PAPER ON SCADA

(Supervisory Control And Data Acquisition)

ABSTRACT
In present days the demand for power is increasing rapidly and thus the need for the
production of more and more power. Due to complex nature of bulk power handling,
critical installations like electrical sub-stations are always been closely monitored.
Traditionally, this has been achieved by operating and maintenance of staff at every
substation. However, with increasing number of sub-stations and pressure to decrease
operational expenses it is no longer possible to man every new substation. On the other
hand at the data gathered in the sub-stations is gaining strategic importance in planning &
operations. In such situation therefore, it is desirable to have quick data acquisition and
instant response to any event, with minimum human intervention. The concept of
SCADA is ideally suited for such situations.
SCADA (Supervisory Control And Data Acquisition) system refers to the combination of
telemetry and data acquisition. It consists of collecting information, transferring it back to
a central site, carrying out necessary analysis and control, and then displaying this data on
a number of operator screens. The SCADA system is used to monitor and control a plant
or equipment. Control may be automatic or can be initiated by operator commands.
The development of SCADA can be traced back to the early 1900s with the advent of
telemetry. Telemetry involves the transmission and collection of data obtained by sensing
real-time conditions. The monitoring of remote conditions became possible with the
convergence of electricity, telegraph, telephone, and wireless communication technology.

In this paper we will discuss about the definition of SCADA, components of SCADA, the
evolution of SCADA, potential benefits of SCADA, the functionality and applications of
SCADA.
DEFINATION OF 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. As such, it is a
purely 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.
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 of several 100 thousands.
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.
ARCHITECTURE:
This section describes the common features of the SCADA products that have been
evaluated at CERN in view of their possible application to the control systems of the
LHC detectors [1], [2].
Hardware Architecture:
One distinguishes two basic layers in a SCADA system: 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. PLCs, 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. The data servers and client stations are NT platforms
but for many products the client stations may also be W95 machines. Fig.1. shows typical
hardware architecture.

Figure 1: Typical Hardware Architecture

Software Architecture:
The products are multi-tasking and are based upon a real-time database (RTDB) located
in one or more servers. Servers are responsible for data acquisition and handling (e.g.

polling controllers, alarm checking, calculations, logging and archiving) on a set of

parameters, typically those they are connected to.

Figure 2: Generic Software Architecture

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
products that were evaluated.
COMPONENTS OF SCADA SYSTEM:
Components of a SCADA System a SCADA system is composed of the following:
1. Field Instrumentation
2. Remote Stations
3. Communications Network
4. Central Monitoring Station

Fig 3: Components of SCADA System

Field Instrumentation refers to the sensors and actuators that are directly interfaced to the
plant or equipment. They generate the analog and digital signals that will be monitored by
the Remote Station. Signals are also conditioned to make sure they are compatible with
the

inputs/outputs

The

Remote

of

Station

the
is

RTU

or

installed

at

PLC
the

at

the

remote

Remote

plant

or

Station.
equipment

being monitored and controlled by the central host computer. This can be a
Remote Terminal Unit (RTU) or a Programmable Logic Controller (PLC).
The Communications Network is the medium for transferring information from one
location to another. This can be via telephone line, radio or cable.
The Central Monitoring Station (CMS) refers to the location of the master or host
computer. Several workstations may be configured on the CMS, if necessary. It uses a
Man Machine Interface (MMI) program to monitor various types data needed for the
operation.
Field Instrumentation:
Field Instrumentation refers to the devices that are connected to the equipment or
machines being controlled and monitored by the SCADA system. These are sensors for
monitoring certain parameters; and actuators for controlling certain modules of the
system.

These instruments convert physical parameters (i.e., fluid flow, velocity, fluid level,alarm
etc.) to electrical signals (i.e., voltage or current) readable by the Remote Station
equipment. Outputs can either be in analog (continuous range) or in digital (discrete
values). Some of the industry standard analog outputs of these sensors are 0 to 5 volts, 0
to 10 volts, 4 to 20 mA and 0 to 20 mA. The voltage outputs are used when the sensors
are installed near the controllers (RTU or PLC). The current outputs are used when the
sensors are located far from the controllers.
Digital outputs are used to differentiate the discrete status of the equipment. Usually, <1>
is used to mean EQUIPMENT ON and <0> for EQUIPMENT OFF status.
Actuators are used to turn on or turn off certain equipment. Likewise, digital and analog
inputs are used for control. For example, digital inputs can be used to turn on and off
modules on equipment. While analog inputs are used to control the speed of a motor or
the position of a motorized valve
Remote Station:
Field instrumentation connected to the plant or equipment being monitored and
controlled are interfaced to the Remote Station to allow process manipulation at a remote
site. It is also used to gather data from the equipment and transfer them to the central
SCADA system. The Remote Station may either be an RTU (Remote Terminal Unit) or a
PLC (Programmable Logic Controller). It may also be a single board or modular unit.
Single Board versus Modular Unit:
The Remote Station is usually available in two types, namely, the single board and the
modular unit. The single board provides a fixed number of input/output (I/O) interfaces.
It is cheaper, but does not offer easy expandability to a more sophisticated system. The
modular type is an expandable remote station and more expensive than the single board
unit. Usually a backplane is used to connect the modules. Any I/O or communication
modules needed for future expansion may be easily plugged in on the backplane.

