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How SCADA Systems Work?.

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Substation Automation (S.A) System Project Supervisor: Stuart Wildy.

An Introduction to SCADA Fundamentals and Implementation Supervisory Control And Data Acquisition.

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Introduction to SCADA

SCADA is an acronym that stands for Supervisory Control and Data Acquisition . SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data.

SCADA systems are used not only in industrial processes: e.g. steel making, power generation (conventional and nuclear) and distribution, chemistry, but also in some experimental facilities such as nuclear fusion. The size of such plants range from a few 1000 to several 10 thousands input/output (I/O) channels. However, SCADA systems evolve rapidly and are now penetrating the market of plants with a number of I/O channels.

Table of Contents

Definition of SCADA

A collection of equipment that will provide an operator at remote location with enough information to determine the status of a particular piece of a equipment or entire substation and cause actions to take place regarding the equipment or network.

What is SCADA?

How : By collecting Information from plant / Load center bend reducing it to the EMS (Power systems in electrical).

Where : Control Centre. Both at Plant and Load

Why : To gather Information as here (voltage, current, frequency, power, circuit breaker status) and To perform online actions.

SCADA systems are used to monitor or to control chemical or transport processes in municipal water supply systems, to control electric power generation, transmission and distribution, gas and oil pipelines, and other distributed processes. Supervisory control and data Acquisition (SCADA) achieves this requirement collecting reliable field data through remote terminal units (RTUs) Intelligent Electric Devices (IEDs) and presenting them to user requirement.

The user interface or the man machine interface (MMI) provides various options of data presentation according to specific application and user needs. There are many parts of a working SCADA system.

SCADA Graphics

Image courtesy : sielcosistemi

A SCADA system usually includes signal hardware (input and output), controllers, networks, Human Machine interface (HMI), communications equipment and software. All together, the term SCADA refers to the entire central system. The central system usually monitors data from various sensors that are either in close proximity or off site.

An industrial measurement and control system consisting of a central host or master (usually called a master station, master terminal unit or MTU); one or more field data gathering and control units or remotes (usually called remote stations, remote terminal units , or RTU’s); and a collection of standard and/or custom software used to monitor and control remotely located field data elements. Contemporary SCADA systems exhibit predominantly open-loop control characteristics and utilize predominantly long distance communications, although some elements of closed-loop control

SCADA is an acronym that stands for Supervisory Control and Data Acquisition. SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data.

SCADA systems are used not only in industrial processes: e.g. steel making, power generation (conventional and nuclear) and distribution, chemistry, but also in some experimental facilities such as nuclear fusion. The size of such plants range from a few 1000 to several 10 thousands input/output (I/O) channels.

Systems similar to SCADA systems are routinely seen in factories, treatment plants etc. These are often referred to as Distributed Control Systems (DCS). They have similar functions to SCADA systems, but the field data gathering or control units are usually located within a more confined area. Communications may be via a local area network (LAN), and will normally be reliable and high speed.

A DCS system usually employs significant amounts of closed loop control. SCADA systems on the other hand generally cover larger geographic areas, and rely on a variety of communications systems that are normally less reliable than a LAN. Closed loop control in this situation is less desirable.

SCADA generally comes under the branch of Instrumentation Engineering. The term SCADA stands for Supervisory Control And Data Acquisition. SCADA systems are used for controlling and monitoring chemical or transport processes and can be used in a factory environment such as electric power generation, water supply systems, gas and oil pipelines or any other distributed processes.

A typical SCADA system comprises of i/o signal hardware, controllers, software, networks and communication. SCADA system is normally used to monitor and control a remote site or a distribution that is spread out for a long distance. An RTU (Remote Terminal Unit) or a PLC (Programmable Logic Controller) is usually used to control a site automatically. The SCADA system also provides a host control functions for the supervisor to control and define settings.

For example, in a SCADA system a PLC can be used to control the flow of cooling water as part of an industrial process. At the same time the supervisor can use the Host control function to set the temperature for the flow of water. It can also have alarms and can record the flow of water temperature and report back to the SCADA system.

The RTUs and PLCs are responsible for data collection such as meter readings, equipment status etc and communicate back to the SCADA system. This data can be stored in a database for later analysis or monitored by a supervisor to take appropriate actions if required.

