21cb087a-facb-433b-87e8-9526a3d2e24f20230926035835570wseas:wseasmdt@crossref.orgMDT DepositWSEAS TRANSACTIONS ON SYSTEMS AND CONTROL2224-28561991-876310.37394/23203http://wseas.org/wseas/cms.action?id=40731220231220231810.37394/23203.2023.18https://wseas.com/journals/sac/2023.phpEfstathiosTheocharisDeptartment of Industrial Design and Production Engineering, University of West Attica, Thivon 250 & P. Ralli, Egaleo, GREECEMichailPapoutsidakisDeptartment of Industrial Design and Production Engineering, University of West Attica, Thivon 250 & P. Ralli, Egaleo, GREECEAndrewShortDeptartment of Industrial Design and Production Engineering, University of West Attica, Thivon 250 & P. Ralli, Egaleo, GREECEKonstantiaZisimouProgramming Teacher in a High School, 10th Gymnasio Nikaias, Artemidos 25, Nikaia, GREECEIncreasing requirements in automation and production make control systems more complex and vulnerable to failure. Breakdowns can cause delays in production, material damage, and above all, work-related accidents. For this reason, directives and legislation have been created at the country, European Union, and global levels that define the essential safety and requirements of industrial equipment. Guidelines must be observed by those involved in the design, supply, purchase, or use of industrial equipment in the European Union and several countries outside the European Union. Some guidelines (CAT, SIL) are created to ensure their safe operation in case of failure of both the hardware and the software. For a reliable operation of a fail safety system together with a system operating at SIL2 or SIL3, it must have Safety hardware and software. Industrial equipment manufacturers are incorporating security features into a variety of devices. Depending on the Safety Integrity Level (SIL) requirements, these features can be used during the design phase to increase safety in the event of failures or malfunctions. With proper design, the process as well as its environment (including people) can be protected by entering a controlled safe state. Manufacturers have approached this problem in a number of ways, including adding redundant Central Processing Units (CPUs), using special hardware to interface input and output signals, and developing secure network protocols for communication. Unfortunately, these features cannot be added to existing machines, at least without upgrading some hardware. As the associated costs lead to slower adoption, manufacturers rely on previous work to support certain security features, notably CPU debugging. This is implemented in the form of software libraries that operate at a low level (logic gate), designed to run on older hardware (PLC) so that they can offer an increased level of security. This study analyzes the required guidelines and legislation that must be followed for the safe operation of a production unit. It describes the mechanisms that basic and specialized PLC systems utilize to ensure the safety of an automation system. The authors have developed algorithms to record behavior measurements of electronic equipment. By further analyzing the results, it is concluded that basic equipment can be reused in these systems to provide safety functions, at the same time conserving both cost and time.9262023926202328329328https://wseas.com/journals/sac/2023/a565103-1274.pdf10.37394/23203.2023.18.28https://wseas.com/journals/sac/2023/a565103-1274.pdf10.1007/s00202-017-0624-1K. Rástočný, J. Ždánsky, J. Balák and P. Holečko;, "Effects of diagnostic on the safety of a control system realised by safety PLC", vol. 7512118, 2016. 10.1007/978-3-319-33693-0_32Dániel Darvas, István Majzik and Enrique Blanco Viñuela, "Formal Verification of Safety PLC Based Control Software", Springer, vol. 9681, 2016. 10.1109/sice.2007.4421408Hiroo Kanamaru, Tsuyoshi Mogi and Naoki Aoyama, "Functional safety application using safety PLC", SICE Annual Conference, vol. 4421408, pp.2489-2492, 2007. Rástočný, J. Ždánsky and K., "Influence of safety PLC parameters to response time of safety functions", in International Conference on Applied Electronics, 2013. Allen Bradley, "literature.rockwellautomation.com," [Online]. Available: https://literature.rockwellautomation.com/idc/gr oups/literature/documents/um/1756-um523_-enp.pdf. [Accessed 12 2021]. 10.1093/law:epil/9780199231690/e1887International Standardization Organization, "www.iso.org," Standardization, International Organization, 12 2015. [Online]. Available: https://www.iso.org/standard/69883.html. [Accessed 12 2021]. International Electrotechnical Commission, "International Electrotechnical Commission (IEC) 60050-114:2014/AMD1," 2017. International Electric Components Standard, "webstore.iec.ch," 17 02 2017. [Online]. Available: https://webstore.iec.ch/publication/59985. [Accessed 12 2021]. 