, with the release of IEC-1131, later to become IEC-61131-3, the industry moved towards increased code standardization with reusable, hardware-independent control software. For the first time, object-oriented programming (OOP) became possible within industrial control systems. This led to the development of both programmable automation controllers (PAC) and industrial PCs (IPC). These are platforms programmed in the five standardized IEC languages: ladder logic, structured text, function block, instruction list and sequential function chart. They can also be programmed in modern high-level languages such as C or C++. Additionally, they accept models developed in analytical tools such as MATLAB and Simulink. Unlike traditional PLCs, which use proprietary operating systems, IPCs utilize Windows IoT. IPCs have the advantage of powerful multi-core processors with much lower hardware costs than traditional PLCs and fit well into multiple form factors such as DIN rail mount, combined with a touch-screen as a panel PC, or as an embedded PC. New hardware platforms and technology have contributed significantly to the evolution of DCS and SCADA systems, further blurring the boundaries and changing definitions.
Discrete controllers
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