SCADA systems typically implement a distributed database, commonly referred to as a tag database, which contains data elements called tags or points. A point represents a single input or output value monitored or controlled by the system. Points can be either “hard” or “soft” .

A hard point is representative of an actual input or output connected to the system, while a soft point represents the result of logic and math operations applied to other hard and soft points. Most implementations conceptually remove this distinction by making every property a “soft” point (expression) that can equal a single “hard” point in the simplest case.

Point values are normally stored as value-timestamp combinations; the value and the timestamp when the value was recorded or calculated. A series of value-timestamp combinations is the history of that point. It’s also common to store additional metadata with tags such as: path to field device and PLC register, design time comments, and even alarming information.

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Home > Industry > Machine and Process Management > An Introduction to SCADA Systems

An Introduction to SCADA Systems

December 11, 2018

2 min read |  Atin Chhabra

This audio was created using Microsoft Azure Speech Services

What is SCADA System?

SCADA System refers to Supervisory Control and Data Acquisition System. Primarily, it is a network of all the machinery and equipment in the system connected through a centralised hub. The hub acquires all the data from the site. It includes information like machine status, process status, health of the machine, its throughput etc.

Functions of SCADA

All the equipment connected through machine control are operated through instruction sent over the web. The processing unit analyses the data and supervises the healthy functioning of the signals transmitted in the entire unit. The data is stored for valuation in a distributed database. The acquired data also has reference metadata stored for in the different database such as a programmable logic controller ( PLC ).

How does it work?

The complete SCADA systems has four significant units namely – data communication, data acquisition, information or data presentation and monitoring and control system. With complete symphony in the above four mentioned units, the entire operation of the automation system can be monitored. The data acquisition system fetches real-time data from all the connected machine units. The data reports about the status of all the components and sensors, where data communication network comes into play. The system ensures accuracy in data being transferred through the internet protocol. Once the data is collected, the processing unit analyses the data and presents it to the operator through Human-Machine Interface ( HMI ).

The comprehensive system works in close connection with predictive maintenance also. The data relayed by communication system after processing is also analysed by this system to detect any shortcomings that may occur in the system. This reduces the susceptibility of system breakdown or expected downtime due to a faulty line.

Application of the System

Although this is a new technology, businesses have already leveraged the technology in both the public and private sector. It has brought about immense satisfaction in the operation managers because the system makes the production line foolproof. This also streamlines packaging and delivery lines following the processes. The overall automation and process control has helped to save a significant amount of money and time. This is the reason why many more enterprises are looking for automating their industrial processes. With the Industrial Internet of Things taking the front seat, it is essential to look for companies helping businesses step towards automation. Schneider Electric India is one of the significant names in the research and development of the automation industry. It has not only brought these systems to common units but also helps the employees to upskill their knowledge by training them how to operate the machinery.

I hope this article equipped you with all the knowledge you were seeking about SCADA System! Comment below if you feel that we’ve missed on anything or if there is something more you want to know.

#SchneiderElectric #LifeIsOn

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SCADA: Supervisory Control and Data Acquisition

What is scada, who uses it and how scada has evolved, scada explained.

Supervisory control and data acquisition (SCADA) is a system of software and hardware elements that allows organizations to control and monitor industrial processes by directly interfacing with plant-floor machinery and viewing real-time data.

Using a SCADA system, industrial organizations can:

• Control industrial processes locally or at remote locations
• Monitor, gather, and process real-time data
• Directly interact with devices such as sensors, valves, pumps, motors, and more through human-machine interface (HMI) software
• Record events into a log file

SCADA systems are crucial for industrial organizations since they help to maintain efficiency, process data for smarter decisions, and communicate system issues to help mitigate downtime.

The basic SCADA architecture begins with programmable logic controllers (PLCs) or remote terminal units (RTUs). PLCs and RTUs are microcomputers that communicate with an array of objects such as factory machines, HMIs, sensors, and end devices, and then route the information from those objects to computers with SCADA software. The SCADA software processes, distributes, and displays the data, helping operators and other employees analyze the data and make important decisions.

For example, the SCADA system quickly notifies an operator that a batch of product is showing a high incidence of errors. The operator pauses the operation and views the SCADA system data via an HMI to determine the cause of the issue. The operator reviews the data and discovers that Machine 4 was malfunctioning. The SCADA system’s ability to notify the operator of an issue helps him to resolve it and prevent further loss of product.

