International Journal of Research and Development in Applied Science and Engineering (IJRDASE)

ISSN: 2454-6844

Review on PLC SCADA Based Automated System

Control Applications and Challenges
Pooja Rai Dr. Awdhesh Kumar
Electrical Dept Electrical Dept
MMMUT, India MMMUT, India
[email protected]

Abstract: Application of PLC SCADA in industrial plants Critical Infrastructures (CI) are often described as the
is getting very common with the advancement of infrastructures which provide essential services and serves as
automation and sensor applications. Due to high rate of the foundation for any nation’s security, economy, and
increase in demand with high quality and precision all the healthcare systems. Cyber-Physical Systems (CPS)/ Internet of
conventional control systems are being replaced by Things (IoT), are supplementing traditional CI with data-rich
automated supervised control system. Thermal power operations. The list of sectors under critical infrastructure
plants are the example of very large systems which are varies from country to country. It generally includes sectors
based on the PLC and SCADA system. Not only the large like agriculture, healthcare, nuclear reactor, transportation,
system but small plants in local operations are also using energy sector, civil and chemical engineering, water plants,
PLC SCADA based control in temperature, pressure etc. research etc. as depicted in Fig. 1. Supervisory Control and
This paper presents the review on the PLC SCADA Data Acquisition (SCADA) systems, an Industrial Control
systems history, development and security. This review is Systems(ICS), have a pivotal role in managing and controlling
helpful is understanding the present applications of of the CI. SCADA systems control and monitor
automation in various industrial systems. geographically distributed assets. Historically, SCADA
frameworks were limited to power transmission, gas
Keyword: PLC, SCADA, Power Plant, Automation conveyance, and water appropriation control frameworks.
Advancements in technology have led to SCADA being
1. Introduction: deployed in steel making, chemical processing industries,
In thermal power plant the demand for higher reliability & telecommunications, experimental and manufacturing
efficiency is increasing. Power plant requires continuous facilities [1]. With Industries 4.0 / Industrial Internet of Things
inspection & monitoring after regular intervals. There may be (IIoT) evolution, modern SCADA systems have adopted CPS/
chances of errors while measuring at various stages by human IoT, cloud technology, big data analytics, Artificial
workers. In order to increase reliability the automation is intelligence (AI) and machine learning. Integration of these
needed so that overall efficiency of power plant gets technologies has significantly improved interoperability, ease
improved. The automation is developed by using PLC & the maintenance and decreased the infrastructure cost.
SCADA which reduces the errors caused by human workers Therefore, leading to a near real-time environment. SCADA
.PLC is programmable logic control. It is used for systems improve the efficiency of the operation of the
implementing various function such as sequencing, timing, industrial critical system as well as provide better protection to
counting, logic, mathematic control through analog and digital the utilised equipment. Moreover, it improves the productivity
input output modules. In order to store the programme in PLC of the personnel. SCADA frameworks give valid identification
it must be interfaced to computer via interfacing unit. The and prompt alert warning to the observing stations by using an
programmed can be implemented through various languages. attested monitoring stage, advanced communications, and
In this paper ladder logic is used for programming .SCADA state-of-the-art sensors. SCADA systems were designed to
system is used to supervise a complete process. The output of work in a standalone way and relied on air-gapped networks
different sensors is given to the PLC which takes necessary and proprietary protocols for securing the system. Therefore,
action to control the parameter. SCADA system consist of initial designs of SCADA never incorporated security features
subsystem such as human machine interface, remote terminal [2, 3]. However in recent years, due to the expansion of
unit, and programmable logic control and communication business and need of central monitoring of distributed
cable. The alarm system is also provided to inform the software, SCADA systems have evolved into sophisticated,
operator. SCADA is used to monitor water level, temperature, complex open systems, connected to the Internet using
pressure using different sensors and corresponding output is advanced technology. Associating SCADA system to the web
given to the PLC. For controlling these parameter. In coal has helped numerous SCADA systems to work from
conveyer belt the belt tear up, overloading and moisture topographically inaccessible areas. However, this has lead the
content is sense by different sensors. The sensor used are IR SCADA system more vulnerable for attackers to target from
sensor, temperature sensor, and humidity sensor. anywhere in the world [4].

