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Category: Automation

Why Industrial Plants Are Turning to Integrated Automation + IT/OT Cybersecurity Services

Posted on by Kyle Davis

Industrial plants are rapidly modernizing their operations, adopting new automation platforms, real-time data systems, and advanced control strategies to stay competitive. As facilities increase connectivity through SCADA networks, IIoT devices, cloud analytics, and centralized data platforms, their risk profile is shifting quickly. Production systems that once operated in isolation are now connected to plant networks, corporate IT environments, and remote-access channels.

This creates major opportunities for efficiency, but it also exposes plants to cybersecurity threats that didn’t exist a decade ago. That’s why more organizations are turning to integrated automation and IT/OT cybersecurity services to protect their processes, improve safety, and maintain uptime.

Automation and Cybersecurity Can’t Operate in Silos Anymore

Traditionally, operational technology teams managed the plant floor such as PLCs, HMIs, DCS systems, instrumentation, and controls. IT teams managed the business network. Each operated independently with minimal overlap.

That separation is gone.

  • SCADA systems now communicate with enterprise networks
  • Engineers rely on cloud platforms for real-time visibility
  • Remote support requires secure external access
  • IIoT devices stream live operational data
  • Vendors need controlled access for updates and diagnostics

In today’s connected environment, automation and cybersecurity can’t be handled separately. When they are, vulnerabilities slip through the cracks and attackers take advantage of them.

Operational Risks Are Growing

Industrial cyber incidents have increased sharply in recent years. Modern threats specifically target OT environments and take advantage of weaknesses like:

  • Outdated or unsupported PLCs
  • Poor network segmentation
  • Unpatched engineering workstations
  • Exposed remote-access ports
  • Misconfigured SCADA servers

A single incident can halt production, damage equipment, compromise safety systems, or shut down an entire facility. Integrated cybersecurity protects the systems plants rely on every day.

Why Plants Are Choosing Integrated Automation + IT/OT Security

1. A Unified View of the Entire Operational Ecosystem

Integrated teams provide complete visibility across IT and OT. This includes:

  • Control systems
  • Network communication paths
  • SCADA and historian servers
  • IIoT devices
  • Remote-access routes
  • Data flow across the plant

A unified view makes it easier to assess risks, streamline maintenance, and plan long-term improvements.

2. Reduced Downtime and More Reliable Production

Cybersecurity isn’t just about blocking threats. It’s about keeping production running. An integrated strategy ensures that:

  • Security tools don’t interrupt automation traffic
  • Firewalls are configured with control systems in mind
  • Patch cycles align with production schedules
  • Vulnerability remediation doesn’t cause unnecessary downtime

When automation and cybersecurity work together, plants gain stability and resilience.

3. Stronger Industrial Network Architecture

Modern plants depend on segmented, well-designed networks to protect both IT and OT environments. Integrated teams can build:

  • Proper VLAN segmentation
  • DMZs for data sharing
  • Secure vendor-access tunnels
  • Hardened SCADA and control networks
  • Unified identity and access control
  • Continuous network monitoring

This level of architecture requires combined cybersecurity and automation expertise.

4. Secure SCADA, PLC, and DCS Modernization

When outdated systems are upgraded, cybersecurity has to be part of the process from day one. Integrated modernization includes:

  • Secure firmware and patching plans
  • Hardened controller settings
  • Encrypted communication channels
  • Safe remote-access solutions for OEMs
  • Role-based user access across systems

This creates modern, efficient systems that stay secure long-term.

5. Compliance and Audit Readiness

Many industries are facing stricter compliance requirements. Integrated IT/OT programs help plants prepare for frameworks like:

  • NIST
  • ISA/IEC 62443
  • Critical infrastructure security standards
  • Vendor and customer cybersecurity requirements

A joint team ensures security practices meet compliance standards without disrupting operations.

How Direct Companies Supports Integrated Automation + Cybersecurity

Direct Companies brings automation engineering and IT/OT cybersecurity together under one roof. Our teams collaborate to build secure, unified, and high-performing operational ecosystems.

Our integrated services include:

  • Secure SCADA, PLC, and DCS configuration
  • OT network design and segmentation
  • 24/7 monitoring and threat detection
  • IIoT and edge device security
  • Secure vendor-access solutions
  • Industrial asset inventory and vulnerability management
  • System hardening and patch planning
  • Managed cybersecurity programs tailored for industrial plants

This model supports every stage of your automation environment, from design and deployment to active protection and long-term reliability.

