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Hybrid Posi cast - based PID - PDA Control Using System Identification for Continuous Tunnel Kilns
(2026-06-30)
Pannil, Pittaya
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Sungsorn, Teenapong
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Trisuwannawat, Thanit
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Julsereewong, Amphawan
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Thepmanee, Teerawat
This paper proposes a hybrid Posicast-based proportional-integral-derivative with proportional-derivative-acceleration (PID-PDA) controller for temperature regulation in delay-dominant continuous tunnel kilns. The controller is developed based on a system-identified second-order-plus-dead-time (SOPDT) model derived from industrial data and implemented in discrete time for programmable logic controllers (PLCs). A unified framework enables comparison with a standard PLC-based proportional-integral (PI) controller, an internal model control (IMC)-tuned PI controller, and a Smith Predictor-PI controller under identical conditions. Simulation results demonstrate faster response, negligible overshoot, and reduced tracking error, with improved settling time and lower, integral of absolute error (IAE), integral of squared error (ISE), and integral of time-weighted absolute error (ITAE), while maintaining comparable control effort. Robustness analysis confirms stable performance under plant perturbations, with IAE variations within approximately ± 10 (servo) and ± 1 (disturbance). The controller is validated on an Allen-Bradley PLC in a silicon controlled rectifier (SCR)-based heating system. Experimental results show improved steady-state performance, including reduced bias, lower mean absolute error (MAE) and root mean squared error (RMSE), reduced oscillation amplitude, and compliance within the ± 1 temperature band. The proposed approach provides a practical, robust, and high-performance solution for upgrading existing PLC-based systems without hardware modifications.
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AN OPEN-SOURCE INTRUSION DETECTION AND NOTIFICATION FRAMEWORK FOR OT ATTACKS TARGETING S7-SERIES PLCS
(2026-06-01)
Smerpitak, Krit
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Saleethong, Chayangkun
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Suphapod, Tanawat
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Wongkharn, Siripong
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Julsereewong, Amphawan
This article presents an open-source intrusion detection and notification (IDN) framework designed to detect attacks targeting Siemens S7-series programmable logic controllers (PLCs) in operational technology (OT) environments. The framework is validated using a simulated weight-based sorting system developed in Factory I/O, with TIA Portal control programs deployed on S7-300, S7-1200, and S7-1500 PLCs. Suricata serves as the core intrusion detection engine, while the Elasticsearch, Logstash, and Kibana (ELK) stack and LINE Notify are integrated to visualize alerts and provide realtime operator notifications. Simulated attacks are carried out using Snap7 to interact with each PLC during live process operations. The experimental results show that the framework reliably detects intrusions across all tested S7 PLC models and delivers timely alerts, demonstrating its effectiveness for real-time monitoring and incident response. In contrast to previous studies that focus primarily on protocol analysis or on individual PLC types, this work offers a practical and scalable intrusion detection solution validated on real hardware and designed to accommodate the coexistence of legacy and modern controllers within OT systems.
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Toward Interoperable SCADA: Node-RED-Based Edge Integration of Heterogeneous PLCs and IoT Devices
(2025-01-01)
Smerpitak, Krit
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Kaewchaiwong, Sattachai
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Ukakimaparn, Prapart
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Julsereewong, Amphawan
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Pongswatd, Sawai
This article presents a novel approach to supervisory control and data acquisition (SCADA) design that emphasizes interoperability through edge integration, using Node-RED as an open-source programming platform deployed on an industrial edge computer. The proposed architecture integrates multiple-vendor programmable logic controllers (PLCs) and an Internet of Things (IoT) gateway at the edge layer to enable seamless interoperability across local control systems. A lab-scale case study demonstrates the feasibility of this integration, featuring four remote terminal units (RTUs) communicating concurrently with a SIMATIC IPC327G edge computer via standard protocols. Specifically, a SIMATIC S7-1200 (RTU-1), MELSEC iQ-F FX5U (RTU-2), and CompactLogix 1769-L30ER (RTU-3) control an object sorting station, a parcel sorting station, a water temperature control station, respectively, while a UG65 gateway (RTU-4) enables bidirectional data transfer between the edge computer and LoRaWAN devices. The inclusion of InfluxDB alongside Node-RED supports data logging and reporting functionalities. By distributing protocol translation, data processing, and shop-floor supervisory control to the edge layer, the architecture achieves real-time, vendor-neutral data orchestration while maintaining compatibility with a higher-level SCADA master terminal unit (MTU) or cloud system. Experimental results from both functional and performance testing confirm the system’s viability as a cost-effective, vendor-agnostic solution for modern industrial automation, offering a scalable model for multi-protocol industrial environments.