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 International Journal of Research and Development in Applied Science and Engineering (IJRDASE)
ISSN: 2454-6844

The modernisation of the SCADA system, standardisation of varied objectives like superior quality, increased efficiency,
communication protocols and growing interconnectivity have high profit and other such points depending upon the purpose
drastically increased the cyber-attacks on SCADA system over of the company that implies it. With the prime objective of
the years. These type of attacks are becoming more catering to these necessities and the needs of the industrial
sophisticated to commit the more traditional cyber espionage sector, significance has been given here to automation.
and sabotage in addition to cyber crimes. The smooth and K. Gowri Shankar (2008) [1] presented here has kept in
genuine operation of SCADA framework is one of the key mind, the ceaseless changes that are relentlessly taking place
concern for the enterprises, because the outcome of break in the contemporary scenario of the industrial segment.
down of SCADA system may range from financial misfortune Emphasis has been given to the automation process that is
to natural harm to loss of human life [5]. A cyber-attack on a now rapidly taking its place in all the power plants across the
nuclear plant will have a global impact. Moreover, the security globe. The Paper has furnished itself to study the integral parts
spillage in small networks can lead to a loss of services and of the entire process involved, their implementation and the
financial loss to the utility company. problems that may show up have also been given their due
importance. The future work deals with the purification of
water to the boiler and the air circulation for the boiler to burn
the fuel using same automation technique.

Over the last decade, efforts from industries and research

communities have been made in addressing the security of
Supervisory Control and Data Acquisition (SCADA) systems.
However, the SCADA security deployed for critical
infrastructures is still a challenging issue today. Ning Cai et.
al., (2008) [2] given an overview of the complexity of
SCADA security. Products and applications in control
network security are reviewed. Furthermore, new
developments in SCADA security, especially the trend in
technical and theoretical studies are presented. Some
important topics on SCADA security are identified and
Fig. 1: SCADA Application Areas highlighted and this can be served as the guide for future
works in this area.
2. Related Work: The security of SCADA systems has been the subject of
K. Gowri Shankar (2008) [1] outlines the various stages of research, standardization and industrial practices for several
operation involved in the conversion of a manually operated years. However, the attacks on SCADA system is getting more
boiler towards a fully automated boiler. Over the years the frequent due to the openness of the SCADA network
demand for high quality, greater efficiency and automated platforms, the advancement of hacking techniques and the
machines has increased in this globalised world. The initial increased availability of hacking tools. It will rise to a
phase of the paper focuses on passing the inputs to the boiler significant level in the future according to the investigation
at a required temperature, so as to constantly maintain a and study by the Committee on Homeland Security [2]. The
particular temperature in the boiler. The Air preheater and cooperative efforts from control/automation and IT specialists
Economizer helps in this process. And the paper mainly are the key to combat the threats facing the SCADA systems.
focuses on level, pressure and flow control at the various New protocols, standards and products are expected to
stages of the boiler plant. Thus the temperature in the boiler is strengthen the security levels of various existing and future
constantly monitored and brought to a constant temperature as SCADA systems. In this paper, we have briefly discussed the
required by the power plant. The automation is further major differences between control network security and
enhanced by constant monitoring using SCADA screen which traditional IT network security. The complexity of SCADA
is connected to the PLC by means of communication cable. By system security is presented. The progress on SCADA system
means of tag values set to various variable in SCADA the security researches and developments is reviewed. Efforts on
entire process is controlled as required. At the automated the SCADA security from governments, international
power plant, the boiler is controlled by Variable Frequency standardization bodies and research communities are
Drive (VFD) to put in action the required processes to be summarized. Some representative products, proposed
carried out at the boiler. Thus the entire cycle is carried out as protocols, and applications are presented. The technical trend
a paper and at various stages each phase is detailed out. This and direction on the SCADA security research are discussed,
paper has proved to be very efficient practically as the need A few research topics, such as high speed real time intrusion
for automation grows day by day. detection, artificial immune system for SCADA system, and
The most important aspect of any power plant is the boiler SCADA security vulnerability assessment, are identified as
control. Several techniques can be implemented to control the promising research areas.
boiler in power plant. The method that has to be used relies on
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 International Journal of Research and Development in Applied Science and Engineering (IJRDASE)
ISSN: 2454-6844

