SCADA

CHAPTER 1
INTRODUCTION

1.1 WHAT IS SCADA?

SCADA stands for Supervisory Control And Data Acquisition. As the name
indicates, it is not a full control system, but rather focuses on the supervisory level. It is a
software package that is positioned on top of hardware to which it is interfaced, in general
via Programmable Logic Controllers (PLCs), or other commercial hardware modules.
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. Basically, SCADA is a computer
system for gathering and analyzing real time data.

1.2 WHAT IS DATA ACQUISITION?

Data acquisition is the process of retrieving control information from the
equipment which is out of order or may lead to some problem or when decisions are need
to be taken according to the situation in the equipment. So this acquisition is done by
continuous monitoring of the equipment to which it is employed. The data accessed are
then forwarded onto a telemetry system ready for transfer to the different sites. They can
be analog and digital information gathered by sensors, such as flow meter, ammeter, etc.
It can also be data to control equipment such as actuators, relays, valves, motors, etc.

So why or where would you use SCADA?

SCADA can be used to monitor and control plant or equipment. The control may
be automatic, or initiated by operator commands. The data acquisition is accomplished
firstly by the RTU's (remote Terminal Units) scanning the field inputs connected to the
RTU ( RTU's may also be called a PLC - programmable logic controller). This is usually
at a fast rate. The central host will scan the RTU's (usually at a slower rate.)

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The data is processed to detect alarm conditions, and if an alarm is present, it will
be displayed on special alarm lists. Data can be of three main types. Analogue data (i.e.
real numbers) will be trended (i.e. placed in graphs). Digital data (on/off) may have
alarms attached to one state or the other. Pulse data (e.g. counting revolutions of a meter)
is normally accumulated or counted.

These systems are used not only in industrial processes. For example,
Manufacturing, steel making, power generation both in conventional, nuclear and its
distribution, chemistry, but also in some experimental facilities such as laboratories
research, testing and evaluation centers, nuclear fusion. The size of such plants can range
from as few as 10 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 of several 100K.

The primary interface to the operator is a graphical display (mimic) usually via a
PC Screen which shows a representation of the plant or equipment in graphical form.
Live data is shown as graphical shapes (foreground) over a static background. As the data
changes in the field, the foreground is updated. E.g. a valve may be shown as open or
closed. Analog data can be shown either as a number, or graphically. The system may
have many such displays, and the operator can select from the relevant ones at any time.

SCADA systems were first used in the 1960s.SCADA systems have made substantial
progress over the recent years in terms of functionality, scalability, performance and
openness such that they are an alternative to in house development even for very
demanding and complex control systems as those of physics experiments. SCADA
systems used to run on DOS, VMS and UNIX; in recent years all SCADA vendors have
moved to NT and some also to Linux.

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CHAPTER 2

BASIC COMPONENTS OF SCADA SYSTEM

A basic SCADA system consists of following components:

1. Human Machine Interface

2. Supervisory System
3. Remote Terminal Units
4. Programmable Logic Controllers (PLCs)
5. Communication Infrastructure
6. SCADA Programming

Fig. 2.1 : Components of Scada system

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1. HUMAN MACHINE INTERFACE

It is an I/O device that allows a human operator to control the process data. This is
achieved by linking SCADA’s databases and software programs for providing
management information like detailed schematics, scheduled maintenance, data
diagnostics and logistic information. The operating personnel can also see the graphical
representation of data.

Fig. 3 – Human Machine Interface in SCADA

2. SUPERVISORY SYSTEM

This system acts as a communication server between the HMI software in control
room workstations and its equipment like PLCs, RTUs, sensors etc.

Smaller Supervisory Control and Data Acquisition systems have only a single PC
that serves as a supervisory or master system. Larger Supervisory Control and Data
Acquisition systems have multiple servers, sites for disaster recovery and distributed
software applications. The servers are configured as dual-redundant or hot-standby
formation for continuously monitoring server failure.

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3. REMOTE TERMINAL UNITS

This system contains physical objects that are interfaced with Remote Terminal
Units (RTUs). These electronic devices are controlled by microprocessors and are used
for transmitting recorded data to the supervisory systems. They also receive data from the
master system in order to control the connected objects.

They are also called as Remote Telemetry Units.

4. PROGRAMMABLE LOGIC CONTROLLERS

PLCs find their use in the Supervisory Control and Data Acquisition system
through sensors. They are attached to the sensors in order to convert the sensor output
signal into digital data.

They are preferred over RTUs because of their configuration, flexibility, affordability and
versatility.

