Introduction to Operational Technology
Table of Contents
What is Operational Technology – An Overview
Components of Operational Technology
What is OT Protocol? : Key Communication Protocols
Importance of Operational Technology & Applications of OT
Difference between OT & IT: Comparing OT, IT, IoT, and IIoT
Future of Operational Technology
What is Operational Technology – An Overview
The term “operational technology” (OT) refers to a grouping of hardware and software systems that interact with the physical world. They are used to monitor or control the physical devices, processes, and infrastructure that are used in various industrial settings such as transportation, energy, manufacturing, and utilities. The best Operational Technology explanation is that OT systems are made up of interconnected control components that work collectively to accomplish a specific objective. These components of operational technology are divided into two main parts – the process and the controller. The process is part of the system that is responsible for generating output, while the controller is dedicated to ensuring that the system complies with established specifications.
Operational Technology has gradually advanced over a period of time with a desire to combine IT capabilities into physical systems which replace or supplement the existing physical control components. Improvements in cost and performance have resulted in the evolution of OT with technologies such as smart transportation, smart buildings, and the Internet of Things (IoT). This evolution reflects a growing desire to integrate digital and physical systems for greater efficiency and effectiveness.
Components of Operational Technology
OT consists of various components, and each one of these components plays an important role in controlling and monitoring industrial processes. ICS (Industrial Control Systems) are the components of operational technology that refer to systems that are used to control and monitor industrial processes such as manufacturing, energy production, and transportation. ICS includes the use of sensors, Programmable Logic Controllers (PLC), Distributed Control Systems (DCS), Human Machine Interfaces (HMI), and other hardware and software components. These components of operational technology are explained below.
Programmable Logic Controllers (PLC)
These are specialized computers used in industrial automation and control systems. As one of the types of operational technology, PLCs are engineered to function reliably under challenging environmental conditions, including extreme temperatures and exposure to moisture, dust, and other contaminants. It comes with features such as shock and vibration resistance and can stand against dust, moisture, and extreme temperatures. They are programmable and flexible and hence can be customized for different industrial needs. PLCs consist of a central processing unit (CPU), input/output (I/O) modules, memory, and communication ports. The CPU executes the control program stored in memory, and the I/O modules are responsible for interfacing with the external sensors and actuators. PLCs are used to automate processes such as a manufacturing plant’s assembly line, robotic machines, conveyor belts and wastewater treatment plants, and much more.
Distributed Control Systems (DCS)
A distributed control system (DCS) is an industrial control system that is specifically engineered with control elements dispersed across a plant or control area. It is one of the types of operational technology control systems used in industrial automation and process control applications. A distributed control system (DCS) utilizes dedicated controllers to manage each process element, machine, or group of machines in multiple sections of a plant’s control area. These local controllers are interconnected via a high-speed communication network.
DCS is ideal for complex, continuous process industries requiring real-time control and monitoring of multiple variables. These systems are built to handle large amounts of data, control multiple processes at the same time, and give operators a comprehensive view of the entire process. The main advantage of DCS is it can operate in redundancy. If one controller fails, the other will take over. They typically include features such as advanced control algorithms, data logging, alarm management, and diagnostic tools and other OT security tools. DCS has been extensively used in many industrial sectors, such as petrochemical plants, oil and gas industries, nuclear power plants, water management systems, and other critical infrastructures.
SCADA (Supervisory Control and Data Acquisition) systems
A SCADA system employs software and hardware components to facilitate the automation of industrial processes by capturing real-time data from operational Technology. This type of operational technology system links the sensors monitoring equipment such as pumps, motors, and valves to an offsite or onsite server. SCADA consists of components such as sensors and other data acquisition devices, a programmable logic controller (PLC) or Remote Terminal Unit (RTU), a supervisory computer, and communication networks. The sensors and data acquisition devices collect data from the physical processes, while the PLC or RTU processes this data and sends it to the supervisory computer. The supervisory computer is responsible for monitoring and controlling the process by sending commands to the PLC or RTU. They provide real-time data on the process parameters, including temperature, pressure, flow rate, and other variables, and can also issue alarms if any of these parameters go beyond their normal range. SCADA systems can also be used to generate reports and provide data for analysis, which can be used to optimize the operation of the industrial process.
HMI (Human-Machine Interface)
HMI software is typically used to create a visual representation of the ICS system, which can include displays of real-time data, control panels for operating the system, and alarms and notifications for monitoring and troubleshooting. The HMI is designed to make it easy for operators to monitor the status of the industrial process and to control and adjust the system as needed. The HMI can also provide tools for data analysis and reporting, which can help operators to optimize the performance of the industrial process.
What is OT Protocol? : Key Communication Protocols
Various communication protocols are used in operational technology (OT) environments to facilitate data exchange between devices and systems. Some of the most widely used protocols in OT settings are:
Modbus:Â Modbus is a popular serial communication protocol used to connect electronic devices, particularly in industrial automation applications. It enables the communication between a master device and multiple slave devices over an operational technology network.
