Energy Reports 12 (2024) 1518–1530

Contents lists available at ScienceDirect

Energy Reports
journal homepage: www.elsevier.com/locate/egyr

Review article

Critical review Of SCADA And PLC in smart buildings and energy sector
Gnana Swathika O.V. a , Aayush Karthikeyan b , K. Karthikeyan c , P. Sanjeevikumar d, * ,
Sajju Karapparambil Thomas e , Amin Babu e
a
Centre for Smart Grid Technologies, School of Electrical Engineering, Vellore Institute of Technology, Chennai, India
b
Schulich School of Engineering, University of Calgary, Calgary, Canada
c
Larsen & Tourbo Pvt,LTD, Chennai, India
d
Department of Electrical Engineering, IT and Cybernetics, University of South-Eastern Norway, Porsgrunn, Norway
e
School of Electrical Engineering, Vellore Institute of Technology, Chennai, India

A R T I C L E I N F O A B S T R A C T

Keywords: SCADA systems proves to be a promising technology to automate dynamical systems. Many automated systems
SCADA around the world are built using the principle of SCADA. The Open-SCADA gathers, archives, visualizes, and
PLC transmits data among other functions. With SCADA-packages, you can save time developing large distributed
Automation
systems by using pre-built components. It is also possible to modify your local operating system by using built-in
Energy
Airport
tools and configuration. The Programmable Logic Controller (PLC) on the other hand has the benefits of simple
Power system function, fast speed, high dependability, high noise resistance and excellent stability, which serve to be highly
Cybersecurity application advantageous for automated control applications. There is a wide range applicability of PLC in our present
market. The studies examined the application of PLCs in engineering studies, energy production research,
controlling and automating industry. PLCs certainly have limits, but data show that they have more pros than
cons. Thus, PLC may be utilized for any application, whether the control system is basic or complex. This paper
along with detailed review of SCADA and PLC discusses about power distribution & SCADA system architecture,
the proposed control & monitoring scheme deployed in a real-time network which ensures that at any point of
time, power supply is available through proper breaker interlocks at every level of switch boards in their
respective substation. To ensure this, even at the SCADA communication network redundant OFC cable and
ethernet switches are maintained at every level of RTU’s. A detailed case study of how PLC and SCADA are
deployed in critical building application is further elaborated.

1. Introduction enabling efficient control and management of power generation and

consumption. SCADA and PLC systems are also critical in ensuring
Supervisory Control and Data Acquisition (SCADA) systems and cybersecurity in industrial control systems. These systems play a vital
Programmable Logic Controllers (PLCs) are critical components in role in detecting, responding, and recovering from cyber threats, miti-
various industries, including power systems, water treatment, renew- gating risks and vulnerabilities. In communication systems and power
ables and environment, communication systems, and critical buildings. plants, SCADA systems provide real-time monitoring, control, and
In power systems, SCADA plays a significant role in monitoring and communication, ensuring optimal performance and efficient utilization
controlling the transmission and distribution of electricity, improving of resources. Lastly, SCADA and PLCs are implemented in critical
system reliability and efficiency (Zhu et al., 2017; Hocine and Chaib, buildings such as hospitals, data centers, and airports, providing
2019; Alawadhi and Naser, 2019). Similarly in wind turbines, SCADA real-time monitoring and control of various systems such as HVAC,
systems provide real-time monitoring, fault detection and control which lighting, and security, ensuring optimal performance and safety. Hence
aids to enhance the turbine’s performance and lifespan. Water treatment SCADA and PLCs are essential components in various industries,
plants use SCADA systems to control and monitor the water treatment providing real-time monitoring, control, and communication, ensuring
process, ensuring quality and efficiency in the treatment of water. optimal performance, efficiency, and safety (Khalil et al., 2021; Bakken
Additionally, PLCs are widely used in renewable energy systems, and Luiijf, 2019; Rauf et al., 2019; Wan et al., 2015).

* Corresponding author.
E-mail address: [email protected] (P. Sanjeevikumar).

https://doi.org/10.1016/j.egyr.2024.07.041
Received 9 March 2024; Received in revised form 16 July 2024; Accepted 20 July 2024
Available online 29 July 2024
2352-4847/© 2024 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
G.S. O.V. et al. Energy Reports 12 (2024) 1518–1530

Fig. 1. SCADA in power system.

Fig. 2. SCADA in wind turbines.