M. N. Lakhoua, (2010) [3], presented the applications of a temperature, pressure and water level. If the temperature and
supervisory control and data acquisition (SCADA) system in pressure inside the boiler exceeds the predefined value then
thermal power plants (TPPs). In fact, a supervisory system the entire system is shut down. In case of emergency different
must take into account the physiological and cognitive automated check valves are used to release pressure, steam
features of the supervisory operator. The paper briefly and inform the concerned authority through alarm. Boiler
discusses on the one hand the different steps of the application automation ladder diagram is designed using WPL soft and
of a SCADA system and the difficulties to manage and on the SCADA design is done by Intouch wonderware.
other hand it presents three examples of the application of a In this paper, Boiler Automation using PLC and SCADA was
SCADA system in a TPP in Tunisia and the instrumentations designed and implemented. Different sensors are used to
and the measurements used. The first application is related to a measure the temperature, pressure and water level. SCADA is
counting system of the natural gas, the second one is related to used to monitor the parameters and PLC used to control the
the supervision of pumps vibrations and the third one is operation. If the temperature and pressure exceed predefined
related to the supervision of heavy fuel oil. value then the entire setup will shut down and automatic check
The SCADA system is used for monitoring and controlling valves are opened to release the steam and pressure. In case of
industrial processes from remote areas. It allows an emergency alarm was energized and automatic check valves
operator to make a set point changes on remote controllers, to are opened to avoid catastrophic failure. Ladder diagram of
open/close valves/switches, to monitor alarms and to gather Delta PLC is simulated using WPL soft and the SCADA
instrument information from a local process to a widely design of boiler automation is simulated using Intouch
distributed process, such as oil/gas fields, pipeline systems, or wonderware software. The future research is to focus on the
hydroelectric generating systems. In the context of SCADA, it application oriented implementation of remote monitoring of
refers to the response of the control system to changes in the boiler Automation by SCADA internet access.
process and makes them similar to real-time control system in
the virtual environment. Comprehensive historical perspectives of different boiler
In this paper, an example of a SCADA system in a TPP is automation techniques are discussed below. This survey
studied and some applications are presented. First, we provides critical reviews and highlights the concepts,
presented the supervision of a counting system of the natural advantages and disadvantages among survey results. This
gas of a TPP. This application was permitting the contribution adds more thoughtful ideas in the design and
branching of counters of the natural gas to a SCADA system development of boiler automation techniques. In present
of the TPP in the one hand, and requires the programming and situation conventional PID control is being used for boiler
the configuration of the counting system, on the other hand. control. These conventional controllers in power plants are not
Second, we presented the supervision of a system of vibratory very stable when there are fluctuations and, in particular, there
surveillance in a TPP. This application enables us the creating is an emergency occurring. Continuous processes in power
and the maintaining dynamics of updating the pumping plant and power station are complex systems characterized by
process displays. Finally, we presented the supervision of nonlinearity, uncertainty and load disturbances. The
heavy fuel-oil tanks of a TPP. This application allows us to conventional controllers do not work accurately in a system
assure the connection between the ultrasound sensor and the having nonlinearity in it. So, an intelligent control using
post of surveillance in the control room of the TPP. However, PLC& SCADA is developed to meet the nonlinearity of the
the paper discusses the need to monitor the process and system for accurate control of the boiler steam temperature
possibly control the operation of TPPs from virtually and pressure level. Embedded system based boiler automation
anywhere. system consist of GSM (Global System for Mobile
Communication), PIC (Peripheral Interface Controller) and
Boiler is one of the most important equipment in any power different sensors which is capable of monitoring the entire
plants which require continuous monitoring and inspection at boiler temperature and pressure. The obtained temperature and
frequent intervals. There are possibilities of errors at pressure measured data are transferred through the PIC
measuring and various stages involved with human workers. microcontroller. The microcontroller read the available data
So a reliable monitoring system is necessary to avoid and processed.
catastrophic failure, which is achieved by Programmable If the temperature and pressure exceeded the maximum value
Logic Controller & Supervisory Control and Data Acquisition then the user will be able to get information about the current
system. S.Kalaivani, M.Jagadeeswari, (2015), [4], outlined temperature in any boiler by simply sending a boiler
the design and development of boiler automation system using identification number [5], [7].
PLC, SCADA and sensors. PLC and SCADA interfaced via
communication cables. The initial phase of the paper focuses Microcontroller is programmed with the fuzzy knowledge
on passing the inputs to the boiler at a required temperature, so base rule to control the boiler temperature. The temperature
as to constantly maintain a particular temperature in the boiler. sensor is interfaced with the microcontroller to monitor the
SCADA is used to monitor the boiler temperature, pressure steam temperature and a level indicator circuit is used to
and water level using different sensors and the corresponding indicate the water level inside the boiler chamber which is
output is given to the PLC which controls the boiler interfaced with the microcontroller and the corresponding
Available online at: www.ijrdase.com Volume 21, Issue 1, 2021
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 International Journal of Research and Development in Applied Science and Engineering (IJRDASE)
ISSN: 2454-6844