The Future of Industrial Operations Is Connected and Secure

As plants continue adopting advanced automation strategies, integrated cybersecurity isn’t optional anymore. Gains in efficiency, throughput, and visibility depend on systems that are secure and resilient.

Forward-thinking organizations are moving toward unified IT/OT models because separate teams and siloed strategies can’t support today’s connected environments. When automation and cybersecurity work as one, plants gain stability, confidence, and a clear competitive advantage.

Enhance Your IT/OT Security

Optimizing Process Control Systems: A Guide to SCADA and DCS Analysis, Troubleshooting, and Improvement

Posted on by Kyle Davis

Written By Carson Merkwan, Director of Business Development, Direct Companies

In the fast-paced world of industrial automation, maintaining peak performance in Supervisory Control and Data Acquisition (SCADA) and Distributed Control Systems (DCS) is essential for operational efficiency, safety, and profitability. At Direct Automation—a division of Direct Companies—we specialize in helping clients like manufacturing plants and process facilities analyze, troubleshoot, and improve their control systems. This article explores practical strategies for the regulatory control layer, starting with the foundational Proportional-Integral-Derivative (PID) control, while addressing its limitations and advanced alternatives. We’ll also cover instrument specifying and calibration, drawing from real-world plant examples to provide actionable insights.

Whether you’re dealing with a legacy DCS in a chemical plant or a modern SCADA setup in water treatment, the goal is always the simplest effective approach. But as systems grow complex, knowing when to escalate beyond PID becomes critical. Let’s dive in.

Understanding SCADA and DCS: The Backbone of Process Control

SCADA systems excel at wide-area monitoring and data acquisition, often integrating remote sensors and actuators for oversight. DCS, on the other hand, distributes control across localized nodes for tighter, real-time process management—ideal for refineries or power plants. Both rely on layered architectures:

  • Supervisory Layer: High-level alarms, trends, and operator interfaces.
  • Regulatory Control Layer: The “workhorse” where PID loops handle setpoint tracking, disturbance rejection, and stability.
  • Advanced Layers: For multivariable or nonlinear processes, as we’ll discuss.

Effective analysis starts here: Regularly audit your system’s health using built-in diagnostics or third-party tools to spot inefficiencies early.

The Regulatory Control Layer: Mastering PID Control

At its core, PID control is the simplest and most reliable method for regulatory tasks in SCADA/DCS. It calculates an error (difference between setpoint and process variable) and applies:

  • Proportional (P): Immediate response proportional to error magnitude.
  • Integral (I): Accumulates past errors to eliminate steady-state offset.
  • Derivative (D): Predicts future errors based on rate of change, damping overshoot.

Why PID First? It’s robust, tunable with minimal parameters, and handles 80-90% of industrial loops effectively. For example, in a temperature control loop for a reactor, a well-tuned PID maintains setpoint with <1% deviation, reducing energy waste.

Analysis: Assessing PID Performance

Begin with data-driven evaluation:

  1. Trend Review: Plot process variables (PV), setpoints (SP), and controller outputs (OP) over 24-72 hours. Look for oscillations (tuning issue), sluggish response (low gain), or bias drift (integral windup).
  2. Key Metrics: Calculate Integral Absolute Error (IAE) or rise time. Tools like DeltaV Analyze (Emerson) or free open-source options (e.g., Python’s control library) quantify this.
  3. Root Cause Mapping: Use cause-and-effect diagrams to link symptoms (e.g., valve hunting) to sources (e.g., sensor noise).

In a recent Direct Automation project at a Midwest ethanol plant, trend analysis revealed 15% of PID loops oscillating due to unaddressed stiction—leading to a quick 20% efficiency gain post-fixes.

Troubleshooting Common PID Issues

Troubleshooting follows a systematic “S-I-T” method: Stabilize (bypass if unstable), Isolate (test components), Tune (adjust parameters).

  • Oscillations: Reduce proportional gain or add derivative action. Check for deadband in actuators.
  • Offset: Increase integral time; verify setpoint limits.
  • Noise Amplification: Filter PV signals or lower derivative gain.
  • Windup: Enable anti-windup features in your DCS (e.g., Honeywell’s Experion).

Practical Tip: Simulate in software like MATLAB/Simulink before live tweaks—avoiding costly downtime.