2. SCADA and its applications in different sectors historical data. The IoT-based SCADA system for hydropower stations
allows for timely information gathering and power station balancing
2.1. SCADA in power system with the national grid. This system supports station information such as
alarms, control and data monitoring, generated capacity and data log-
The current power system is capable of managing a decent amount of ging. The data packet analyzer and WIFI analyzer are also used to
Distributed Generator (DG) penetration and work in a competitive analyze the IoT-based SCADA system performance. A time series anal-
environment. The future power system (PS) will have to integrate with ysis is also used to analyze historical data (generated electricity) and
DG on a large scale to make systems more flexible and secure. Thus predict future production. In this study, past data from the Yeywa hy-
SCADA plays a vital role in PS as shown in Fig. 1. Present SCADA dropower station is used to analyze generated capacity (Myint et al.,
adaptation to match with future PS needs does not meet every expec- 2021).
tation. After taking different scenarios to consideration, the data and
control options are redefined (Vale et al., 2009). An advanced metering
infrastructure is developed with the help of SCADA to improve the 2.2. SCADA in wind turbines
reliability of state estimation in the power distribution system. A model
and data driven estimator is used to make a hybrid state estimation (SE). SCADA systems are used in several fault detection techniques and
There is a problem which existed b/w the AMI scans and DSSE. To solve this application is widely used in identifying faults in wind turbines as
this a topology identification method is adapted. This proposed system is shown in Fig. 2. It uses SCADA for the data accusation and by examining,
robust and reliable. When the AMI data is updated, the SE goes back data prediction can be made about fault, making operator jobs easy.
from the data driven estimators to model based one and this helps to Thus, SCADA is used to optimize and predict the maintenance required
identify system changes in real time (Huang et al., 2019). in order to reduce the operation cost of wind turbines which are often
SCADA is easily integrated with a power plant’s generator for col- regarded as one of the most efficient ways to generate sustainable en-
lecting station data, analyzing SCADA communication metrics and ergy. It is important to focus on collecting data on failure detection and
predicting electricity production without hydrological events using condition monitoring of the turbines. A novel-multiagent system archi-
tecture is used which supports multiple input and helps to bring more

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Table 1
Comparison of SCADA in PS and WT.
Aspect Scada in power Systems Scada in Wind turbine

Application Used to improve the reliability of Used for fault detection and
state estimation in the power condition monitoring of wind
distribution system turbines to optimize
maintenance and reduce
operation cost
Data Uses advanced metering Uses a novel-multiagent system
analysis infrastructure and a hybrid state architecture and recurrent
estimation model to analyze data neural network prediction to
and control options analyze data in polar, cartesian,
and cylindrical coordinates for a
better understanding of wind
and energy generation
Benefits Improves the reliability of state Provides real-time status of the
estimation in the power system, helps in early fault
distribution system, identifies detection, and gives more time
system changes in real time, and to operators to make decisions,
supports timely information improves accuracy of anomaly
gathering and power station detection by using a fuzzy Fig. 3. SCADA in water treatment.
balancing with the national grid synthetic evaluation method
Techniques Uses a model and data-driven Uses multiple inputs and focuses control technologies. The aim of the study is to minimize failures in
estimator, as well as a topology on failure detection, condition
identification method, and monitoring, and anomaly
automated metro railway systems by integrating information from
analyzes SCADA communication detection using neural various subsystems. The paper presents a prototype of an automated
metrics and historical data to networks, as well as a data metro train system that uses PLC and SCADA for real-time monitoring
predict electricity production analysis framework for and control. The authors provide a comprehensive overview of the
visualizing data and a fuzzy
proposed system, including the hardware and software components used
synthetic evaluation method to
improve accuracy and how the different subsystems are connected. The proposed system
Example Yeywa hydropower station is Wind turbine current data, past overcomes the drawbacks of the current centralized automatic train
used to analyze generated data, and other wind turbine control (CATC) system and provides significant benefits such as
capacity data are used to train the enhancing services, increasing network flexibility and allowing easy
condition parameter prediction
model and the abnormal level
modification of existing programs. The use of SCADA and PLC tech-
prediction model nology for improving the performance of real-time signaling and train
control systems in metro railways is an innovative approach that has the
potential to significantly improve the safety and efficiency of metro
data that aids to improve fault detection. The advantages of these sys- railway systems (Tomar et al., 2023).
tems are that they provide real time status of the system and help in
early-fault detection, thereby giving more time to operators to make 2.4. SCADA in water treatment
decisions (Tautz-Weinert and Watson, 2017; Zaher et al., 2009; Jin et al.,
2020). Another way to monitor wind turbines is to incorporate SCADA The supply of drinking water is not an unlimited natural resource.
systems in their turbines and log the acquired information in form of a Rapid societal growth tends to pollute the entire ecosystem including the
time series data. The data analysis framework is used for visualizing data drinking water. Water quality and quantity characteristics are moni-
from the SCADA system. In this study, a recurrent neural network pre- tored in real time and gives us early warning and more time to react. The
diction is utilized. The data is studied in the form of a polar, cartesian SCADA system allows for continuous monitoring of a variety of physical,
and cylindrical coordinates for a better understanding of the wind and chemical and biological factors allowing quick and accurate detection of
energy generation. Wind speed, direction, generated active power and system anomalies. The saved data will help for future reference. It is an
theoretical power are all anticipated and compared to current ap- integral part of new optimized operational management system of water
proaches. The results show that it can be used in real-world scenarios to supply. It further helps in controlling, reducing and optimizing water
help management teams control the energy generated by the wind tur- loss in the water supply system (Babunski et al., 2018a).
bine (Delgado and Fahim, 2021; Yadav and Paul, 2021). SCADA helped in the transition of changing manual boilers towards
This paper focuses on early anomaly detection using SCADA data and automated one. In the starting stages, using the input of air preheater
to do that neural networks are used, I/P parameters were selected based and economizer aids in maintaining the boiler temperature. The main
on existing domain knowledge. The data sets are wind turbine (WT) focus is given on pressure, level and flow control at various stages in the
current Data, WT past data and other WT data which are used to train. boiler. This monitoring helps in maintaining the desired temperature for
MAE index is also used to train the condition parameters and aid in the boiler. SCADA screen is configured through PLC to further improve
prediction of parameters such as temperature, wind speed and the pre- automation. Also variable frequency driver is used to carry out required
diction model. Abnormal level index is also introduced in order to action of the boiler at the automated power plant (Shankar, 2008).
measure the error in abnormal level prediction. Accuracy in this sce- Water pollution is a big challenge that is globally faced. The chal-
nario is improved by using a fuzzy synthetic evaluation method. The test lenge of modern water supply is to provide safe drinking water with less
carried out shows the method is effective in wind turbine fault anomaly contamination. A SCADA system when implemented is able to check the
detection (Sun et al., 2016). Table 1 compares the application of SCADA water quality to give real time updates and alerts as well as shown in
in PS and WT. Fig. 3. To realize this system, it is necessary to implement a measuring
station using SCADA. The saved data gives way for additional analysis. A
single methodology is also provided to efficiently manage water re-
2.3. SCADA in metro railways sources in communal water supply (Babunski et al., 2018b).