5. COMMUNICATION INFRASTRUCTURE

Generally, a combination of direct wired connection and radio is used in

Supervisory Control and Data Acquisition systems. However, SDH/ SONET can also be
used for larger systems like railways and power stations.

Among the compact SCADA protocols, few recognized and standardized protocols
deliver information only when the RTUs are polled by the supervisory station.

6. SCADA PROGRAMMING

SCADA programming in HMI or master station is used for creating diagrams and
maps that provide vital information during process or event failure. Most of the
commercial Supervisory Control and Data Acquisition systems use standardized
interfaces in programming.

C language or derived programming language is generally used for such programming.

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CHAPTER 3

FEATURES OF SCADA SYSTEMS

Although SCADA systems may include special features for specific industries or
applications, most systems support the following features:

 Data acquisition is a foundation of SCADA systems; sensors collect data and

deliver it to field controllers, which, in turn, feed data to the SCADA computers.
 Remote control is achieved through the control of field actuators, based on the
data acquired from field sensors.
 Networked data communication enables all SCADA functions. Data collected
from sensors must be transmitted to SCADA field controllers, which, in turn,
communicate with the SCADA supervisory computers; remote control commands
are transmitted back to actuators from the SCADA supervisory computers.
 Data presentation is achieved through HMIs, which represent current and
historical data to the operators running the SCADA system.
 Real-time and historical data are both important parts of the SCADA system, as
they enable users to track current performance against historical trends.
 Alarms alert SCADA operators to potentially significant conditions in the system.
Alerts can be configured to notify operators when processes are blocked, when
systems are failing, or when other aspects of SCADA processes need to be
stopped, started or adjusted.
 Reporting on SCADA system operations can include reports on system status,
process performance and reports customized to specific uses.

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CHAPTER 4
ARCHITECTURE
In this section we are going to details which describe the common
architecture required for the SCADA products.

4.1 HARDWARE ARCHITECTURE

The basic hardware of the SCADA system is distinguished into two basic layers:
the "client layer" which caters for the man machine interaction and the "data server layer"
which handles most of the process data control activities. The data servers communicate
with devices in the field through process controllers. Process controllers, e.g. PLC’s, are
connected to the data servers either directly or via networks or fieldbuses that are
proprietary (e.g. Siemens H1), or non-proprietary (e.g. Profibus). Data servers are
connected to each other and to client stations via an Ethernet LAN. Fig.1. shows typical
hardware architecture.

Figure 1: Typical Hardware Architecture

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4.2 SOFTWARE ARCHITECTURE

The SCADA products are multi-tasking and are based upon a realtime database
(RTDB) located in one or more servers. Servers are responsible for data acquisition and
handling like polling controllers, alarm checking, calculations, logging and archiving) on
a set of parameters, typically to which those are connected.

However, it is possible to have dedicated servers for particular tasks,

e.g. historian, datalogger, alarm handler. Fig. 2 shows a SCADA architecture that is
generic for the product.

Figure 2: Generic Software Architecture

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4.3 LEVELS OF SCADA ARCHITECTURE

SCADA systems operate at five of the six levels defined in the Purdue Enterprise
Reference Architecture for enterprise integration:

 Level 0. The field level includes field devices, such as sensors, used to forward
data relating to field processes and actuators used to control processes.
 Level 1. The direct control level includes local controllers, such as PLCs and
RTUs, that interface directly with field devices, including accepting data inputs
from sensors and sending commands to field device actuators.
 Level 2. The plant supervisory level includes local supervisory systems that
aggregate data from level controllers and issue commands for those controllers to
carry out.
 Level 3. The production control level includes systemwide supervisory systems
that aggregate data from Level 2 systems to produce ongoing reporting to the
production scheduling level, as well as other site or regionwide functions, like
alerts and reporting.
 Level 4. The production scheduling level includes business systems used to
manage ongoing processes.

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CHAPTER 5
COMMUNICATION

5.1 INTERNAL COMMUNICATION:

Server-client and server-server communication is in general on a publish-
subscribe and event-driven basis and uses a TCP/IP protocol, i.e., a client application
subscribes to a parameter which is owned by a particular server application and only
changes to that parameter are then communicated to the client application.

5.2 ACCESS TO DEVICES:

The data servers poll the controllers at a user defined polling rate. The polling rate
may be different for different parameters. The controllers pass the requested parameters
to the data servers. Time stamping of the process parameters is typically performed in the
controllers and this time-stamp is taken over by the data server. If the controller and
communication protocol used support unsolicited data transfer then the products will
support this too.

