What is an industrial control system (ICS)?
An ICS is a set of computing, control, and communication components used to monitor and control industrial processes.
What is the role of sensors in an ICS?
Sensors measure physical process variables and provide feedback to controllers.
What is the role of actuators in an ICS?
Actuators execute control commands and influence the physical process.
What are the main tasks of controllers in an ICS?
Controllers collect and process sensor readings, issue commands to actuators based on control logic, and report aggregated process data to supervisory systems.
What is a control loop?
A control loop consists of sensor input, a controller algorithm, and actuator output, with feedback from the process sent back to the controller.
What is data concentration in industrial control?
Data concentration means collecting process data in one place and exposing it via a single communication protocol, even if the controller does not directly control the process.
What is a programmable logic controller (PLC)?
A PLC is a self-contained computing device geared mostly for general-purpose industrial applications.
What is a remote terminal unit (RTU)?
An RTU forwards sensor readings and commands between controllers and field devices over longer distances.
What is a master terminal unit (MTU)?
An MTU is the main controller of an industrial system and collects data from RTUs.
What is an intelligent electronic device (IED)?
An IED realizes communication between MTU/RTU components and polling field devices.
What is a safety instrumented system (SIS)?
An SIS is an independent and isolated control system used to ensure physical safety.
What is the purpose of safety controllers or SIS components?
They detect hazardous conditions and restore the system to a safe state, including shutdown if necessary.
Which kinds of failures can a safety controller override?
Sensor and actuator failures, control loop failures, and failures caused by cyber attacks.
What is a human-machine interface (HMI)?
An HMI is the local graphical or textual interface between an operator and an industrial process.
What does an HMI typically do?
It supervises and controls a subprocess, exchanges data with the controller, displays alarms and status information, and allows operators to set control points or issue commands.
Where can an HMI be located?
It can run on a remote machine or be physically attached to part of the system.
What is a supervisory workstation?
A supervisory workstation collects process data for oversight and high-level process management, usually with little or no direct control of controller control points.
How does a supervisory workstation differ from an HMI?
It is more centralized, covers the complete ICS, and is usually more read-oriented with less direct control.
What is a data historian?
A data historian records and stores time-tagged ICS data such as sensor readings and actuator commands for long-term use.
Why is a data historian important?
It enables long-term storage, reporting, and exporting of process data to higher-level systems such as MES or ERP.
What is an engineering workstation?
An engineering workstation is used for configuration, maintenance, diagnostics, and developing, testing, and updating control software.
Why is an engineering workstation security-critical?
Because it often has direct access to controller software and configuration.
What are key characteristics of PLCs?
PLCs are real-time digital computers for industrial control, provide analog and/or digital I/O, and communicate with HMIs or other PLCs over industrial protocols.
Why are PLCs considered rugged devices?
They are designed to operate in harsh environments with vibration, electrical noise, temperature variation, and dust.