SCADA and PLC technology are being used to improve the perfor-
mance of metro rail systems by utilizing real-time signaling and to train

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large, centralized system to distributed and networked architectures,

and now to Internet of Things (IoT) systems. IoT SCADA systems enable
even more remote monitoring and control of systems through the use of
computer networks and the internet as shown in Fig. 4. The shift towards
IoT SCADA systems has made it possible to collect data from a wider
range of devices and sensors, which can then be used to better analyze
system performance and detect potential issues. This can lead to
increased efficiency and better overall system performance (Aghenta
and Iqbal, 2019b).
The authors of this paper describe a low-cost, open source SCADA
system that uses the Thinger.IO local server IoT platform as the Master
Terminal Unit (MTU) and the ESP32 Thing microcontroller as the
Remote Terminal Unit (RTU). The system was tested by remotely
Fig. 4. SCADA and PLC in IoT. monitoring a 260 W, 12 V Solar PV System, including the Photovoltaic
(PV) voltage, current and power, as well as the storage battery voltage.
2.5. SCADA and PLC in IoT applications The authors also created some Human Machine Interfaces (HMIs) on the
Thinger.IO Server, allowing operators to remotely monitor the system
Supervisory Control and Data Acquisition (SCADA) is a type of data in the cloud and initiate supervisory control activities if the ac-
technology used to control and monitor distributed processes, such as quired data fall outside of the expected range. This can be done using a
those found in factories, energy plants, transportation systems, and computer connected to the network or Thinger.IO Mobile Apps. Overall,
water treatment plants. SCADA is a combination of hardware and soft- this SCADA system provides a cost-effective solution for monitoring and
ware that helps users remotely manage and optimize these systems. controlling distributed processes and its open source nature allows for
There are four primary components to a SCADA system: Field Instru- easy modification and customization (Mellado and Núñez, 2022). It
mentation Devices (FIDs), Remote Terminal Units (RTUs), Master Ter- combines web services with conventional SCADA to provide robust su-
minal Units (MTUs), and SCADA Communication Channels.As pervisory control and monitoring. The system is a low-cost alternative to
technology has advanced, SCADA systems have evolved from being one traditional SCADA and can be used in various applications, such as

Fig. 5. SCADA in Cybersecurity.

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Fig. 6. Data and control flow in a plant.

renewable energy systems, manufacturing plants, and water treatment Dynamic Link Library (DLL) Injection, we can show how malware dis-
facilities. It also introduces a device called IoT-PLC that caters to the rupts critical process logic and infiltrates the SCADA host process. We
functionalities of Industry 4.0-oriented control systems. The device propose an algorithm to efficiently block DLL Injection, implement it as
operates as a containerized piece of equipment with separate containers a library, and test it against several DLL Injection scenarios. This method
for each functionality, and it is equipped with live migration function- should prevent malicious attacks from taking over all SCADA hosts, thus
alities, allowing loop reconfiguration without restarting the controller. maintaining the system’s sanity (Lee and Hong, 2020).
Laboratory experiments demonstrate the effectiveness and potential of
the proposed device.
In addition, a new application for the SCADA system, which monitors 2.7. SCADA in communication system and power plants
a hybrid system comprising photovoltaic, wind, and battery energy
storage systems. The system monitors electrical parameters in real-time, SCADA is used to manage and collect data from major in-
allowing network operators to remotely control the components of the frastructures, companies, and institutions. The major features in SCADA
hybrid power system. To design a cost-effective system, low-cost elec- network is the data collection and gathering information that can be
tronic components and an Arduino Integrated Development Environ- hacked or changed. So, most of the research was focused on finding
ment ATMega2560 remote terminal unit are utilized to develop a solutions to protect this information. Cryptography is the most common
hardware prototype for experimental analysis. The simulation and technique, which encrypts the data sent between channels. Hybrid
experimental results demonstrate the feasibility of the proposed system, cryptography and cross-cryptography algorithms, which combine two
which has advantages in terms of reliability and cost-effectiveness algorithms to get the best features of both, are the most advanced ones
compared to other existing techniques (Qays et al., 2022). that help to combine more than one algorithm. SCADA networks are also
used in photovoltaic (PV) power plants for controlling, observing remote
communication.The two effective solution put forward to improve the
2.6. Cybersecurity for SCADA systems security of the SCADA networks are security authentication and the
other one is data encryption, role based access control These procedures
Recent developments in automation made SCADA systems less in- can solve communication security difficulties between the RTU and
dependent in a highly interconnected environment. This in turn im- SCADA establishing server.
proves the efficiency of the system in controlling and monitoring The SCADA system offers network redundancy and the switching
processes, but this system can be susceptible to external threats. so, a technique can be developed by using 4 redundancy services. The
security system should be developed. The first step is to identify the availability of the SCADA system can be established by the SCADA
potential security breaches and design a system to counter it (Upadhyay sorting server. SCADA systems are meant to operate in a closed envi-
and Sampalli, 2020). Cyber-attacks on SCADA systems are becoming ronment. As a result, there are no methodologies to analyze threats
more complex. The developed SCADA security measures fall into three when inspected. The recent researches about technological and
categories: physical network separation, message security, and security economical changes shifted SCADA system from serial to TCP/Ip. Fig. 6
monitoring. Even though this system are necessary the recent malware explains what are the factors included in this process. This research
attacks show they are insufficient. Fig. 5 explains the detailed working looks into the use of machine learning to detect new security vulnera-
of SCADA in cyber security Malware attacks on SCADA systems exploit bilities to SCADA networks and the Modbus protocol. A dataset of
software vulnerabilities and take control of host processes. Using Modbus-based Remote Terminal Unit (RTU) communications was