A Basic SCADA Diagram  

Who Uses SCADA?

SCADA systems are used by industrial organizations and companies in the public and private sectors to control and maintain efficiency, distribute data for smarter decisions, and communicate system issues to help mitigate downtime. SCADA systems work well in many different types of enterprises because they can range from simple configurations to large, complex installations. SCADA systems are the backbone of many modern industries, including:

Virtually anywhere you look in today's world, there is some type of SCADA system running behind the scenes: maintaining the refrigeration systems at the local supermarket, ensuring production and safety at a refinery, achieving quality standards at a waste water treatment plant, or even tracking your energy use at home, to give a few examples.

Effective SCADA systems can result in significant savings of time and money. Numerous case studies have been published highlighting the benefits and savings of using a modern SCADA software solution such as Ignition.

The Birth of SCADA

To understand the origins of SCADA, we must understand the problems industrial organizations are trying to solve. Before the concept of SCADA was introduced in the mid-20th century, many manufacturing floors, industrial plants, and remote sites relied on personnel to manually control and monitor equipment via push buttons and analog dials.

As industrial floors and remotes site began to scale out in size, solutions were needed to control equipment over long distances. Industrial organizations started to utilize relays and timers to provide some level of supervisory control without having to send people to remote locations to interact with each device.

While relays and timers solved many problems by providing limited automation functionality, more issues began to arise as organizations continued to scale out. Relays and timers were difficult to reconfigure, fault-find and the control panels took up racks upon racks of space. A more efficient and fully automated system of control and monitoring was needed.

In the early 1950s, computers were first developed and used for industrial control purposes. Supervisory control began to become popular among the major utilities, oil and gas pipelines, and other industrial markets at that time. In the 1960s, telemetry was established for monitoring, which allowed for automated communications to transmit measurements and other data from remotes sites to monitoring equipment. The term “SCADA” was coined in the early 1970s, and the rise of microprocessors and PLCs during that decade increased enterprises’ ability to monitor and control automated processes more than ever before.

The Evolution of SCADA

The first iteration of SCADA started off with mainframe computers. Networks as we know them today were not available and each SCADA system stood on its own. These systems were what would now be referred to as monolithic SCADA systems.

In the 80s and 90s, SCADA continued to evolve thanks to smaller computer systems, Local Area Networking (LAN) technology, and PC-based HMI software. SCADA systems soon were able to be connected to other similar systems. Many of the LAN protocols used in these systems were proprietary, which gave vendors control of how to optimize data transfer. Unfortunately, these systems were incapable of communicating with systems from other vendors. These systems were called distributed SCADA systems.

In the 1990s and early 2000s, building upon the distributed system model, SCADA adopted an incremental change by embracing an open system architecture and communications protocols that were not vendor-specific. This iteration of SCADA, called a networked SCADA system, took advantage of communications technologies such as Ethernet. Networked SCADA systems allowed systems from other vendors to communicate with each other, alleviating the limitations imposed by older SCADA systems, and allowed organizations to connect more devices to the network.

While SCADA systems have undergone substantial evolutionary changes, many industrial organizations continued to struggle with industrial data access from the enterprise level. By the late 1990s to the early 2000s, a technological boom occurred and personal computing and IT technologies accelerated in development. Structured query language (SQL) databases became the standard for IT databases but were not adopted by SCADA developers. This resulted in a rift between the fields of controls and IT, and SCADA technology became antiquated over time.

Traditional SCADA systems still use proprietary technology to handle data. Whether it is a data historian, a data connector, or other means of data transfer, the solution is messy and incredibly expensive. Modern SCADA systems aim to solve this problem by leveraging the best of controls and IT technology.

Modern SCADA Systems

Modern SCADA systems allow real-time data from the plant floor to be accessed from anywhere in the world. This access to real-time information allows governments, businesses, and individuals to make data-driven decisions about how to improve their processes. Without SCADA software, it would be extremely difficult if not impossible to gather sufficient data for consistently well-informed decisions.

Also, most modern SCADA designer applications have rapid application development (RAD) capabilities that allow users to design applications relatively easily, even if they don't have extensive knowledge of software development.

