The history and evolution of SCADA (Supervisory Control and Data Acquisition) and DCS (Distributed Control Systems) can be traced back to the 20th century. DCS and SCADA are commonplace in the facilities of process manufacturers for monitoring and controlling processes (Chkara and Seghiouer 38). The DCS was developed as an alternative to the laborious use of individual analog and pneumatic loop controllers in extensive operations such as refineries. SCADA was initially designed to manage activities covering large regions, such as pipelines and utilities. Eventually, a variation using Programmable Logic Controllers (PLCs) and a human-machine interface (HMI) for factory automation arose. SCADA and DCS systems have many similarities as they are both computer systems for gathering and analyzing real-time data, allowing for remote monitoring and control of networks. The history and evolution of SCADA and DCS systems have led to their popularity in automation, and their integration with emerging technologies is expected to improve their efficiency while emphasizing the importance of cybersecurity.
The adoption of Industrial Internet of Things (IIoT) systems aided with more network devices and sensors. It helped both SCADA and DCS systems get better at monitoring, collecting, and analyzing data. Cybersecurity also became important as industrial companies got more significant along with increased connectivity. Enhancing cybersecurity protected computer systems against potential risks and ensured industrial operations’ safety and reliability (Gunduz and Das 94). A fresh approach founded on standards has been developed to integrate Information Technology (IT) and Operational Technology (OT) systems (Ortiz 30). SCADA systems, which have a centralized design, gather data from sensors and other devices. As this is going on, experts in the field of cyber security are expanding their knowledge to include the traditionally separate OT and IT domains.
DCS and SCADA systems have evolved to perform various tasks beyond traditional monitoring and control. DCS and SCADA are enhancing the investor experience, safety, and protection by integrating additional intelligence at each level of manufacturing automation construction to enable analytical benefit life process management and value shackle optimization. The broad transition of industrial automation systems is only getting started. Still, this transition to a new control system is already in full swing (Sabatini et al. 72). Yet distributed control systems (DCS) were developed in the 1970s to manage complex manufacturing operations. In a decentralized control system (DCS), many controllers are spread out throughout a facility; each controller controls a specific process element. Compared to SCADA systems, this approach provides much more leeway and backup.
This move will benefit process manufacturers since it should increase their capacity and return on investment from industrial automation. Vendors have been examining how they can rethink operational technology (OT) automation technologies employing modules that are readily accessible off the shelf (COTS) and information technology (IT) in light of the newly identified difficulties that have been brought to light by end users. Customers want manufacturers to construct automation systems with best-in-class COTS hardware and software which exceeds existing DCSs in terms of reliability, security, and value for the customer. Customers want manufacturers to create automation systems with best-in-class COTS hardware and software.
There has been a trend toward SCADA and DCS system convergence in recent years. A distributed control system is an abbreviation for this concept. Increasing automation and robotics contribute to the need for more effective and flexible process control (Javaid et al. 75). Soon, SCADA and DCS systems will be connected with robotic systems in a more widespread manner. Humans can delegate mechanical equipment work that is either hazardous or too exhausting for the human operator. In addition, the processing speeds of robotic systems may be quicker than people, and their accuracy may be higher.
The exemplary architecture under consideration by OPAF would include several desirable characteristics, such as connectivity, flexibility, conventional conformance, standard safety regulation, expansion, and mobility. NOA allows for the direct collection of data from sources such as robots, drones, and cutting-edge deterioration, sound, and vibration sensors. This information is acquired in a distinct domain from the present system called M+O (Monitoring and Optimization). Additionally, OPC UA imports data from the existing system, enabling complex control, analysis, and diagnostics in the field. Compatibility across IEC62443 zone designs is enhanced, and the complexity of system design and maintenance is reduced from a safety point of view.
The fact that certain DCS suppliers do not consistently offer updates is a more significant problem. If a manufacturer’s vendor ceases supplying system upgrades, switching to a new system and replacing the old one is the only alternative. In most cases, the initial investment in the latest technology is outweighed by the costs associated with production downtime and related expenses incurred during the transition to the new system. Establishing an open and interoperable definition is the primary objective of OPAF, which seeks to promote the development of process control systems that are both more effective and less costly.
Future evolution of SCADA and DCS systems will likely focus on increasing their integration with new technologies like artificial intelligence and deep learning. This connection would allow for more comprehensive data analysis from various systems, resulting in even higher efficiency and precision in industrial operations (Finnan and Nakagawa). Additionally, as these networks become more interconnected and the potential hazards of cyber assaults on industrial processes expand, cybersecurity will undoubtedly be more emphasized.
In conclusion, SCADA and DCS systems have advanced dramatically since their inception in the twentieth century. Combining IIoT with cloud computing has expanded data accessibility, increasing productivity and cybersecurity. Merging SCADA and DCS systems with new technologies such as AI and deep learning will improve industrial operations accuracy. Cybersecurity will become increasingly crucial as networks grow more linked. By developing an open definition, OPAF hopes to facilitate the development of practical and cost-effective process control systems.
Works Cited
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Finnan, Kevin, and Wataru Nakagawa. “The Roles of DCS and Scada in Digital Transformation.” Automation. 2021. Web.
Gunduz, Muhammed Zekeriya, and Resul Das. “Cyber-Security on Smart Grid: Threats and Potential Solutions.” Computer Networks, vol. 169, 2020, p. 94. Web.
Javaid, Mohd, et al. “Substantial Capabilities of Robotics in Enhancing Industry 4.0 Implementation.” Cognitive Robotics, vol. 1, 2021, pp. 58–75. Web.
Ortiz, John D. “Patient Health Literacy: Understanding Barriers to Improve Outcomes.” Nature Reviews Nephrology, vol. 18, no. 3, 2022, pp. 129–30. Web.
Sabatini, Roberto, et al. “Avionics Systems Panel Research and Innovation Perspectives.” IEEE Aerospace and Electronic Systems Magazine, vol. 35, no. 12, 2020, pp. 58–72. Web.