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Table 2 customer generation. The aggregation network contains a network of

Comparison Between SCADA and PLC for Cybersecurity and Communication buses, consumers, distributed generations and an aggregator for
System and Power plants. resource management and scheduling (Abrishambaf et al., 2018). Using
SCADA and PLC for Cybersecurity SCADA In Communication System Internet of Things (IoT), a remote electrical power SCADA system with
And Power Plants IIS for web servers is built, an ASP. For remote electrical power sur-
Discusses the need for security measures Discusses the need for security measures veillance and control a NET model–view–controller (MVC) is used, and
in SCADA systems due to external in SCADA systems to protect data from along with Microsoft SQL Server database. TCP/IP protocol is used for
threats being hacked or changed collecting sensing data and to send to the client, which has multiple
Describes potential security breaches Discusses the use of cryptography,
screen size compatibility for easy mobile configuration. A lot of labor
and proposes countermeasures hybrid cryptography, and cross-
including physical network cryptography algorithms to encrypt data and time is saved because users is able to give their instruction imme-
separation, message security, and sent between channels diately without the need of checking the physical condition manually.
security monitoring To make human-machine interface much easier a visual interface is
Proposes an algorithm to efficiently Describes the use of security developed where the current system has analog and a digital I/p and o/p
block DLL Injection to prevent authentication, data encryption, and
malicious attacks from taking over role-based access control to improve
for motor driver connection and an inverter to remotely control the
SCADA hosts communication security difficulties SCADA system using the IoT for efficient power management (Kao et al.,
between the RTU and SCADA 2018).
establishing server Photovoltaic control systems are developed using SCADA which are
Discusses the shift of SCADA systems Describes the use of SCADA networks in
low cost and open source. Along with the conventional SCADA system,
from serial to TCP/IP and the use of photovoltaic (PV) power plants for
machine learning to detect new controlling and observing remote IoT is also included to incorporate web services. For PV data acquisition,
security vulnerabilities and the communication an Arduino controller interfaced with a current and voltage sensor is
Modbus protocol used. Raspberry pi with node red compiles the data which is collected.
Presents an algorithm that was tested Discusses the use of network redundancy Further, this data collected is stored in the local server, master terminal
against several DLL Injection scenarios and switching technique for SCADA
unit using IoT technologies. In this paper, data is collected and stored
to maintain system’s sanity systems to establish availability
Mentions recent malware attacks that Mentions the lack of methodologies to from the 260 W and 12 V photovoltaic with help of above systems
show the inadequacy of current analyze threats in closed environment (Aghenta and Iqbal, 2019a). A tool called TRACE MODE V6.05 is
SCADA security measures SCADA systems developed using SCADA for cement production. It was based on a
cement kiln’s six-dimensional precise logic temperature controller. By
establishing a function that is inversely related to the function linking
utilized to train ML-based detection algorithms. The methods used are
this loop of the controller to its other loops, an additional set of pro-
SVM, decision trees, k-nearest neighbours, and k-means clustering.
duction rules compensates for the mutual influence of control loops. The
While all algorithms fared well, SVM, Decision Trees, and K-nearest
temperature in calcination zone has more accuracy after using above
Neighbors performed better with certain attack types. Specific assault
proposed system which results in less fuel usage (Muravyova et al.,
types did not fare well with K-means grouping (Phillips et al., 2020).
2018).
Table 2 discussed how SCADA and PLC are utilized in cybersecurity and
communication systems.
3. PLC and its application in different sectors