The products provide communication drivers for most of the common PLCs and
widely used field-buses, e.g., Modbus. Of the three fieldbuses that are recommended are,
both Profibus and Worldfip are supported but CANbus often not. Some of the drivers are
based on third party products (e.g., Applicom cards) and therefore have additional cost
associated with them. VME on the other hand is generally not supported.

A single data server can support multiple communications protocols; it can generally
support as many such protocols as it has slots for interface cards. The effort required to
develop new drivers is typically in the range of 2-6 weeks depending on the complexity
and similarity with existing drivers, and a driver development toolkit is provided for this.

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5.3 INTERFACING
Application Interfaces / Openness

The provision of OPC client functionality for SCADA to access devices in an

open and standard manner is developing. There still seems to be a lack of
devices/controllers, which provide OPC server software, but this improves rapidly as
most of the producers of controllers are actively involved in the development of this
standard.

THE PRODUCTS ALSO PROVIDE

• an Open Data Base Connectivity (ODBC) interface to the data in the

archive/logs, but not to the configuration database,

• an ASCII import/export facility for configuration data,

• a library of APIs supporting C, C++, and Visual Basic (VB) to access data in the
RTDB, logs and archive. The API often does not provide access to the product's
internal features such as alarm handling, reporting, trending, etc.

The PC products provide support for the Microsoft standards such as Dynamic Data
Exchange (DDE) which allows e.g. to visualize data dynamically in an EXCEL
spreadsheet, Dynamic Link Library (DLL) and Object Linking and Embedding (OLE).

5.4 DATABASE
The configuration data are stored in a database that is logically centralized but
physically distributed and that is generally of a proprietary format. For performance
reasons, the RTDB resides in the memory of the servers and is also of proprietary format.
The archive and logging format is usually also proprietary for performance reasons, but
some products do support logging to a Relational Data Base Management System
(RDBMS) at a slower rate either directly or via an ODBC interface.

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5.5 SCALABILITY
Scalability is understood as the possibility to extend the SCADA based control
system by adding more process variables, more specialized servers (e.g. for alarm
handling) or more clients. The products achieve scalability by having multiple data
servers connected to multiple controllers. Each data server has its own configuration
database and RTDB and is responsible for the handling of a sub-set of the process
variables (acquisition, alarm handling, archiving).

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CHAPTER 6
TYPES OF SCADA SYSTEMS
There are different types of SCADA systems that can be considered as SCADA
architectures of four different generations:

1. First Generation: Monolithic or Early SCADA systems,

2. Second Generation: Distributed SCADA systems,
3. Third Generation: Networked SCADA systems and
4. Fourth Generation: Internet of things technology, SCADA systems

1. Monolithic or Early SCADA Systems

Minicomputers are used earlier for computing the SCADA systems. In earlier
times, during the time of first generation, monolithic SCADA systems were developed
wherein the common network services were not available. Hence, these are independent
systems without having any connectivity to other systems.

Fig. 6.1 : Monolithic or Early SCADA Systems

All the remote terminal unit sites would connect to a back-up mainframe system
for achieving the first generation SCADA system redundancy, which was used in case of
failure of the primary mainframe system. The functions of the monolithic SCADA
systems in the early first generation were limited to monitoring sensors in the system and
flagging any operations in case of surpassing programmed alarm levels.

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2. Distributed SCADA Systems

In the second generation, the sharing of control functions is distributed across the
multiple systems connected to each other using Local Area Network (LAN). Hence, these
were termed as distributed SCADA systems. These individual stations were used to share
real-time information and command processing for performing control tasks to trip the
alarm levels of possible problems.

Fig. 6.2 : Distributed Scada System

The cost and size of the station were reduced compared to the first generation
system, as each system of the second generation was responsible for performing a
particular task with reduced size and cost. But even in the second generation systems also
the network protocols were not standardized. The security of the SCADA installation was
determined by a very few people beyond the developers, as the protocols were
proprietary. But generally the security of the SCADA installation was ignored.

3. Networked SCADA Systems

The current SCADA systems are generally networked and communicate using

Wide Area Network (WAN) Systems over data lines or phone. These systems use
Ethernet or Fiber Optic Connections for transmitting data between the nodes frequently.
These third generation SCADA systems use Programmable Logic Controllers (PLC) for
monitoring and adjusting the routine flagging operators only in case of major decisions
requirement.

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Fig. 6.3 Networked SCADA Systems

The first and second generation SCADA systems are limited to single site networks or
single building called as sealed systems. In these systems, we can not have any risk
compared to the third generation SCADA system which are connected to the internet
causing the security risks. There will be several parallel working distributed SCADA
systems under a single supervisor in network architecture.

