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Get to know SCADA, the central network of industrial control systems

The term SCADA refers to supervisory data control and acquisition; it applies to the entirety of the central system for a processing or manufacturing plant. SCADA includes both the hardware and the software that run the operation. Usually, the whole system receives monitoring through an industrial control panel called a human machine interface (HMI). SCADA can be a widespread system, comprising many individual buildings or even regions.

I recommend: Find out more about SCADA industrial control systems through the information provided by TechFAQ. It outlines the details about the hardware and software elements. Spread Spectrum Scene gives you more information and provides further data such as primers and reference books.

Acquaint yourself with DCS, overseer of your industrial control equipment

DCS is a term that stands for distributed control system. A DCS usually runs a utility or processing system, such as gas, electrical and water utilities and chemical or food processing systems; they also handle automotive plants. DCSs are similar to SCADA in form and function - for instance, both are usually operated through industrial control panels - but a DCS has more confined boundaries with regard to area; usually it is within a single building or complex.

I recommend: Read about DCSs and a comparison with scalable control systems at SixNet. You can also learn more about how DCSs and related industrial control equipment work by going to Water and Wastewater.

Learn about the individual industrial control components in your system - the PLCs

A PLC is any individual computer-based device that controls industrial processes; the term means programmable logic controller. A PLC is simply the unit that manages a particular machine tool in a process; it has input and output ports for the transmitting of data between the central system and the individual equipment. These industrial control products are used within DCSs to keep track of the operation and signals of all the machinery within a plant.

I recommend: Get more information on PLCs and related industrial control products by checking out the Wise Geek. You can also look at All About Circuits, which has several diagrams explaining the function of PLCs.

Helpful advice for making the most of this Guide

• •  Although typically, these components integrate in a certain way - SCADA oversees DCSs, which in turn control PLCs - this is not a hard and fast rule. Your business might be organized a little differently, or may not even have all three industrial controls.

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Choose industrial control equipment designed for material handling systems

Material handling systems sort and manage a simple-to-complex network of belts, diverters, rollers and more. Programmable controllers also analyze production as needed.

I recommend: Work with companies specializing in industrial controls for material handling, such as Indiana Automation, which offers control systems for a number of automated services. Remtron offers material handling equipment controls and controls used for concrete pumps, cranes, construction equipment and other applications.

Invest in a top notch industrial control panel for automated staging and retrieval systems

For commercial or industrial use, industrial control products for automation help increase productivity, organization and meet needs requiring fast results.

I recommend: Look to McNaughton-McKay for automation controls for all markets including retrieval systems. Control Logic provides laser bar code scanners, tracking software and real-time monitoring automated industrial control panels.

Design and develop an industrial control system customized for specific needs

Many industrial control distributors design custom controls per industry need. Specialization in custom controls often allows for better systems, ideally suited for the business owner's need.

I recommend: Choose custom industrial controls from BWI Eagle, which specializes in controls like wireless remote controls for electrical needs and multi-functional controls and devices. For water purification process automation applications, customized controls are available from Siemens. Controls for air conditioning, pressure, valve controls, temperature and steam controls are available from Spence Engineering. Taco offers customized HVAC controls including electronic controls and air controls for industrial applications.

Determine industrial control components needed for sensors

Industrial controls performing monitoring or sensory work require high quality, reliable sensors. Find controls implementing sensory technology.

I recommend: Purchase wireless sensors, ultrasonic sensors and flow monitors from Turck, which offers a range of industrial control products. SICK is a manufacturer that offers controls for industrial and machinery applications, providing a range of sensory and scanning products. These products include magnetic proximity sensors, color sensors and distance measurement sensors.

Helpful advice for making the most of this Guide

• •  Analyze all fabrication and manufacture of industrial controls from industrial control distributors and manufacturers for new technology. Some new types of technology deliver better results and offer energy savings.

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Enhance your resume with industrial controls education and training

Take advantage of relevant training programs available through industrial training sources, as well as industrial control distributors.

I recommend: Learn more about the Control Systems Technician Training Series offered by TWL Industrial, a division of TWL Knowledge Group. The company supplies training courses dealing with plant operations, maintenance and safety to manufacturing and continuous process industries. Its training delivery methods include online, print, videotape, CD-ROM and DVD. Designed for electrical maintenance and instrumentation technicians, industrial control training topics include Continuous Process Controls, Control Networks, Programmable Controllers and Controls/Variable Speed Drives. Industrial Controls, a distributor of controls for commercial HVAC process applications/industrial automation applications, also offers technical training programs. Its Pneumatic HVAC Controls Training program aims itself at operators and supervisors from plants, warehouses and large office buildings, as well as HVAC servicemen/managers from mechanical contractors or controls contractors. At any of the company's locations throughout the U.S., each student gets hands-on training working at an industrial control panel.

Get certified through an industrial controller training program

Certification programs will boost credibility and professional development while providing the knowledge to work on various systems.

I recommend: Start out with training programs like the one at Columbus Technical College, the Industrial Motor Control Technician Certificate program.Earn a certificate in programmable logic controllers and SCADA Systems by completing the online training program from Business Industrial Network, a Better Business Bureau online accredited business that delivers onsite and other forms of engineering and maintenance training. This particular course gears itself towards engineers, electricians, maintenance and others interested in the latest developments in PLC and SCADA systems, fundamentals of their design, installation, troubleshooting and more.

Take advantage of certification options for industrial control systems

Even with so many benefits to technology, no one can deny one of its serious down sides -- the increased potential for cyber attacks. Those who manufacture or operate mission critical systems used in controlling transportation, power generation, oil production and water treatment understand the need for more secure critical infrastructure control systems resistant to cyber attack. Certification programs available for industrial control products can alleviate many of your concerns.

I recommend: Visit the Mu Dynamics website to learn more about Mu's Secure Industrial Control (MUSIC) certification program. Industrial control system vendors can use the (MUSIC) certification program for onsite certification testing of industrial control components, and industrial control system end users can use MUSIC certification to verify that vendors have actually accomplished claimed certification tests. Learn more about the Achilles Certification program from Wurldtech Labs, the research center of Wurldtech Security Technologies. The program offers device manufacturers independent verification of their product's security, and it gives control system operators assurance of the security of their deployed products.

Helpful advice for making the most of this Guide

• •  Before registering for any online industrial control system training program, review the company's website for its customer/technical support availability.

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Learn about industrial control systems like distributed control systems (DCS)

Distributed control systems (DCS) have industrial control components over connected sub-systems. These types of systems are often used in wastewater treatment plants and in oil and gas refineries.

I recommend: GlobalSpec gives a detailed description of DCS. WaterandWastewater.com describes how a DCS is used at a wastewater treatment plant.

Look into programmable controllers

Programmable logic controllers (PLC) can be used in DCS systems or on their own, but are primarily use for controlling computer-based processes, like power plant and other industrial plant processes.

I recommend: Frost Environmental Rooms shows an example of a PLC industrial control panel that works with a PLC system.

Consider SCADA industrial controls

A supervisory control and data acquisition (SCADA) industrial control system is used to collect data from several different locations, route that information to a central location where the data is then controlled and monitored.

I recommend: Gopher Utility Services has a detailed description of SCADA industrial control equipment. Tech-FAQ clearly describes a SCADA system, including its user interface and software and hardware components.