RTU versus PLC:

The RTU (Remote Terminal Unit) is a ruggedized computer with very good radio
interfacing. It is used in situations where communications are more difficult. One
disadvantage of the RTU is its poor programmability. However, modern RTUs are now
offering good programmability comparable to PLCs.
The PLC (Programmable Logic Controller) is a small industrial computer usually found
in factories. Its main use is to replace the relay logic of a plant or process. Today, the PLC
is being used in SCADA systems to due its very good programmability. Earlier PLC's
have no serial communication ports for interfacing to radio for transferring of data.
Nowadays, PLC's have extensive communication features and a wide support for popular
radio units being used for SCADA system. In the near future we are seeing the merging
of the RTU's and the PLC's.
FEATURES & BENEFITS OF PLC BASED SCADA SYSTEMS:
Now lets look at some of the features and benefits you'll receive from a properly
engineered PLC-based SCADA system.
Features:

PLCs have no moving parts. They are extremely robust and reliable.

If communication with the MTU is lost, a PLC-based RTU can operate alone
through "intelligent" programming.

PLC programs are easy to understand and easy to use and can be completely
documented with simple and extensive descriptions, technical programming and
support manuals.

PLCs are modular and can provide room for future expansion and growth.

Programming for security sensors can be integrated into PLCs providing security
and monitoring of door switches, heat and motion detectors. The SCADA system
can then automatically notify as prescribed.

No waiting period to replace electrical components. The SCADA system can be

designed to use components that any local or national electrical distributor
supplies.

Standard built in diagnostics can continuously monitor and display all status and
fault information in easy to understand text.

The HMI (Human Machine Interface) software can provide extensive, on-screen
documentation including operators manual, wiring diagrams, programs, etc.

PLC-based SCADA systems can automatically gather and report data necessary to
comply with local, state and federal regulations in formats that integrate well will
Microsoft Excel, Access and Word.

Data collected can be stored in the PLC and also in the MTUs database providing
a more robust reporting system.

The SCADA system can keep managers and operators informed 24 hours a day
through automatic email, paging and dial-up call features.

Multiple user features can easily be integrated into the SCADA system through
web-based technology.

Benefits:
PLC-based equipment is usually more reliable and can run without direction from
the master control.
Operators can see real-time system trouble.
The number of customer complaints/inquiries can be drastically reduced, for
example: incoming calls concerning low pressure or poor water quality in water
systems.
PLC SCADA systems save time and money.
Wear and tear on equipment can be reduced by continuously monitoring levels.
The number of man-hours for troubleshooting and/or maintenance can be
drastically reduced.
Labor costs can be reduced through automatic report generating.

 Operating costs can be reduced and greater ROI (return on investment) can be
achieved by using a PLC-based SCADA system compared to a proprietary
system.
Compliance with local, state & federal agencies is met easier.
Expensive service calls by repair technicians can be eliminated.
Local system integrators and electrical distributors can provide the needed
support.
NBT PLC-based SCADA systems use open architecture, non-proprietary products
and protocol. Price lists are published to eliminate "hostage", discriminatory price
fixing.
Communication Network:
The Communication Network refers to the communication equipment needed to transfer
data to and from different sites. The medium used can either be cable, telephone or radio.
The use of cable is usually implemented in a factory. This is not practical
for systems covering large geographical areas because of the high cost of the
cables,

conduits

and

the

extensive

labor

in

installing

them.