The introduction of modern IT standards and practices such as SQL and web-based applications into SCADA software has greatly improved the efficiency, security, productivity, and reliability of SCADA systems.

SCADA software that utilizes the power of SQL databases provides huge advantages over antiquated SCADA software. One big advantage of using SQL databases with a SCADA system is that it makes it easier to integrate into existing MES and ERP systems, allowing data to flow seamlessly through an entire organization.

Historical data from a SCADA system can also be logged in a SQL database, which allows for easier data analysis through data trending.

Learn About Ignition: The New SCADA®

Ignition hmi/scada software.

Ignition by Inductive Automation® is an industrial automation software platform that many businesses and organizations have switched to for their HMI/SCADA needs.

Ignition has been installed in thousands of locations in over 100 countries since 2010. Its powerful and robust nature allows SCADA system integrators to reach the demands of their customers while costing less than other SCADA software solutions.

Here are a few reasons why more enterprises are choosing Ignition:

• Ignition uses modern IT practices that make it compatible with current SCADA system components.
• Its unique licensing model lets users pay a flat fee based on the number of servers. Other SCADA vendors typically charge per client or per tag, but Ignition offers unlimited clients and tags.
• Ignition is web-deployable: it can be downloaded and installed in a few minutes, and clients can be launched or updated instantly.

Inductive Automation's motto of "Dream It, Do It" is a perfect embodiment of what Ignition can do. While its bold claims may sound too good to be true, one demonstration of the software proves how powerful it really is. Once you see what's possible, you’ll begin to imagine how the software can fit your SCADA needs and open up new possibilities.

Ignition SCADA Architecture  

Try Ignition for yourself for free and visit Inductive University to master the platform at your own pace.

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How SCADA Systems Work

Scada stands for supervisory control and data acquisition. it is a type of software application program for process control. scada is a central control system which consist of controllers network interfaces, input/output, communication equipments and software. scada systems are used to monitor and control the equipments in the industrial process which include manufacturing, production, development and fabrication. – powerpoint ppt presentation.