2.8. SCADA in other sectors 3.1. A. PLC in renewable and environment

In the current world scenario, it is evident that all the industries Real time gate control of hydroelectric power plants is realized using
require remote access connections. The need for this type of access is to PLC to control parameters like level and flow. PLC is used as a control
send data of various equipment and stations. As a result, a wireless based device and the signals are provided from the push buttons, level and
signal transfer for SCADA applications is presented. This setup would be flow sensor to the control unit. The prototype has five levels of upper
executed using Wincc software along with it a smart server is used to tank and two levels of lower tank. The ladder logic is controlled by level
solve the problems b/w the human machine interface. In this work, the sensor and the PLC used was an ALLEN BRADLEY MICROLOGIX 1200
processes for conducting the fundamental configuration is defined in (Rajeswari et al., 2012). Automation is a hot topic in the current in-
great depth (Wasel and Abdulwahid, 2020). The PLC and SCADA are dustry, as machines tend to replace humans in many tasks, while
new ways to control VFD which in turn controls three-phase induction humans are unable to replace machines in many professions. In indus-
motor and conveyor belt using VFD output. Three sensors are attached trial automation, management and industrial systems monitoring are
to conveyor belt which detects the motion of the object and execute the critical. Installing supervision and monitoring systems is essential for
instructions given by programing logic of PLC through a computer. assuring Photovoltaic (PV) system dependability and stability. This
SCADA controlling software is used in PCs to give control of the entire study proposes a real-time monitoring and control of pumping system
operation to the human operator (Dorjee, 2014). The problems in parameters using Siemens PLCs and HMIs (Bouraiou et al., 2021).
clearing an alarm could pose a risk to the crucial infrastructure which in Environment in which plants are grown is not suitable for cables and
turn can affect a nation’s reliability and security. To solve this issue a the main objective of this paper is to design a control system for water
SCADA alarm communication management is developed. The above pumping wirelessly and it is experimentally set up in the laboratory. In
alarm-handling model uses a common approach in which alarm trans- control system a PLC and industrial wireless local area network is used to
actions are used along with dispatcher directives and substation oper- process the communication data. PLC along with distributed (I/O) and
ator maintenance. The above system is simulated in power systems with two IWLAN, water pumps and sensor are used in this paper. This system
certain scenarios with different substations and error is compared to uses industrial ethernet and uses internet protocol for carrying out
show the potential of the suggested alarm-handling methodology parameterization, configuration and diagnostics. PLC controlled motor
(Mahmoudi-Nasr, 2019). incorporates a digital signal for controlling the tank level and it is
SCADA is also deployed in the office and customer service sectors. determined by using a pressure transmitter and limit switches. This
One such example is the integrated model with tools for efficient paper provides low cost and easy to maintain solutions where cable
resource management and the proposed SCADA integrated system sup- cannot be implemented (Bayindir and Cetinceviz, 2011). In Solar tech-
ports to decide and participate in demand response events in an office nology, a PLC was used to control movement of electromechanical
building. An aggregate model is used to control consumption and two-axis sun tracking systems. The energy gathered was measured and