The Modbus TCP/IP variant extends the functionality of the original Modbus protocol and allows for more efficient and versatile communication between devices in industrial automation systems.
DNP3 (Distributed Network Protocol):Â DNP3 is primarily used in the utility industry for supervisory control and data acquisition (SCADA) systems. It facilitates communication between controllers, remote terminal units (RTUs), and intelligent electronic devices (IEDs).
IEC 61850:Â This protocol is designed specifically for electrical substation automation and power system protection. It enables communication and interoperability between various devices in a substation.
EtherCATÂ (Ethernet for Control Automation Technology): EtherCAT is an industrial Ethernet protocol that offers high-speed, real-time communication for automation systems. It is widely used in motion control, robotics, and other high-performance applications.
PROFIBUS (Process Field Bus):Â PROFIBUS is a widely adopted field bus communication protocol used in process automation and manufacturing. It enables the communication between devices such as PLCs, sensors, and actuators on the factory floor.
PROFINET (Process Field Network):Â PROFINET is an industrial Ethernet-based protocol designed for real-time data exchange in automation systems. It is the successor to PROFIBUS and offers greater flexibility, speed, and performance.
OPC-UA (Open Platform Communications-Unified Architecture):Â OPC-UA is a platform-independent, service-oriented architecture that provides a unified approach to data exchange and communication between devices and systems in industrial automation.
Importance of Operational Technology & Applications of OT
Operational Technology (OT) has a wide range of applications in various industrial sectors. Let us see some of the examples here.
Manufacturing
OT is widely used in the manufacturing industry to control and automate the production process. OT systems are used to control assembly lines, robots, to monitor and control temperature, humidity, and other process parameters.
Transportation
OT systems are used to control and monitor transportation infrastructure, such as traffic signals, toll gates, and railway systems. They are also used in aviation and marine transport systems to control and monitor navigation, fuel management, and other critical systems.
Energy
OT is used in the energy industry to control and monitor power generation, transmission, and distribution systems. OT systems are used to monitor and control the flow of electricity, gas, and oil and to ensure the reliability and stability of the power grid.
Utilities
OT systems are used in water treatment plants, waste management systems, and other utilities to control and monitor the distribution and management of resources. They are also used to monitor and control the quality of water, air, and other environmental factors.
Healthcare
There is great importance of operational technology in the healthcare industry too. OT is used in healthcare to control and monitor medical devices, such as imaging equipment and patient monitoring systems. OT systems are also used in hospital facilities to control and monitor environmental factors, such as temperature and humidity.
Difference between OT & IT: Comparing OT, IT, IoT, and IIoT
The key difference between OT & IT is that Operational Technology deals with physical devices, while IT (Informational Technology) deals with information and data. OT systems typically use specialized hardware and software designed for industrial control systems, such as PLCs, HMIs, and SCADA systems. IT systems, on the other hand, use general-purpose hardware and software such as servers, desktops, and laptops, and use operating systems and software designed for office environments.
This is the primary difference between OT and IT.
The Internet of Things (IoT)Â involves connecting tangible objects to the Internet, allowing them to communicate and exchange data with other devices, services, and systems. The difference between IoT and OT is that IoT technology has numerous applications across various industries and can be utilized to enhance functionality and efficiency in a variety of contexts. Applications include common household things like lightbulbs, smart devices, smart cities, healthcare assets, and much more. Some applications have their own apps. These IoT-enabled devices are connected to and receive and transfer data over wireless IT networks, potentially with the help of a data center, with limited human intervention.
Industrial Internet of Things (IIoT)Â refers specifically to the use of IoT technologies in industrial settings. IIoT involves connecting sensors, machines, and other industrial equipment to the internet to enable real-time monitoring and control of industrial processes. One of the most significant advantages of the IIoT is that it enables greater visibility and control over industrial processes, even in remote or difficult-to-access locations.
Future of Operational Technology:
The future of Operational Technology (OT) is promising, with several emerging trends and innovations that are set to transform industrial Technology. Here are some of the key trends and predictions for the future of OT.
Industrial Internet of Things (IIoT)
The IIoT is a network of connected devices, sensors, and machines that can communicate with each other and share data in real time. This will enable companies to collect and analyze vast amounts of data, leading to improved efficiency, reduced downtime, and enhanced predictive maintenance.
Artificial Intelligence (AI) and Machine Learning (ML)
AI and ML will play a significant role in OT, enabling systems to make real-time decisions based on data analysis, leading to improved process efficiency and automation.
Cloud Computing
Cloud-based OT systems will become more prevalent, allowing companies to store and process large amounts of data in a secure and scalable environment.
Cybersecurity
As the threat of OT attacks on systems increases, there will be a growing focus on cybersecurity in the OT space. This will lead to increased investment in security technologies and training for OT professionals.
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