• SCADA stands for supervisory control and data acquisition. It is a type of software application program for process control.  SCADA is a central control system which consist of controllers network interfaces, input/output, communication equipment's and software. SCADA systems are used to monitor and control the equipment's in the industrial process which include manufacturing, production, development and fabrication.
• The infrastructural processes include gas and oil distribution, electrical power, water distribution.  Public utilities include bus traffic system, airport.  The SCADA system takes the reading of the meters and checks the status of sensors in regular interval so that it requires minimal interference of human.
• Generally SCADA system is a centralized system which monitors and controls entire area.
• It is purely software package that is positioned on top of hardware. 
• A supervisory system gathers data on the process and sends the commands control to the process.
• The SCADA is a remote terminal unit which is also known as RTU.
• Most control actions are automatically performed by RTUs or PLCs.
• The RTUs consist of programmable logic converter which can be set to specific requirement.
• The SCADA system allows operators to change the set point for the flow
• It enable alarm conditions in case of loss of flow and high temperature and the condition is displayed and recorded.
•  The SCADA system is a centralized system to communicate with both wire and wireless technology to Clint devices.
• The SCADA system controls can run completely all kinds of industrial process.
• The generally SCADA system can be classified into two parts
• Clint layer
• Data server layer
• The Clint layer which caters for the man machine interaction.
• The data server layer which handles most of the process data activities.
• The SCADA station refers to the servers and it is composed of a single PC. 
• The data servers communicate with devices in the field through process controllers like PLCs or RTUs.
• The PLCs are connected to the data servers either directly or via networks or buses. 
• The SCADA system utilizes a WAN and LAN networks.
• The WAN and LAN consists of internet protocols used for communication between the master station and devices. 
• The physical equipments like sensors connected to the PLCs or RTUs. 
• The RTUs convert the sensor signals to digital data and sends digital data to master.
• Most of the monitoring and control operations are performed by RTUs or PLCs.
• Most of the servers are used for multitasking and real time database.
• The servers are responsible for data gathering and handling. 
• The SCADA system consists of a software program to provide trending, diagnostic data, and manage information.
• It scheduled maintenance procedure, logistic information, detailed schematics for a particular sensor or machine and expert system troubleshooting guides.
• This means the operator can sea a schematic representation of the plant being controlled.
• Data Acquisitions
• Data Communication
• Information/Data presentation
• Monitoring/Control
• These functions are performed by sensors, RTUs, controller, communication network. 
• The sensors are used to collect the important information and RTUs are used to send this information to controller and display the status of the system.
• According to the status of the system, the user can give command to other system components.
• This operation is done by the communication network.
• Real time system consists of thousand of components and sensors.
• It is very important to know the status of particular components and sensors.
• For example, some sensors measure the water flow from the reservoir to water tank and some sensors measure the value pressure as the water is release from the reservoir.
• The SCADA system uses wired network to communicate between user and devices.
• The real time applications use lot of sensors and components which should be control remotely.
• The SCADA system uses internet communications.
• All information is transmitted through internet using specific protocols.
• Sensor and relays are not able to communicate with the network protocols so RTUs used to communicate sensors and network interface.
• The normal circuit networks have some indicators which can be visible to control but in the real time SCADA system.
• There are thousand of sensors and alarm which are impossible to be handled simultaneously.
• The SCADA system uses human machine interface (HMI) to provide all of the information gathered from the various sensors.
• The SCADA system uses human machine interface.
• The information is displayed and monitored to be processed by the human.
• HMI provides the access of multiple control units which can be PLCs and RTUs.
• The HMI provides the graphical presentation of the system.
• For example, it provides the graphical picture of the pump connected to the tank. The user can see the flow of the water and pressure of the water.
• The important part of the HMI is an alarm system which is activated according to the predefined values.
• The tank water level alarm is set 60 and 70 values. If the water level reaches above 60 the alarm gives normal warning and if the water level reach above 70 the alarm gives critical warning.
• The SCADA system uses different switches to operate each device and displays the status at the control area.
• Any part of the process can be turned ON/OFF from the control station using these switches.
• SCADA system is implemented to work automatically without human intervention but at critical situations it is handled by man power.
• In large industrial establishments many process occur simultaneously and each needs to be monitored.
• Which is actually a complex task. 
• The SCADA systems are used to monitor and control the equipment's in the industrial processes.
• It include water distribution, oil distribution and power distribution. 
• The main aim of this project is to process the real time data and control the large scale remote industrial environment.
• In the real time scenario, a temperature logging system for a remote plant operation is taken.
• The temperature sensors are connected to the microcontroller.
• It is connected to the PC at the front end and software is loaded on the computer. 
• The data is collected from the temperature sensors. 
• The temperature sensors continuously send the signal to the microcontroller which accordingly displays these values on its front panel. 
• One can set the parameters like low limit and high limit on the computer screen.
• When the temperature of a sensor goes above set point the microcontroller send a command to the corresponding relay. 
• The heaters connected through relay contacts are turned OFF and ON.
• The SCADA system provides on board mechanical and graphical information.
• The SCADA system is easily expandable. We can add set of control units and sensors according to the requirement.
• The SCADA system ability to operate critical situations.
• One disadvantage is that TCP/IP based SCADA systems are (extremely) vulnerable to cyber warfare/cyber terrorism attacks which, in the worst scenario case, could cause not only financial loss but also loss of life, directly or indirectly.
• Power generation, transmission and distribution
• Water distribution and reservoir system
• Public buildings like electrical heating and cooling system.
• Generators and turbines
• Traffic light control system
• A large number of processes occur in large industrial establishment. Every process you need to monitor is very complex because each machine gives different output. The SCADA system used to gather the data from sensors and instruments located at remote area. The computer then processes this data and presents in a timely manner. 

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What is a SCADA System : Architecture & Its Working

A large number of processes occur in large industrial establishments. Every process, you need to monitor is very complex because each machine gives the different output. The SCADA system used to gather data from sensors and instruments located in remote areas. The computer then processes this data and presents it promptly. The SCADA system gathers the information (like a leak on a pipeline occurred) and transfers the information back to the system while giving the alerts that leakage has occurred and displays the information in a logical and organized fashion. The SCADA system used to run on DOS and UNIX operating systems. This entire process is known as automation . This article discusses an overview of the SCADA system.

What is a SCADA System?