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FUNCTION BLOCK IMPLEMENTATION OF PROPORTIONAL-INTEGRAL-DERIVATIVE GAIN SCHEDULING ON DISTRIBUTED CONTROL SYSTEM MODELED CENTUM VP
(2024-12-01)
Thepmanee, Teerawat
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Pedyod, Chalermpon
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Julsereewong, Amphawan
This article presents an engineering technique to practically implement a gain scheduling for a proportional-integral-derivative (PID) control loop, which consists of software function blocks executing in an industrial distributed control system (DCS) modeled CENTUM VP. The main feature of the proposed technique is to use a standard graphical language of function block diagram, which supports simplicity and reality for industrial applications. The implementation of the PID loop with gain scheduling by using regulatory control blocks and calculation blocks is described. The proportional band, integral time, and derivative time of the PID control block are continuously adjusted with a scheduling variable, which is selectively set to be the manipulated output value, setpoint value, process variable, control deviation value, or other measured variables. Based on a virtual test function of the DCS, simulation results of the PID loops with/without gain scheduling to control a simulated first-order plus time-delay process are included to demonstrate the performance of the implemented gain scheduler. Compared with the PID block with constant tuning parameters, the PID block with varying tuning parameters can provide better stability and performance of setpoint tracking.
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Family of Fibonacci-Type Marx Generators with a Single Inductor in a Three-Phase Configuration
(2024-01-01)
Eguchi, Kei
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Ishibashi, Takaaki
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Julsereewong, Amphawan
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Thepmanee, Teerawat
High-voltage discharge applications have seen a widespread adoption of solid-state Marx generators (SSMGs) in recent years. In this paper, we propose a new hybrid solid-state Marx generator (HSSMG) with a single inductor. Through the application of a three-phase Fibonacci scheme, the HSSMG is capable of achieving a substantial increase in voltage output. Furthermore, the proposed HSSMG is able to generate high voltage efficiently with fewer components. The integration of the Fibonacci and boost modules is a crucial idea in the proposed technique, where the boost module increases the output voltage of the Fibonacci module to achieve higher output voltage. Regarding the proposed two-stage HSSMG, the theoretical feasibility of the proposed topology is confirmed by theoretical analysis and Simulation Program with Integrated Circuit Emphasis (SPICE) simulations. As a result of comparative analysis, it was found that the number of circuit components of the proposed two-stage HSSMG is approximately half that of the traditional SSMG. Moreover, the newly suggested two-stage HSSMG accomplishes more than 86% power efficiency at 5 W.
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DIAGNOSTIC DATA-BASED SAFETY AND AVAILABILITY ENHANCEMENTS FOR AN ALTERNATIVE OF FEEDFORWARD CONTROL USING FOUNDATION FIELDBUS
(2023-06-01)
Sittigon, Jirasak
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Suwanmanee, Ittimon
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Ukakimaparn, Prapart
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Julsereewong, Amphawan
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Kummool, Sart
To enhance plant safety and production availability in case of transmitter failures for an alternative of Foundation Fieldbus (FF)-based feedforward control, this article proposes a practical technique for configuring control strategy using function block diagram concept. The proposed configuration technique is based on fault diagnostic data automatically accessed from FF transmitters to take actions for operating the studied FF-based control loop that utilizes a Bias/Gain (BG) function block to build feedforward summing function outside of a proportional-integral-derivative (PID) function block. The minor 'Uncertain' problem can be treated as severe 'Bad' problem to increase the safety of the control loop. On the other hand, the 'Uncertain' status can be configured to be treated as 'Good' status to improve the availability of the control loop. Six options for configuring function blocks to operate the temperature control performed at the DeltaV host system are described as a case study to demonstrate the workability of the proposed technique. Experimental results of the alternate feedforward control loop configured with different parameter options confirm that the diagnostic data provided by the transmitters used are very useful for implementing either the interested control loop with increased safety or the interested control loop with increased availability. Therefore, the user can strike a balance between safety and availability for the FF-based feedforward control utilizing BG function block.