outputs are given as the two inputs for the Fuzzy Inference get affected .SCADA is used for monitoring the operation of
System. After fuzzification of the inputs and applying suitable equipment and PLC is used to control the operation . The
rules and defuzzifying the output the microcontroller generates different sensors are used to sense different parameter such as
appropriate control signals [6]. temperature, pressure, tearing of belt, overloading, water level
etc. If the parameter exceed the predetermined value the n it is
Fuzzy PID controller is used for temperature superheated informed by SCADA system to the operator. in order to
steam of boiler based on the fuzzy control methodology. The automate the boiler and coal conveyer belt the ladder logic is
control process is simulated through the Simulink MATLAB developed. The SCADA screen shows the status of equipment
software. It shows that the system can demonstrate good so that operator can take necessary corrective action. In case
control ability and dynamic effects even in large delay and of emergency different automated check valves are used to
stochastic disturbance circumstances [8]. From the literature release pressure, steam and inform the concerned authority
works that are discussed; it is evident that have several through alarm. The most common Faults in coal conveyer belt
disadvantages. In the proposed system the previous papers are belt tear up fault, moisture content and overloading fault.
disadvantages are overcome by using PLC & SCADA for In this paper Boiler, Coal conveyer belt, Ash handling plant
boiler automation to monitor and control the boiler ladder are developed in PLC. Different sensors are used to
temperature, pressure and water level in thermal power plant. measure pressure, temperature and water level. Different
sensors are used to the monitor and measure the parameter and
As the need of automation increases significantly, a control PLC used to control the system operation. SCADA system are
system needs to be easily programmable, flexible, reliable, developed to estimate and monitor current operation states and
robust and cost effective. Ephrem Ryan Alphonsus et. al. to collect, analyze and diagnose fault alarm.
(2016) [9] reviewed on the application of programmable logic
controller (PLC) in our current market is discussed. The automation control of a boiler superheated steam
Investigations on the applications of PLCs in energy research, temperature is considered. It is important to keep the
engineering studies, industrial control applications and superheated steam temperature at the given level. In case of
monitoring of plants are reviewed in this paper. PLCs do have discrepancy, the boiler operates inefficiently and emergency
its own limitations, but findings indicate that PLCs have more situations can occur. Namely, the boiler water is flooded
advantages than limitations. This paper concludes that PLCs alongside steam into a turbine set. A system of multistage
can be used for any applications whether it is of simple or cooling of boiler superheated steam through a condensate
complicated control system. injection is described by Olga V. Kolesnikova et. al. (2018)
PLC was first conceivedinlate60’s and now has become a [11]. The system of automatic control over the temperature of
major player in automation system. Generally from the review superheated steam for the boiler with three-tier steam cooling
that has been done, PLCs can be fully adaptable for any system is considered. A regulating algorithm rests on a
research, industry applications, control of simple or advanced cascade control method with the temperature error correction
system, monitoring and even joint control with any other based on a force signal. The force signal is a speed of steam
controller in the market such as PID, PICMCU, PLA, PAL temperature change after the condensate injection. A
and fuzzy controller to name a few. As more advancement of mathematical model of boiler steam cooling is described. The
PLCs in the current market, either if its in the hardware of model takes into account a nonlinear nature of the shut-off and
software application, we can see that more people are coming control valves of a real boiler. The model was implemented in
to terms in using PLCs as their main controller in their Simulink (Matlab) and tested on actual data of a steam boiler.
applications. Programming system using ladder diagram The simulation results demonstrate that the method for control
comparing with other type of programming languages are very over the boiler superheated steam temperature has good
much beneficial since even an electrician with limited quality characteristics, which imply effective control.
knowledge of programming would be able to understand and The system of superheated steam temperature control on the
program a PLC base on his knowledge of electrical system. basis of cascade control and force signals recording is
Programming is no more for programmers but simple layman suggested. The model of the controlled object was developed
can involve in programming machines. in the program Simulink (MATLAB). This model takes into
account all the complexity of the control loop of boiler
Thermal power plant consist of many important equipment superheated steam temperature. This model contains a three
which is required for the generation such as boiler ,coal step system of a desuperheater and nonlinearity, such as
conveyer belt ,ash handling plant ,cooling system etc. These looseness, level and time quantization, hysteresis, dead zone.
equipment requires continuous inspection and monitoring . This model operation was checked on actual data. The results
Akash R. Jaiswal et.al. (2016) [10], outlined the automation show that the developed model for control is effective as it has
of boiler &coal conveyer .Automation leads to greater good quality parameters.
efficiency &reliability .The automation is achieved by using
PLC&, SCADA. PLC & SCADA is connected through Supervisory Control and Data Acquisition system facilitates
communication cable .This paper focuses on passing the the monitoring and control of industrial process from the
inputs to the equipment so that equipment operation must not designated control station. The cost investment for
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 International Journal of Research and Development in Applied Science and Engineering (IJRDASE)
ISSN: 2454-6844