SCADA stands for supervisory control and data acquisition. It is a type of software application program for process control.  SCADA is a central control system that consists of controllers network interfaces, input/output, communication equipment, and software. SCADA systems are used to monitor and control the equipment in the industrial process which includes manufacturing, production, development, and fabrication. The infrastructural processes include gas and oil distribution, electrical power, water distribution.  Public utilities include a bus traffic system, airport.  The SCADA system takes the reading of the meters and checks the status of sensors in regular intervals so that it requires minimal interference of humans.

History of SCADA

Earlier, the controlling of industrial plants and manufacturing floors can be done manually with the help of analog equipment and push-buttons. As the industry’s size is growing, so they employed timers and relays to provide supervisory control to a fixed level for minimal automation. So, a fully automated with a more efficient system was necessary for all the industries.

We know that, for industrial control purposes, computers were implemented in the year 1950. After that, the concept of telemetry was implemented for data transmission as well as virtual communication . In the year 1970, the SCADA system was developed along with the microprocessors as well as PLC.

So these concepts were fully helped while developing automation that is operated in industries remotely. The distributed SCADA systems were implemented in the year 2000. After that, new SCADA systems were developed to monitor & control real-time data anyplace in the globe.

SCADA System Architecture

Generally, the SCADA system is a centralized system that monitors and controls the entire area. It is a pure software package that is positioned on top of the hardware. A supervisory system gathers data on the process and sends the commands control to the process. The SCADA is a remote terminal unit which is also known as RTU.

Most control actions are automatically performed by RTUs or PLCs. The RTUs consists of the programmable logic converter which can be set to specific requirement. For example, in the thermal power plant, the water flow can be set to a specific value or it can be changed according to the requirement.

 The SCADA system allows operators to change the set point for the flow, and enable alarm conditions in case of loss of flow and high temperature, and the condition is displayed and recorded. The SCADA system monitors the overall performance of the loop. The SCADA system is a centralized system to communicate with both wired and wireless technology to Clint devices. The SCADA system controls can run completely all kinds of the industrial process.

For example,  if too much pressure is building up in a gas pipeline the SCADA system can automatically open a release valve.

Hardware Architecture

  The generally SCADA system can be classified into two parts:

• Client layer
• Data server layer

The Clint layer caters to the man-machine interaction.

The data server layer handles most of the process of data activities.

The SCADA station refers to the servers and it is composed of a single PC.  The data servers communicate with devices in the field through process controllers like PLCs or RTUs. The PLCs are connected to the data servers either directly or via networks or buses. The SCADA system utilizes a WAN and LAN networks, the WAN and LAN consist of internet protocols used for communication between the master station and devices.

The physical equipment like sensors connected to the PLCs or RTUs. The RTUs convert the sensor signals to digital data and sends digital data to the master. According to the master feedback received by the RTU, it applies the electrical signal to relays. Most of the monitoring and control operations are performed by RTUs or PLCs as we can see in the figure.

Software Architecture

Most of the servers are used for multitasking and real-time database. The servers are responsible for data gathering and handling. The SCADA system consists of a software program to provide trending, diagnostic data, and manage information such as scheduled maintenance procedures, logistic information, detailed schematics for a particular sensor or machine, and expert-system troubleshooting guides. This means the operator can see a schematic representation of the plant being controlled.

Examples are alarm checking, calculations, logging, and archiving; polling controllers on a set of parameters, those are typically connected to the server.

SCADA System Working

The SCADA system performs the following functions

Data Acquisitions

Data communication.

• Information/Data presentation

Monitoring/Control

These functions are performed by sensors, RTUs, controllers, a communication network.  The sensors are used to collect the important information and RTUs are used to send this information to the controller and display the status of the system. According to the status of the system, the user can give the command to other system components. This operation is done by the communication network.

The real-time system consists of thousands of components and sensors. It is very important to know the status of particular components and sensors. For example, some sensors measure the water flow from the reservoir to the water tank and some sensors measure the value pressure as the water is released from the reservoir.

The SCADA system uses a wired network to communicate between users and devices. Real-time applications use a lot of sensors and components which should be controlled remotely. The SCADA system uses internet communications. All information is transmitted through the internet using specific protocols. Sensors and relays are not able to communicate with the network protocols so RTUs used to communicate sensors and network interfaces.