4. Internet of Things

In fourth generation, the infrastructure cost of the SCADA systems is reduced by

adopting the internet of things technology with the commercially available cloud
computing. The maintenance and integration is also very easy for the fourth generation
compared to the earlier SCADA systems.

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Fig. 6.4 : Internet Of Things

These SCADA systems are able to report state in real time by using the horizontal
scale from the cloud computing facility; thus, more complex control algorithms can be
implemented which are practically sufficient to implement on traditional PLCs.

The security risks in case of decentralized SCADA implementations such as a

heterogonous mix of proprietary network protocols can be surpassed using the open
network protocols such as TLS inherent in the internet of things which will provide
comprehendible and manageable security boundary.

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CHAPTER 7
APPLICATIONS OF SCADA
SCADA systems are used for monitoring a variety of data like flows, currents,
voltages, pressures, temperatures, water levels, and etc., in various industries. If the
system detects any abnormal conditions from any monitoring data, then the alarms at the
central or remote sites will be triggered for alerting the operators through HMI.

There are numerous applications of SCADA systems, but a few most frequently used
SCADA applications include:

1. Manufacturing Industries
2. Waste Water Treatment and Distribution Plants
3. SCADA in Power System

1. SCADA In Manufacturing Industries

In manufacturing industries the regular processes like running the production

systems to meet the productivity targets, checking the number of units produced and
counting the completed stages of operations along with temperatures at various stages of
the manufacturing process, and so on, are taken care by using the SCADA application.

2. SCADA Application in Waste Water Treatment and Distribution Plants

Wastewater treatment plants are of different types such as surface-water treatment

and a well water treatment system in which many control systems and automation
processes are involved in water treatment and distribution systems. SCADA systems are
used for controlling the automatic operations of the equipment used like backwashing the
filters based on the hours of working or amount of water flow through the filters.

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Fig. 7.1 Waste Water Treatment and Distribution Plants

In distribution plants the water tank levels, pressure of system, temperature of

plant, sedimentation, filtration, chemical treatment and other parameters or processes are
controlled using the SCADA applications such as PLCs, PC based workstations which are
connected each other using Local Area Network (LAN) such as Ethernet.

3. SCADA in Power System

Power system can be defined as constituent of power generation, transmission and

distribution. All these sectors are needed to be monitored regularly for improving the
system efficiency. Thus, the application of SCADA in power system improves the overall
efficiency of the system by providing the supervision and control over the generation,
transmission and distribution systems. SCADA in the power system network increases the
system’s reliability and stability for integrated grid operation.

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Fig. 7.2 :Scada in Power System

Wireless SCADA

In large scale industries like power plants, steel plants and so on, many processes
and operations such as movement of conveyer belts for coal or product transport, boiler
heat temperature, etc. are to be monitored continuously and there is need to control the
factors affecting these parameters. So, application of wireless SCADA will provide better
control over the required control systems and operations.

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Fig. 7.3 : Wireless Scada

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CHAPTER 8
FUNCTIONALITY
8.1 ACCESS CONTROL
Users are allocated to groups, which have defined read/write access
privileges to the process parameters in the system and often also to specific
product functionality.

8.2 MMI
The products support multiple screens, which can contain combinations of
synoptic diagrams and text. They also support the concept of a "generic" graphical object
with links to process variables. These objects can be "dragged and dropped" from a library
and included into a synoptic diagram. Most of the SCADA products that were evaluated
decompose the process in "atomic" parameters (e.g. a power supply current, its maximum
value, its on/off status, etc.) to which a Tag-name is associated. The Tagnames used to link
graphical objects to devices can be edited as required. The products include a library of
standard graphical symbols, many of which would however not be applicable to the type
of applications encountered in the experimental physics community. Standard windows
editing facilities are provided: zooming, re-sizing, scrolling... On-line configuration and
customization of the MMI is possible for users with the appropriate privileges. Links can
be created between display pages to navigate from one view to another.

8.3 TRENDING

The products all provide trending facilities and one can summarize the common
capabilities as follows:

• the parameters to be trended in a specific chart can be predefined or defined on-

line

• a chart may contain more than 8 trended parameters or pens and an unlimited
number of charts can be displayed (restricted only by the readability)

• real-time and historical trending are possible, although generally not in the same
chart

• historical trending is possible for any archived parameter

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• zooming and scrolling functions are provided

• parameter values at the cursor position can be displayed

The trending feature is either provided as a separate module or as a graphical object

(ActiveX), which can then be embedded into a synoptic display. XY and other statistical
analysis plots are generally not provided.