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compared to that collected on a fixed surface inclined 32 degrees to the The shipbuilding industry is concerned with the safety of workers at
south. The results proved that moving panels captured more energy. construction sites around the world. However, current wireless
41.34 % of more energy was captured (Abdallah and Nijmeh, 2004) communication methods used to facilitate efficient communication be-
(Ouberri et al., 2019). discusses about PV modeling approach for poly- tween workers are sometimes hindered by physical barriers, resulting in
crystalline and monocrystalline PV modules that makes use of an areas where radio signals cannot reach. As a solution to this issue, SUN-
automation PLC for maximum power point tracking (MPPT). In this COM Co., Ltd in the Republic of Korea has developed a PLC-based
study, the SIEMENS S7–300 PLC will be employed as the control system. communication system and established a test-bed facility in collabora-
WINCC flexible runtimes will be used to simulate and validate the I-V tion with SK Telecom Co., Ltd and Hyundai Heavy Industries Co., Ltd.
and P-V characteristic curves of the two technologies, which will be used The system aims to minimize work-related accidents and can be adapted
to validate the proposed modeling technique. to other industries facing similar challenges, providing uninterrupted
communication and safer working conditions. Additionally, the solution
3.2. PLC in other sector includes mobile communication services within ships during the ship-
building process, enabling prompt processing of work reports and in-
PLC is used for automation of electromechanical processes. It con- structions and swift responses to emergency situations, ultimately
verts previously used relay logic into ladder logic and in this project, improving work efficiency and ensuring the safety of workers (Huh
Siemens LOGO is used. This paper deals with automatic Fluid level et al., 2018).
control using PLC in Alameda textile Factory. over there they use old PLC-based device was used at a French railway company for verifi-
relays to control the level of fluid level which in turn results in wastage cation and validation of the power supply. This aims to reduce the
of money and resources and this paper tries to solve this issue (Alem and workload on engineers. The system is divided into two stages, The first
Vankdoth, 2016). The paper discusses the design and fabrication of stage focuses on the automatic generation of PLC programs, wiring di-
magnetic levitation using PLC. displacement sensor provides it O/P to agrams and test-based recipe books, and the second stage is the imple-
PLC. The O/P voltage is increased when distance between the sensor and mentation of formal verification and control synthesis techniques
target is increased. PLC decrease the current through the electromagnet (Niang et al., 2020). IoT is widely used in many applications. It is
and vice versa happens when distance is getting shorter, hence a desired increasingly used in the industry due to its benefits in improving overall
position is maintained (Ahmed et al., 2016). Automation of packaging system performance. Many industries require IoT technology to meet
and material handling is discussed in this paper. Process of placing their needs. This is the Industrial IoT. This paper presents a prototype
materials in boxes, detection of good and bad items and sealing using system to achieve artificial control and monitoring using IoT. The article
package tape is automated Purpose of this paper is to replace manual compares and contrasts two control systems: PID and fuzzy logic.
systems and compare the time and manpower requirement with auto- Modbus protocol is used to connect PLC to OPC server and sensors. The
mated systems. The Mitsubishi FX series PLC is used along with prox- IoT system will use OPC and MQTT to gather data and upload it to the
imity sensor and load sensor for input; motors, pneumatics and solenoids cloud (Ali et al., 2020).
as output. The ladder diagram as a software is used to control I/P and
O/P components. A full automation of the system is produced by an 4. SCADA and PLC in other sectors
experimental prototype. It is found that the system saves around
50–75 % time and a significant amount of manpower is also reduced. 4.1. A. SCADA in renewables
This system is 90 % fully automated without humans. This paper also
discussed the potential of adding HUMAN machine interface, a feedback Renewable resources have experienced an international investment
mechanism for rejected items using AI (Baroro et al., 2014). bang in the previous decade, as well as the importance of hydropower
Wireless technology has advanced significantly, allowing us to con- has increased the economy. Hydropower facilities must function as
nect gadgets. A study attempting to connect wireless technologies efficiently as possible in order to compensate for the changes in energy
(ZigBee) to a programmable logic controller was made, thus making us production caused by renewable sources. This is due to the advantages
control distant fields wirelessly (Li et al., 2010). Online Battery energy of hydropower plants, which include faster response and excellent
storage systems are added to the grid to provide peak demand with ease flexibility. Using excavation techniques incorporated into an unique
and at same time improving the overall quality and stability in grid module of the SCADA system, it is proposed that the administrator can
function. The current BESS systems are facing some issues to become be helped to ensure that the hydropower plants are operated at their
more efficient because it cannot handle high-power rating BESS, life most efficient. Some of the most significant advantages are reduction in
cycle is short, electromagnetic immunity is low and lacks proper in- the time interval as well as high efficiency (Garbea et al., 2021)
terfaces for input and output operation. PLC was used to control 200kwh Even with the usage of RESs, distribution networks are now plagued
BESS as online backup for grid. The code is written on steep 7, by issues such as complexity and productivity.MG with RES based on
SIMANTIC. WINcc is used to build the interface of SCAD systems SCADA are a good way to control them. The advancement of SCADA
(Mohammed and Danapalasingam, 2017). One of the process in making systems and communication infrastructures is strongly linked to the use
motorcycle pistons is to drill oil holes. In this process, the drill can make of these interfaces. SCADA. systems for MG and active distribution
some problems. Therefore Pokayoke sensor system using Laser sensor is network control and operation increase production and efficiency. The
integrated with engine using a PLC. This sensor detects the presence of SCADA system’s real-time data show that we can achieve adequate
drill and can provide feedback to control the machine. PLC processes balance in a LAMBDA MG testbed and, as a result, reduce the LAMBDA
this signal and if any error occurs operators are alerted. This system MG and main grid exchange power (Kermani et al., 2020).
detects the drill at the max distance of 982 mm and minimum diameter
1 mm. This tool uses a magnetic stand as a holder. This project reduces 4.2. SCADA in other sectors
the error and rejection of products (Ardi and Al-Rasyid, 2016).
A home management system is necessary to save cost by efficiently In this paper, SCADA measures Value in terms of complex variables
managing the consumption and generation of the energy. To manage the apart from the traditional SCADA Measurement methods used. We are
energy part, an energy management system based on ZIG-Be is used and assuming that voltage and current amplitudes are available. We can
for generation, a renewable energy system based on a Programmable solve this equation by using least-squares method. using this method
logic controller (PLC) is used. Servers in home gathers data and analyze initialization, the convergence issue is solved (Dobakhshari et al., 2019).
them for better estimation to achieve. This HEMS system is expected to A Hybrid state estimation system was proposed where SCADA and
optimize house energy consumption (Han et al., 2014). phasor calculation units are separated. Distinct levels of PMU and