Information/Data Presentation

The normal circuit networks have some indicators which can be visible to control but in the real-time SCADA system, there are thousands of sensors and alarm which are impossible to be handled simultaneously. The SCADA system uses the human-machine interface (HMI) to provide all of the information gathered from the various sensors .

The SCADA system uses different switches to operate each device and displays the status of the control area. Any part of the process can be turned ON/OFF from the control station using these switches. SCADA system is implemented to work automatically without human intervention but in critical situations, it is handled by manpower.

SCADA Components

The SCADA system components include the following.

Supervisory System

The supervisory system works like a communication server among the human-machine interface software within the control room of workstations as well as its apparatus such as RTUs, Sensors, PLCs, etc. Smaller SCADA systems include simply a single personal computer to serve like a master system otherwise supervisory whereas, large SCADA systems include numerous servers, sites for tragedy recovery as well as distributed software applications. The servers are connected like hot-standby formation otherwise dual-redundant to monitor server failure continuously.

RTUs (Remote Terminal Units)

The RTU or remote terminal unit is an electronic device and it is also known as remote telemetry units. This system comprises physical objects that are interfaced through RTUs.

The controlling of these devices can be done through microprocessors. Here, microprocessors are utilized for controlling RTUs which are used to transmit the recorded data toward the supervisory system. The data can be received from the master system for controlling the connected objects.

PLCs (Programmable Logic Controllers)

The term PLC stands for programmable logic controllers which are used in SCADA systems with the help of sensors. These controllers are connected to the sensors for converting the output signal of the sensor into digital data. As compared with RTUs, these are used due to their flexibility, configuration, versatility & affordability.

Communication Infrastructure

In the SCADA system, a mix of radio & the direct-wired connection is used. But, SONET or SDH can also be utilized for superior systems such as power stations & railways. Few standardized 7 recognized protocols are used between the compact SCADA protocols to deliver information simply once the RTUs are polled through the supervisory station.

SCADA Programming

In HMI otherwise master station, SCADA programming is mainly used to make maps, diagrams to provide very important information throughout progression otherwise when event failure occurs. Most of the commercial SCADA systems utilize consistent interfaces in C programming language otherwise derived programming language can also be used.

Human Machine Interface

The SCADA system uses the human-machine interface. The information is displayed and monitored to be processed by a human. HMI provides access to multiple control units which can be PLCs and RTUs. The HMI provides the graphical presentation of the system.

For example, it provides a graphical picture of the pump connected to the tank. The user can see the flow of the water and the pressure of the water. The important part of the HMI is an alarm system that is activated according to the predefined values.

For example , the tank water level alarm is set 60% and 70% values. If the water level reaches above 60% the alarm gives a normal warning and if the water level reaches above 70% the alarm gives a critical warning.

Types of SCADA System

SCADA systems are classified into four types which include the following.

Monolithic SCADA Systems

Distributed scada systems, networked scada systems, iot scada systems.

Monolithic SCADA systems are called as early or first-generation systems. In these types of systems, minicomputers are used. The development of these systems can be done when common network services are not available. The designing of these systems can be done like independent systems without any relation to other systems.

The data can be gathered from all RTUs using a backup mainframe. The main functions of these first-generation systems are restricted to flagging processes in crisis cases &to monitor the sensors.

Distributed SCADA systems are called second-generation systems. The distribution of the control functions can be done across numerous systems by connecting with a local area network. The control operations can be performed by sharing real-time data & command processing.

In these types of systems, the size and cost of each station are reduced however there were no consistent network protocols. As the protocols were proprietary, fewer people understand the SCADA system security while installation & this factor were ignored largely.

The networked SCADA systems are also known as third-generation systems. The networking and communication of present SCADA systems can be done using the WAN system through data lines or phones. The data transmission among two nodes can be done with the help of Ethernet or Fiber-optic connections.

This type of SCADA system uses PLC to adjust and monitor the flagging operations simply once there is a necessity for main choices.

IoT SCADA systems are fourth-generation systems. In these systems, the system’s infrastructural cost is reduced by implementing IoT through cloud computing . Maintaining as well as integrating these systems is easy as compared with others.