The use of telephone lines (i.e., leased or dial-up) is a cheaper solution for systems with
large coverage. The leased line is used for systems requiring on-line connection with the
remote stations. This is expensive since one telephone line will be needed per site.
Besides that the leased lines are more expensive than ordinary telephone line. Dial-up
lines

can

be

used

on

systems

requiring

updates

at

regular

intervals

(e.g., hourly updates). Here ordinary telephone lines can be used. The host can dial a
particular number of a remote site to get the readings and send commands.
Remote sites are usually not accessible by telephone lines. The use of radio offers an
economical solution. Radio modems are used to connect the remote sites to the host. An

on-line operation can also be implemented on the radio system. For locations wherein a
direct radio link cannot be established, a radio repeater is used to link these sites.
Central Monitoring Station (CMS):
The Central Monitoring Station (CMS) is the master unit of the SCADA system. It is in
charge of collecting information gathered by the remote stations and of generating
necessary action for any event detected. The CMS can have a single computer
configuration or it can be networked to workstations to allow sharing of information from
the SCADA system.
A Man-Machine Interface (MMI) program will be running on the CMS computer. A
mimic diagram of the whole plant or process can be displayed onscreen for easier
identification with the real system. Each I/O point of the remote units can be displayed
with corresponding graphical representation and the present I/O reading. The MMI
program can also create a separate window for alarms. The alarm window can display the
alarm tag name, description, value, trip point value, time, date and other pertinent
information. All alarms will be saved on a separate file for later review.
A trending of required points can be programmed on the system. Trending graphs can be
viewed or printed at a later time. Generation of management reports can also be
scheduled on for a specific time of day, on a periodic basis, upon operator request, or
event initiated alarms.
Access to the program is permitted only to qualified operators. Each user is given a
password and a privilege level to access only particular areas of the program. All actions
taken by the users are logged on a file for later review.

ADVANTAGES 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 well-established framework that enhances
reliability and robustness.

Technical support and maintenance by the vendor.

A user-friendly interface for plant operators to monitor and control plant operation
and performance.

Immediate user-friendly notification of faults and out of specification operation.

A history of plant performance and events which allow easy fault finding.

Data upon which to base continual improvement adjustments.

A window into the plant for remote operators and supervisors via connection to
the site through standard grade telephone line and remote computer systems.

APPLICATIONS OF SCADA:
MISC. OIL & GAS SCADA & TELEMETRY

Water/C02 Injection Well SCADA System

Variable Frequency Drive (VFD) SCADA Communication

Wireless Tank Level Gauging System

CELLULAR SCADA & TELEMETRY

Cellular SCADA Networks using UNICON IP

Cellular SCADA for Well Monitoring

SATELLITE SCADA & TELEMETRY

UNICON Sat Satellite Modem for Pipeline Break monitoring

High Speed Satellite System gives Remote Access for Maintenance &
Configuration

SatAlarm Sentry for Flow Monitoring

SatAlarm Sentry for Compressor Monitoring

WATER SCADA & TELEMETRY

Remote Valve Control Telemetry

Sewage Treatment Plant Inflow Telemetry

Water Reservoir Pump Control Telemetry

Rechlorination Monitoring Telemetry

Municipal Water Wide Area SCADA / Tail End Data Extension

MANUFACTURING SCADA & TELEMETRY

Distributed Radio Network for Overhead Crane PLC Communications

ENVIRONMENTAL / AGRICULTURAL

Agricultural Monitoring System

GENERAL APPLICATIONS

Wireless ETHERNET Radio Connects Remote PLC To Host at 27+ Miles

Wireless I/O / End-to-End I/O Telemetry

CONCLUSION:
SCADA systems of today are an excellent means for operators of process control sites to
save time and money. SCADA networks require careful consideration of each
component, the network connecting the components, and the available power. Cost must
be considered when selecting the communications medium. The public Telephone
companies can be expected to provide favorable rates for SCADA systems, which
represent a major business segment in their territories. If wire is not available there is the
option of cellular communications. In some cases, such as power sub stations, cellular has
the advantage of an indirect connection, by-passing the requirement for expensive decoupling and protection for physical phone lines, which is very expensive. The modems
and the power source must be rugged and the specifications for this equipment must
exceed the temperature extremes anticipated at the installation. In conclusion this paper
gives a brief review of the SCADA components, architecture, benefits and applications.
BIBLIOGRAPHY:
1) A.Daneels, W.Salter, "Selection and Evaluation of Commercial SCADA Systems
for the Controls of the CERN LHC Experiments", Proceedings of the 1999
International Conference on Accelerator and Large Experimental Physics Control
Systems, Trieste, 1999, p.353.
2) www.micrologic-systems.com/primers/scada6.htm
3) www.epgco.com/scada-resources.html
4) www.arcweb.com
5) www.scadalink.com

6) www.wonderware.com/products/scada
7) www.dayton-knight.com/Projects/SCADA