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Design of step grate firing by utilizing palm empty-fruit-bunch fuel for industrial steam boiler construction
(2022-04-01)
Srasri, Supphachai
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Bhudsarakam, Niran
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Limsutthiphong, Pornchai
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Ratanapitag, Tanapat
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Julsereewong, Amphawan
To achieve desired performance of steam boiler and low emission of hazardous air pollutants for generating electric power from palm oil industry, combustion characteristics of grate firing should be optimal for difficult biomass fuels. This article aims to present a design of step grate firing with high thermal efficiency for combustion of selected palm empty fruit bunch (EFB) fuel with moisture content of 38.4% and ash content of 3.39%. The proposed grate firing is not only specially designed for continuous 3-month operation but also particularly suited to construction of an industrial boiler rated at 80 tons/h, 45 bar, and 430 °C. The reciprocating step grate as well as air distribution for optimized combustion characteristics is specified based on computational fluid dynamics (CFD) analysis and practical experience. The required boiler can be successfully constructed and smoothly operated by installing the designed step grate firing as part of a whole system at a biomass power plant in Thailand.
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PFD analysis of LNG fuel gas supply system for improving combined-cycle power plant safety
(2022-04-01)
Thepmanee, Teerawat
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Julsereewong, Amphawan
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Pongswatd, Sawai
In order to determine an unavailability of each safety function subsystem that influences on an overall unavailability of entire protection system for safety analysis and enhancement, a modeling is required. This article presents a safety system modeling to evaluate the detected–undetected failures and repairable behaviors of each safety function subsystem in the studied fuel gas supply system (FGSS), which is utilized in a combined-cycle power plant. The proposed modeling deals with probability of failure on demand (PFD) analysis for calculation of the unavailability of three safety function subsystems, which are gas analytical subsystem (GAS), fuel gas controller subsystem (FGC), and shutdown valve subsystem (SDV). The interested GAS includes two different groups of gas analyzers in 2-out-of-2 (2oo2) voting scheme, when using three gas analyzers in each group in 2-out-of-3 and diagnosis (2oo3D) voting scheme. The interested FGC consists of two controllers in 2oo2 voting scheme, when the structure of each controller is in 1-out-of-1 and diagnosis (1oo1D) voting scheme. The interested SDV consists of two shutdown valves, which are installed in 1-out-of-2 (1oo2) voting scheme. The reliability block diagram is utilized for representative of combination of all three safety function subsystems, and the fault tree is utilized for calculation of PFD unavailability of each safety function subsystem. As the results obtained from the proposed safety function modeling, the influence of three safety function subsystems on the total unavailability of the FGSS is described. In addition, an example of the proposed modeling application to provide two guidelines for effective engineering design and operation is also presented. The first is a guideline to implement an effective human machine interface (HMI) at an operator workstation for real-time monitoring of the studied FGSS in the presence of failures that can be automatically detected by device diagnosis. The latter is a guideline to maintain and troubleshoot the failures that can be revealed by proof test. Based on diagnostic information and proof test results, operation and maintenance savings can be achieved.
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AVAILABILITY THROUGH FIELD DEVICE DIAGNOSIS IN FEEDFORWARD CONTROL: A CASE STUDY OF FOUNDATION FIELDBUS-BASED TEMPERATURE CONTROL
(2022-02-01)
Kummool, Sart
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Suwanmanee, Ittimon
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Weerathaweemas, Songchai
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Julsereewong, Amphawan
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Sittigorn, Jirasak
For endusers, requiring an action to enable a fieldbus-based process control that is not hazardous to continue its operation in the event of transmitter failures, it is essential to understand how diagnostic capability of field instruments is helpful in availability enhancement. In order to effectively implement a feedforward control strategy with increased availability, this article presents a control configuration method when utilizing a Foundation Fieldbus (FF)-based temperature feedforward control as an illustrative case study. Four function block assignment options for configuring the studied control strategy during engineering phase are described. The ‘Uncertain’ measurement status provided by temperature transmitters is treated as ‘Good’ measurement status in all control configuration options for availability goal by reducing process downtime. In addition, based on experimental results, a simplified Petri net model for logical behavior representation of the interested FF-based feedforward is also proposed.
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Safety enhancement for basic process control using 4-20 milliampere signal transmission
(2021-08-01)
Julsereewong, Amphawan
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Muangmool, Phongphiphat
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Thepmanee, Teerawat
To enhance safety of basic process control using traditional 4-20 mA current loops with/without transmitting a return signal of actual actuator position back to a host, this article presents a useful technique to provide fault-state and fault-recovery actions in four patterns. The proposed technique is a design of control drawings configured in a distributed control system (DCS) host for conventional proportional-integral-derivative (PID) loops with/without feedforward path to improve actions of the control loops in response to sensor and actuator failures. The configuration design based on functions of failure status propagation and failure mode shedding for eight control drawings that contain software function blocks for running on the DCS host modeled CENTUM VP is described. Simulation results by employing the DCS virtual test function verify that all designed control drawings can successfully perform the desired fault-state and faultrecovery actions for process safety enhancement.

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