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SCADA can be handled by the proposed SE system. Proposed SE system its design and implementation is discussed in this paper. Special
is compatible with PMU measurements. This model is tested on real graphical user-interface is used to programing PLC, Both the ladder di-
world power systems and the test results show that SE model out per- agram and word instruction are used for programming (Sanver et al.,
forms conventionally used Hybrid SE systems (Kabiri and Amjady, 2018).
2018).The Supervisory Control and Data Acquisition system allows the Another work mentions self-tuning nonlinear controller ASPECT,
chosen control station to monitor and control industrial processes. this is used to fix nonlinear systems whose characteristics vary often
Developing a customized SCADA system lowers the cost of software throughout its operation and it is given with three sophisticated control
components and brings the system closer to small and medium-sized methods. The processes are displayed using low order local linear
businesses.so they are using SCADA programme written in the C# lan- models whose parameters are found using online learning algorithms.
guage and successfully monitored and control of industrial processes in This approach combines model identification to offer dependable op-
this study. The software developed is capable of remotely supervising, erations, and monitors and assesses control performance of closed loop
controlling, and observing the facilities, as well as data recorded in an systems. This controller is developed using a PLC and performance is
IoT server (Phuyal et al., 2020). verified on proper control on the pressure of hydraulic valve (Gerkšič
et al., 2006).
4.3. PLC teaching technique Researches are also carried in the field of synchronous electric drives.
The studies were done using PLC, created control signal unit and +ve
PLC is used for control and operation in industries. 4-year electrical dynamic feedback. The correcting method was adopted from earlier
engineer courses cover various topics on PLC and after each lecture’s investigations. The findings demonstrate that the suggested mode has
students do the practicals in RS Logix. students were able to make greater efficiency than typical IR-compensation and by dynamic quali-
necessary changes by observing the operation of programs by the end, ties, responsiveness to the load and outperforms the closed-movement of
students were able to learn basic PLC programming. This paper dis- electric drive (Kodkin et al., 2017). Due to its resilience to frequency
cussed 3 projects which include PLC (Guo and Pecen, 2009). In indus- channels, OFDM is commonly utilized in power-line communications.
trial engineering, with a good curriculum and advanced manufacturing These aspects are significant in the overall quality of the medium access
technology will help students to acquire vast practical skills and in- approach. A unique OFDM time synchronization and channel estimate
dustrial exposure, hence this is the motive of the author to make this approach for PLC is described. OFDM leverages cross correlation from a
paper. In this paper. automatic transfer switch (ATS) based on PLC is broadcast pilot symbol with acceptable correlation qualities for com-
developed for laboratory purposes to activate the above intentions. The bined fine synchronization and channel evaluation. However, these
general concept of ATS is discussed. steps such as designing and approaches frequently have a significant computational burden, making
implementation of the above setup is discussed in the paper. This pro- eventual actual implementations problematic. Our idea takes use of
posed setup proved to improve students and also have potential to be corresponding pairs of sequences’ strong correlation qualities and
used for commercial purposes (Ashour, 2004). inexpensive creation and correlation techniques. We also construct
This paper discusses the development of an Integrated virtual several realistic synchronization criteria that adjust to the current SNR
learning system to teach about PLC. The article describes the construc- and channel circumstances. Finally, simulation has validated all theo-
tion and assessment of modules of PLC timer and instructions of counter. retical proposals, including performance analysis (Colombo et al.,
These lessons were first built using an smart instructing system (ITS). 2019).
After the success, a web related ITS was refined. The authoring tool
related to ITS timer components were tested among students. and web- 5. Case study: scada and plc implemented in critical building
based ITS timer and counter modules were examined among another set
of students. In both cases it was found that this helps students to better A case study proposed is implemented in a critical building appli-
understand PLC (Hsieh and Yeehsieh, 2004). cation where there are 13 substations located at various locations are to
be monitored and controlled using a fool proof SCADA from a central-
4.4. PLC in other sector ized location ensuring power changeover happens from 3 different
power sources and no single point failure at 11KV & 415 V.
PLC plays a vital role in the manufacturing industry. PLC is used in
many factories to cut down cost and increase speed, PLC makes use of 5.1. Schematics of power distribution network
ladder logic and other unique computer programming. Higher level
languages can be used for more complex system but still ladder logic 5.1.1. Following Employer intent is taken care in the Electrical design
remains as a dominant choice (Erickson, 1996).PLC is a laboratory based
subject due its complexity. we need additional component to make • Redundant incoming power supply @ 66KV from two different
controllable for humas. As PLC courses grow to include IEC 6–1131 substations
defined programming languages, a need for a portable PLC system that • Power transformers (66/11KV) are with N+1 configuration
can be used in a training or classroom arises. The purpose of this work is • Distribution transformers (11/0.415KV) are with N+1 configuration
to address this problem (Barrett, 2008). • 100 % standby DG power backup with N+1 redundancy
PLC is the central control unit in industry. Effective processing and • Ring main topology formed @ 11KV network & @ Main 415 V LT
safety can be achieved by effective programming. This paper Compares panel
the past and present and Future capabilities of PLC By implementing • Ring main topology formed for OFC SCADA network
PLC, SCADA and DCS, the RLC is avoided which causes human inter- • Essential loads are feed from two different substations @ Main 415 V
vention and greater error. According to this paper the word automation LT panel
is discussed as working processes in efficient manner by incorporating • Single point failure to be taken care up to sub-distribution panel of
mechanism and control system several times with less deviation from essential loads
output (Hudedmani et al., 2017). Earlier days of automation consisted of • Single point failure to be taken care up to Remote terminal unit
relays and contractors and development of semiconductor technology (RTU) level in SCADA distribution
Brought in PLC which was a breakthrough in automation systems in
industry. With PLC control of opto-couplers and voltage converters were 5.1.2. List of new substations
done. It consisted of a microcontroller/microprocessor, relay or tran- Following are the new substations which are controlled and moni-
sistor compared with industrial PLC, PLC using PIC18F2580 is cheap and tored through SCADA:

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Fig. 7. Real-time power distribution network.

Fig. 8. Typical building power distribution.

66/11KV GIS substation – Power center for complete building loads). As a standby power 5 nos. of 3000 kVA HT DG set are synchro-
11KV HT DG – 100 % Backup power center nized and fed to the 11 kV main HT panel as a backup power as shown in
11KV/415 V Chiller substation-1 – Power center for Chiller bank-1. Fig. 7.
11KV/415 V Chiller substation-2-Power center for Chiller bank-2.
11KV/415 V substation-1- Power center for Building 1 5.1.4. Typical building power distribution
11KV/415 V substation-2-Power center for Building 2 Fig. 8 shows the single line diagram of the real-time power distri-
11KV/415 V substation-1-Power center for Building 3 bution in a typical building where the 11 kV is further stepped down to
11KV/415 V substation-2-Power center for Building 4 0.433 kV through 3 nos. of 1.6MVA distribution transformer. Further
11KV/415 V substation-1-Power center for Building 5 the LT supply is fed to final lighting power and other building loads.
11KV/415 V substation-2-Power center for Building 6
11KV/415 V critical substation-1-Power center for Building 7 5.1.5. Typical Schematic For Chiller SS-1 & 2
11KV/415 V critical substation-2-Power center for Building 8 Fig. 9 shows the schematic for Chiller SS-1 & 2. The LT supply is fed
11KV/415 V critical substation-Power center for Building 9 to the chiller and pump loads via the Chiller Main LT panel.