In real-time, the condition of these systems can be reported through cloud computing. Therefore the implementation of algorithms like intricate control can be done that are frequently used on usual PLCs.

SCADA Security

At present, SCADA networks are used extensively in current industries to check & examine real-time data, industrial processes can be controlled, communicate with devices. So SCADA systems are essential for industrial organizations because these systems include hardware & software. So, SCADA security is also essential in industries.

The term SCADA security is used to protect the SCADA networks which are fabricated with computer hardware. SCADA networks used by some of the systems are electricity , natural gas, etc. The private and government organizations have taken the measures of these networks because of the valuable role to make sure the security of the SCADA systems.

Examples of SCADA Security

The threats that occur in SCADA systems include the following.

• Error Inside

The weakness of SCADA security mainly occurs because of the following reasons.

• Poor Training
• Loopholes Development of App
• Issues while Monitoring
• Less Maintenance

The SCADA system can be protected by mapping all present systems, monitoring, and detecting the institute, and create processes for the security of the network.

Difference between PLC and SCADA

The difference between PLC and SCADA include the following.

SCDA for Remote Industrial Plant

In large industrial establishments, many processes occur simultaneously and each needs to be monitored, which is a complex task. The SCADA systems are used to monitor and control the equipment in the industrial processes which include water distribution, oil distribution, and power distribution. The main aim of this project is to process the real-time data and control the large scale remote industrial environment. In the real-time scenario, a temperature logging system for a remote plant operation is taken.

The temperature sensors are connected to the microcontroller, which is connected to the PC at the front end, and software is loaded on the computer. The data is collected from the temperature sensors. The temperature sensors continuously send the signal to the microcontroller which accordingly displays these values on its front panel.

One can set the parameters like low limit and high limit on the computer screen. When the temperature of a sensor goes above-set point the microcontroller sends a command to the corresponding relay. The heaters connected through relay contacts are turned OFF and ON.

This is a temperature logging system. Here 8 temperature sensors in multiplexing mode are connected to the microcontroller through ADC 0808. Then the values of all the sensors are sent serially by the microcontroller through Max 32 to the com port of the PC. A Software “DAQ System” loaded on the PC takes these values and show them on its front panel, and also logs them to the database “daq.mdb”.

One can set by the interactive way some parameters like a set point, low limit, and high limit on the computer screen. When the temperature of some sensor increases beyond the setpoint, the microcontroller sends commands to relay driver IC. The heaters connected through relay contacts are (specific for that sensor) turned OFF (or ON in opposite case). High limit and low limits are for alarm. When the temperature goes above the high limit or below the low limit the alarm will be turned on.

The advantages of the SCADA system include the following.

• The quality of service can be improved
• Reliability can be improved
• Maintenance cost is less
• The operation can be reduced
• Large system parameters can be monitored
• Manpower can be reduced
• Repair time can be reduced
• Fault detection & fault localization
• It stores a large amount of data
• As per the user requirement, it displays the data in various formats.
• Thousands of sensors can be interfaced with SCADA for controlling and monitoring
• Real data simulations can be obtained by operators
• Gives fast response
• It is flexible as well as scalable while adding extra resources.
• The SCADA system provides onboard mechanical and graphical information
• The SCADA system is easily expandable. We can add a set of control units and sensors according to the requirement.
• The SCADA system is able to operate in critical situations.

Disadvantages

The disadvantages of the SCADA system include the following.

• It is complex in terms of dependent modules & hardware units.
• It needs analysts, programmers & skilled operators to maintain
• High installation cost
• Unemployment rates can be increased
• This system supports hardware devices and restricted software’s

 Applications

The applications of the SCADA system include the following.

• Generation and Distribution of Power
• Public Transport
• Water and Sewage System
• Manufacturing
• Industries & Buildings
• Communication Networks
• Oil & Gas Industries
• Power generation, transmission, and distribution
• Water distribution and reservoir system
• Public buildings like electrical heating and cooling system.
• Generators and turbines
• Traffic light control system

Thus, this is all about an overview of the SCADA system (Supervisory Control and Data Acquisition). This system is controlled by a computer, used to control as well as monitor different processes in plants. This system uses GUI (graphical user interface), data communications &extended management for monitoring systems. Here is a question for you, what is PLC?

Photo Credit:

• General SCADA Network by mycpanel

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