10.3311/ppee.9051Attila Hilt, Gabor Jaro amd Ostvan Bakos, "Availability Prediction of Telecommunication Application Servers Deployed on Cloud P", Periodica Polytechnica, Electrical Engineering, DOI: 60.72-81.10.3311/PPee.9051., 2016. 10.30929/2307-9770.2022.10.04.02SIEMENS, "Siemens S7-1500 Technical Slides," SIEMENS, 2019. [Online]. Available: https://assets.new.siemens.com/siemens/assets/ap i/uuid:8ad3e246-011b-4206-aa85- 1ec60aac51ac/version: 1562856005/simatic-s7- 1500-redundant-systems--techslides-2018-11-12- en.pdf. [Accessed 05 2022]. Schneider-electric, "https://download.schneiderelectric.com," Schneider-electric, 11 12 2018. [Online]. Available: Redundant Control and Communication for Power Control Systems (whitepaper) - https://download.schneiderelectric.com/files?p_enDocType=White+Paper& p_File_Name=asc-pcm-wp-redundantcontrol.pdf&p_Doc_Ref=PCM-WP-REDCONT. [Accessed 6 2023]. Nguyen Tuan Hung and Truong Dinh Chau, "An Application Solution for PLC Redundancy in Distributed Control System", International Symposium on Industrial Electronics, 2011. 10.1109/sofa.2009.5254867G. Gabor, D. Zmaranda, C. Gyorodi and S. Dale, "Redundancy method used in PLC related applications", 3rd International Workshop on Soft Computing Applications, DOI: 10.1109/SOFA.2009.5254867., pp.119-126, 2009. 10.1109/tns.2010.2103325D. J. Rankin and J. Jiang, "A Hardware-in-theLoop Simulation Platform for the Verification and Validation of Safety Control Systems"," IEEE Transactions on Nuclear Science , vol. 58, pp.468-478, 2011. 10.1007/978-3-319-33693-0_32D. Darvas, I. Majzik and E. Blanco Viñuela, "Formal Verification of Safety PLC Based Control Software," Integrated Formal Methods, vol. 9681. V.A. Gapanovich, E.N. Rozenberg and I.B. Shubinsky, "Some Concepts of Fail-Safety and Cyber Protection of Control Systems", DOI: 10.21683/1729-2646-2014-0-2-88-100, 2014. 10.1109/elektro.2018.8398311J. Ždánsky and J. Valigurský, "Application diagnostic of distributed control system with safety PLC", ELEKTRO, DOI: 10.1109/ELEKTRO.2018.8398311, pp.1-6, 2018. IEC Standards, "webstore.iec.ch," 30 4 2010. [Online]. Available: https://webstore.iec.ch/publication/5517. [Accessed 3 2023]. Heidi Hartmann, Dr. Eric Scharpf and Hal Thomas, "Practical SIL Target Selection - Risk Analysis per the IEC 61511 Safety Lifecycle", ISBN: 978-1-934977-03-3. 10.37394/23203.2020.15.74E. Theocharis, M. Papoutsidakis, A. Sort and C. Drosos, "Experimentation on the Electromechanical Behavior of Automation Safety Buttons Applied to an Industrial PLC" WSEAS Transactions on Systems and Control, ISSN / E-ISSN: 1991-8763 / 2224-2856, Volume 15, 2020, Art. #74, DOI: 15. 10.37394/23203.2020.15.74, 2021. Mitsubishi Electric, 01 2008. [Online]. Available: http://dl.mitsubishielectric.com/dl/fa/document/c atalog/plc/l08117eng/l08117enga.pdf. [Accessed 2023 07]. 10.1016/j.jlp.2016.09.020Feng Wang, Ou Yang, Ruibo Zhang and Lei Shi, "Method for assigning safety integrity level (SIL) during design of safety instrumented systems (SIS) from database”,", Loss Prevention in the Process Industries, 2016. D. Smith and K. Simpson, The Safety Critical Systems Handbook”, Elsevier Ltd, ISBN: 9780128207000., 2011 . 10.1109/ki48306.2020.9039878K. Rástočný, J. Ždánsky and J. Hrbček, "The Problems Related to Realization of Safety Function with SIL4 Using PLC", Cybernetics & Informatics (K&I), DOI: 10.1109/KI48306.2020.9039878, pp.1-5, 2020. 10.23919/ae.2018.8501425J. Ždánsky and J. Valigurský, "Time response of safety function realised by decentralised SRCS with safety. PLC", International Conference on Applied Electronics (AE), DOI: 10.23919/AE.2018.8501425, pp.1-4, 2018. 10.1109/mie.2012.2207815G. Buja and R. Menis, "Dependability and Functional Safety: Applications in Industrial Electronics Systems", IEEE Industrial Electronics Magazine, vol. 6, pp.4-12, 2012. 10.1109/hst47167.2019.9032992Abdullah Al Farooq Jessica Marquard, Kripa George and Thomas Moyer, "Detecting Safety and Security Faults in PLC Systems with Data Provenance", IEEE International Symposium on Technologies for Homeland Security, 2019. plcopen.org, "https://plcopen.org," 2018. [Online]. Available: https://plcopen.org/system/files/downloads/ plc open_safety_part_1_version_2.01.pdf (Accessed 12/2021). [Accessed 01 2022]. 10.1109/elektro49696.2020.9130307M. M. a. J. Ždánsky, "Safety PLC Programming Based on UML Statechart," ELEKTRO, DOI: 10.1109/ELEKTRO49696.2020.9130307, pp.1-5, 2020. 10.1016/j.ress.2004.07.019Younju Oh, Junbeom Yoo, Sungdeok Cha and Han Seong Son, "Software safety analysis of function block diagrams using fault trees, Reliability Engineering & System Safety", vol. 88, no. 3, pp.215-228, 2005.