The Limits of PID and Advanced Solutions

PID shines in linear, single-variable systems but falters in:

  • Multivariable interactions (e.g., coupled pressure-flow loops).
  • Nonlinearities (e.g., valve saturation or dead zones).
  • Constraints (e.g., rate limits on actuators).

When limits hit, escalate to advanced options—keeping it as simple as needed:

  • Advanced Regulatory Control (ARC): Extends PID with feedforward, gain scheduling, or override logic for constraint handling. Ideal for batch processes; e.g., in a pharmaceutical DCS, ARC prevented overfills by dynamically adjusting gains.
  • Advanced Process Control (APC): Model Predictive Control (MPC) variant for multivariable optimization. Uses dynamic models to forecast and adjust multiple loops simultaneously—boosting throughput by 5-15% in refineries. Tools like AspenTech’s DMC3 integrate seamlessly with DCS.
  • Fuzzy Logic: Rule-based for imprecise, nonlinear scenarios (e.g., level control in surge tanks). If-then rules mimic human intuition: “If error is high AND rate is slow, THEN boost output aggressively.” Simpler than neural nets, it’s great for legacy SCADA upgrades.

Choose based on complexity: Start with ARC for single enhancements; scale to APC for enterprise-wide gains. Direct Automation assesses ROI—often, a hybrid PID+ARC yields 90% of APC benefits at 30% the cost.

Instrument Specifying and Calibration: The Foundation of Reliable Control

No control system outperforms its instruments. Specifying and calibrating them correctly prevents 40% of loop failures.

Specifying Instruments

  • Match to Process: Select based on range, accuracy (e.g., ±0.5% for flow meters), and environment (e.g., IP67 for hazardous areas).
  • Key Criteria: Response time (< process dynamics), turndown ratio (>10:1 for valves), and compatibility (e.g., HART protocol for DCS integration).
  • Example: For a high-pressure gas line, specify a Coriolis meter over orifice for better nonlinearity handling.

Use standards like ISA-5.1 for symbols and specs to ensure interoperability.

Calibration Best Practices

  • Frequency: Annual for critical loops; use as-found/as-left checks.
  • Methods: Dry-block calibrators for thermocouples; live zeroing for transmitters.
  • Traceability: NIST-certified standards; automate with tools like Fluke 754.
  • Troubleshooting: If calibration drifts, inspect for fouling or EMI—common in SCADA field devices.

In our training, we simulate calibration errors to show how a 2% drift cascades into 10% PID instability.

Improvement Strategies: From Analysis to Implementation

Holistic improvement loops back to data:

  1. Benchmark: Compare against industry KPIs (e.g., <5% loop variability).
  2. Implement: Stage changes—test in simulation, then shadow mode.
  3. Monitor: Post-tune audits with KPIs like Mean Time Between Failures (MTBF).
  4. Scale: Integrate with IIoT for predictive analytics.

A Direct Automation client in Sioux Falls saw 25% reduced variability after PID tuning plus ARC on 20 loops—translating to $150K annual savings.

Training: Hands-On Mastery with Real-World Tools

Empower your team with targeted training. Direct Automation offers:

  • Free In-House Tools: Custom Python scripts and Excel-based tuners for quick PID analysis.
  • Commercial Options: Courses on Rockwell’s RSLogix, Siemens’ PCS 7, or Emerson’s DeltaV—using licensed simulators.
  • Curriculum: Built from plant examples (e.g., troubleshooting a fuzzy logic floodgate in a wastewater SCADA), research (ISA papers), and industry feedback. Practical examples demystify concepts; instructors run live simulations so participants tweak parameters and witness outcomes—like stabilizing a chaotic pH loop in real-time.

Sessions are flexible: On-site or virtual, 1-3 days, tailored to your DCS/SCADA vendor. Graduates report 30% faster issue resolution.

Partner with Direct Automation for Superior Control

At Direct Companies, our Direct Automation team is led by Brent Steven, Director of Automation, who brings deep technical expertise in process control and industrial automation. Brent and his team have helped clients across ethanol, energy, and manufacturing industries achieve measurable improvements in SCADA and DCS environments, driving greater efficiency, reliability, and compliance.

This article was authored by Carson Merkwan, Director of Business Development at Direct Companies, who works directly with plant leaders to assess challenges and connect them with the right technical solutions. You can reach Carson directly at 1-605-464-1667.

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