5.1.3. Power distribution network

Fig. 7 indicates the real-time power distribution network. It is clearly 5.2. High level SCADA system architecture
shown in the figure that 2 nos. 66 kVincoming line from the utility board
is feeding the consumer 66 kV Gas Insulated Substation (GIS) panel. Fig. 10 depicts the high level SCADA system architecture. It includes
Further the 66 kV line is fed to 2nos 30MVA power transformer from a dedicated server and workstation to monitor and control the electrical
where the voltage is stepped from 66 kV to 11 kV. Further the 11 kV parameters from a centralized location. Table 3 shows I/O summary of
supply is fed to the 11 kV main HT panel (essential and non essential SCADA.
To handle the variety of stations on which development, testing,

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Fig. 9. Schematic for Chiller SS-1 & 2.

Fig. 10. High level SCADA system architecture.

operating, local monitoring, remote monitoring and maintenance are systems simultaneously. The SCADA software must support imple-
performed, the SCADA software package (AVEVA Plant SCADA) pro- mentations involving a combination of any of the previously listed
posed shall support all of the following Microsoft ® operating systems; a) operating systems, for example a SCADA server may be implemented on
Windows® 8 b) Windows® 7c) Windows Server® 2008 d) Windows a Windows server 2012 platform, the clients on a Windows 8 platform
Server® 2012 e) 32 & 62 Bits The SCADA software is intended to support and the development performed on a Windows 7.
development and runtime implementations on all of these operating

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• MFM in all panels

5.4. Salient Feature of proposed SCADA System

RTU (Modicon) shown in Fig. 12 stands for Remote terminal unit,

will be proposed locally at each substation to connect Input/Output data
(IO data) from each field devices. Each field device transfers information
(analog & digital) through sensors, transducers, power contactors based
on the respective component data which is intended to process further in
the PLC to achieve a required operation. Typically this happens in all the
RTUs and its associated field devices. In order to minimize the single
point failure following additional measures are implemented:

• Fiber Optic cable Ring Topology for communication network.

• Different Routing ensured for both Incoming & Outgoing fiber at
substation level(Field Level).
• Redundant LIU’s and Ethernet Switches (ESU) at Substation Level to
avoid single point failure
• Ring topology used at Substation level for RTU communication
through CAT-6 cable and Fiber Option (FO) cables
• Standalone RTU with HOT STANDBY PROCESSOR MODULE M580
can control the Substation even the communication loss from Control
Room.

5.5. Protocol

IEC61850 is a standard protocol appropriate for all IEDs (MiCOM)

associated with VCBs, ACBs and MCCBs in the proposed system to
transfer the data to RTUs. IEC67870–101/104 is a standard protocol for
telecontrol implementation in the proposed SCADA system. For appro-
priate protocols (e.g. IEC61850, IEC 60870–5–101/104), the I/O Device
Fig. 11. SCADA server interfacing.
Subsystem shall be capable of receiving data time-stamps from the field
device, as well as historical data in the form of alarms and data log files.
This information shall be automatically populated into the SCADA his-
Table 3
torical records without any user configuration or intervention.
I/O Summary for SCADA.
I/O Name Quantity
6. Conclusion
DIGITAL INPUT(DI) 13,000
DIGITAL OUTPUT(DO) 3500 This paper presents a detailed review of SCADA and PLC in various
ANALOGUE INPUT 100
ANALOGUE OUTPUT 50
real-time applications. A detailed case study of how PLC and SCADA are
SOFT I/O-(Modbus & IEC− 61850) 9000 deployed in critical building application is further elaborated. In the
TOTAL 25,650 case study, power distribution & SCADA system architecture are
analyzed. The proposed control and monitoring scheme will ensure that
at any point of time, power supply is available through proper breaker
5.3. Controlling and monitoring of components
interlocks at every level of switch boards in their respective substation.
To ensure this,even at the SCADA communication network redundant
5.3.1. Control and monitoring of following electrical equipments are
OFC cable and ethernet switches are maintained at every level of RTU’s.
envisaged for building substations

CRediT authorship contribution statement

• 66KV GIS through BCU.
• 11KV HT DG set through C&R panel.
Gnana Swathika OV: Supervision, Project administration, Meth-
• LT DG set through AMF relay.
odology, Investigation, Formal analysis, Data curation, Conceptualiza-
• All 11KV panels incomers, buscouplers and outgoings which have
tion. Sajju Karapparambil Thomas: Writing – review & editing,
electrically operated VCB.
Writing – original draft, Software, Investigation. Amin Babu: Writing –
• All Main LT panel incomers, buscouplers and outgoings which have
review & editing, Writing – original draft, Software, Methodology,
electrically operated ACB and MCCB.
Investigation. Aayush Karthikeyan: Resources, Conceptualization.
• All MLDB & UPS panel incomer which have electrically operated
Karthikeyan K: Supervision. Sanjeevikumar Padmanaban: Visuali-
MCCB.
zation, Validation, Funding acquisition.
5.3.2. Monitoring of following electrical equipments are envisaged for the
substations Declaration of Competing Interest

• 66KV power transformer. The authors declare that they have no known competing financial
• 11KV distribution transformer. interests or personal relationships that could have appeared to influence
• Outgoings of MLDB and UPS panels. the work reported in this paper.

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Fig. 12. RTU interfacing.

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