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As a control engineer, one of the most frustrating aspects of working with SCADA systems is how simple tasks become complex due to the way the software is designed. Recently, I spent an unreasonable amount of time trying to configure something as basic as a button logic. The goal was straightforward: enable the button only when conditions are met, and disable it in all other cases. Simple, right?
The challenge lies in how newer software, developed by IT professionals, approaches logic from a programming perspective rather than a control engineering perspective. In Industrial Control Systems (ICS), we think in terms of interlocks and conditions: If A and B are true, enable. If not, disable. But SCADA systems can make this a nightmare because they often require mixing Boolean logic and numerical comparisons.
Why Is This Such an Issue?
For control engineers, logic should be simple, intuitive, and easy to configure. Yet, modern software requires convoluted scripts, intermediate tags, or a trial-and-error process just to get a button to function. Many cases feel like forcing the software to do something that should be simple.
The Disconnect
The root cause is that SCADA software development is led by IT professionals who don’t fully understand how ICS are designed and implemented in a plant. This leads to a fundamental gap between what the software can do and what control engineers need.
The Real-World Impact
When a button that should take five minutes to configure ends up consuming real time, it’s frustrating, inefficient, and impacts productivity. Control engineers shouldn’t have to navigate a maze just to get basic functions working.
The Real Problem Is the Software, Not the User
The issue doesn’t stem from a lack of knowledge—it’s the software itself being inherently difficult to handle simple, real-world control logic. Control engineers are experts in logic, interlocks, and systems. The problem is that software is simply not designed to handle these concepts intuitively.
What SCADA Software Should Do
- Provide straightforward, pre-built interlock templates.
- Simplify logical expressions without forcing scripting.
- Prioritize real-world control logic that matches ICS needs.
- Reduce reliance on trial-and-error configurations.
You Should Know: Practical SCADA & Control System Commands
To mitigate these challenges, here are some practical commands and steps to streamline SCADA and PLC interactions:
Linux & Scripting for SCADA Automation
- Use `cURL` to interact with SCADA APIs:
curl -X GET "http://scada-server/api/tags" -H "Authorization: Bearer API_KEY"
- Automate tag updates with `jq` (JSON processor):
curl -s http://scada-server/api/tags | jq '.tags[] | select(.name == "pressure")'
- Schedule logic checks using
cron:/5 /usr/bin/python3 /scripts/check_interlocks.py
Windows SCADA & PLC Tools
- PowerShell script to monitor PLC tags:
Get-PLCTag -Name "Motor_Status" -Server "192.168.1.10"
- Use `OPC DA/Auto` for tag logging:
opcclient.exe -s "OPC.Server" -t "Temperature.Tag" -log "C:\logs\temp.csv"
PLC Debugging & Logic Simplification
- Ladder logic best practices:
- Use sealed-in coils for state retention.
- Avoid complex scripting inside SCADA—keep logic in PLC.
- Structured Text (ST) example for button enable/disable:
IF (Condition_A AND Condition_B) THEN Button_Enable := TRUE; ELSE Button_Enable := FALSE; END_IF;
What Undercode Say
The disconnect between SCADA software design and control engineering needs is a persistent issue. While IT-driven development brings scalability, it often overlooks the simplicity required in industrial automation. Engineers must adapt by:
– Keeping logic in PLCs rather than SCADA scripts.
– Automating checks with external scripts (Python, Bash).
– Advocating for better SCADA design standards.
Expected Output:
A more intuitive SCADA system that aligns with control engineering workflows, reducing unnecessary complexity and improving efficiency in industrial automation.
For further reading on SCADA best practices, check:
References:
Reported By: Jeremy Mcdonald – Hackers Feeds
Extra Hub: Undercode MoN
Basic Verification: Pass ✅