8.4 ALARM HANDLING

Alarm handling is based on limit and status checking and performed in the data
servers. More complicated expressions (using arithmetic or logical expressions) can be
developed by creating derived parameters on which status or limit checking is then
performed. The alarms are logically handled centrally, i.e., the information only exists in
one place and all users see the same status (e.g., the acknowledgement), and multiple
alarm priority levels (in general many more than 3 such levels) are supported.

It is generally possible to group alarms and to handle these as an entity (typically filtering
on group or acknowledgement of all alarms in a group). Furthermore, it is possible to
suppress alarms either individually or as a complete group. The filtering of alarms seen on
the alarm page or when viewing the alarm log is also possible at least on priority, time and
group. However, relationships between alarms cannot generally be defined in a
straightforward manner. E-mails can be generated or predefined actions automatically
executed in response to alarm conditions.

8.5 LOGGING/ARCHIVING
The terms logging and archiving are often used to describe the same facility.
However, logging can be thought of as medium-term storage of data on disk, whereas
archiving is long-term storage of data either on disk or on another permanent storage
medium. Logging is typically performed on a cyclic basis, i.e., once a certain file size,
time period or number of points is reached the data is overwritten. Logging of data can be
performed at a set frequency, or only initiated if the value changes or when a specific
predefined event occurs. Logged data can be transferred to an archive once the log is full.
The logged data is time-stamped and can be filtered when viewed by a user. The logging
of user actions is in general performed together with either a user ID or station ID. There
is often also a VCR facility to play back archived data.

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8.5 REPORT GENERATION

One can produce reports using SQL type queries to the archive, RTDB or logs. Although
it is sometimes possible to embed EXCEL charts in the report, a "cut and paste"
capability is in general not provided. Facilities exist to be able to automatically generate,
print and archive reports.

8.6 AUTOMATION
The majority of the products allow actions to be automatically triggered by
events. A scripting language provided by the SCADA products allows these actions to be
defined. In general, one can load a particular display, send an Email, run a user defined
application or script and write to the RTDB.

The concept of recipes is supported, whereby a particular system configuration

can be saved to a file and then re-loaded at a later date. Sequencing is also supported
whereby, as the name indicates, it is possible to execute a more complex sequence of
actions on one or more devices. Sequences may also react to external events. Some of the
products do support an expert system but none has the concept of a Finite State Machine
(FSM).

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CHAPTER 9
EVOLUTION

SCADA vendors release one major version and one to two additional minor
versions once per year. These products evolve thus very rapidly so as to take advantage of
new market opportunities, to meet new requirements of their customers and to take
advantage of new technologies.

As was already mentioned, most of the SCADA products that were evaluated decompose
the process in "atomic" parameters to which a Tagname is associated. This is impractical
in the case of very large processes when very large sets of Tags need to be configured. As
the industrial applications are increasing in size, new SCADA versions are now being
designed to handle devices and even entire systems as full entities (classes) that
encapsulate all their specific attributes and functionality. In addition, they will also
support multi-team development.

As far as new technologies are concerned, the SCADA products are now
adopting:

• Web technology, ActiveX, Java, etc.

• OPC as a means for communicating internally between the client and

server modules. It should thus be possible to connect OPC compliant third
party modules to that SCADA product.

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CHAPTER 10

POTENTIAL BENEFITS OF SCADA:

The benefits one can expect from adopting a SCADA system for the control of
experimental physics facilities can be summarized as follows:

• A rich functionality and extensive development facilities. The amount of effort

invested in SCADA product amounts to 50 to 100 p-years!

• The amount of specific development that needs to be performed by the end-user is

limited, especially with suitable engineering.

• Reliability and robustness. These systems are used for mission critical industrial
processes where reliability and performance are paramount. In addition, specific
development is performed within a wellestablished framework that enhances
reliability and robustness.

• Technical support and maintenance by the vendor.

For large collaborations, using a SCADA system for their controls ensures a common
framework not only for the development of the specific applications but also for operating
the detectors. Operators experience the same "look and feel" whatever part of the
experiment they control. However, this aspect also depends to a significant extent on
proper engineering.

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CHAPTER 11
CONCLUSION

 SCADA systems are most advancing computer application , so even once the
SCADA system is installed its up gradation can be easily done.

 SCADA is a control system with

 More interfaces and efficient storage

 More front end functionality

 Less expensive than DCS , but offer different functionality than DCS and finally
various applications.

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