implementing the SCADA system is expensive and is not in with very low-cost investment compared to the commercial
approach of small and medium scale industries these days. products.
Developing the customized SCADA system helps to reduce All types of power generation, transmission and distribution
the cost in software components and becomes more close system, industries and all types of process monitoring purpose,
approach to the small and medium scale industries. In this the emerging technology of supervisory control and data
research Sudip Phuyal et. al. (2020) [12], presented a acquisition (SCADA) is being implemented and also the
SCADA software developed in C# environment and cloud-based control systems are also emerging in this field for
successfully tested in industrial process monitoring and the advanced monitoring and control of the process from the
control. The developed SCADA software is capable of supervisory level. This reduces the workforce required, less
remotely supervise, control and data monitoring facility and is time of action for decision taking, easy planning of system
also capable of data logging in the IoT server. This approach task, easy and proper visualization of the system process.
has been found to be efficient in both aspects, technically and As the commercial SCADA products available in the market is
economically. expensive and higher in budget size for small and medium
By using the platform of C# environment and using Schneider industries, we implemented a low-cost SCADA software
M221 series PLC as RTU, we successfully tested the developed in C# environment and tested successfully in the
performance of low-cost SCADA system in in the milling and process monitoring and control of Mayos noodles industry in
roller unit of Mayos Noodles plant in Banepa, Kavre. The Banepa. The test of this system has proved that we can reduce
setup was installed in the existing running unit of the industry the cost investment in purchasing the software to monitor the
by adding the infrared sensors to detect the flow of materials industrial process and can run the industry in fully automatic
in the roller, ultrasonic sensors to detect the materials and monitored environment. The product implemented has a
available in the mixer unit, PLC for logical controls and a huge possibility of upgrade and can be used in commercial
SCADA interface to monitor and supervise the entire plant industries to reduce their production costs by increasing the
process. Additionally, the necessary electrical safety was machines utilization, reduction in workforce requirement and
provided by protection devices like MCCB, MCBs, overload can also improve the quality of products by monitoring the
relays, contactors and the add-in blocks, fuses etc. wherever process more precisely.
required. The results obtained in this work can be implemented in the
The setup includes the wireless control and supervision of the commercial and educational purpose to produce SCADA
plant process through the use of internet and the plant process software and hardware for the monitoring and control of full
is made to be accessible to monitor and control through industry. For more facilitated and expanded service, the SMS
mobile applications and the web interface. alerts can be sent to system administrators of any critical
This can be easily implemented in small and medium scale notifications, the user-interface can be developed more user
industries, isolated and hybrid microgrid systems very easily friendly so that it can be operated from the webpage directly
from using the selector switches and input data.

Table 1: Comparison Table

Protocol Use Data Use Behavioral Model Simulated Data References
No Protocol, Source IP, Destination IP, Source Port, Destination No Simulated Data [6]
Port
Yes Packets PDU Yes [12]
No Features extracted by sliding window over a sequence (n-gram) No Real Data [13]
Yes Master ID, Slave ID, Function Code, Transaction Status, No Simulated Data [15]
Operation Data, Access Type, Memory Contents, Memory
Address
No Number of different packets in a time period, Number of No Simulates Data [16]
packets, between two specific types of packets, Relative
difference in the packet rates, Number of different source
addresses in a time period.
Yes Modbus protocol fields, service discovery Yes Simulates Data [10]
No Features extracted by sliding window over a sequence (n-gram, No Simulates Data [18]
invariant induction)
No Link utilization, CPU usage, Login failure Yes Simulates Data [19]
Yes Modbus protocol fields, service discovery Yes [17]

3. Conclusion: The systems based on PLC SCADA are the subject under
standardization, research, and industrial applications from

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 International Journal of Research and Development in Applied Science and Engineering (IJRDASE)
ISSN: 2454-6844

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