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Architecture & Its Working

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SCADA stands for supervisory control and data acquisition. It is a type of software Structure & Tuning Methods

application program for process control. SCADA is a central control system that New 100+ Top Electrical Projects Ideas
consists of controllers network interfaces, input/output, communication equipment,
and software. SCADA systems are used to monitor and control the equipment in the
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industrial process which includes manufacturing, production, development, and First name or full name
fabrication. The infrastructural processes include gas and oil distribution, electrical
power, water distribution. Public utilities include a bus traffic system, airport. The
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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.
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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.

SCADA System Hardware Architecture

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.

Software Architecture of SCADA

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.
Data Acquisitions

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.

Data Communication

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.

Monitoring/Control

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.

Human Machine Interface

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

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

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.

Networked SCADA Systems

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

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.

Hackers
Terrorists
Malware
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.

PLC SCADA

The term PLC stands for programmable The term SCADA stands for Supervisory
logic control Control and Data Acquisition

PLC is hardware-based SCADA is software-based

PLCs are mainly used to control the SCADA is used to observe & run the
process of complex industries like motors processes of the plant.
and running machines.

The PLC includes Processor, I/O The SCADA system includes three
Modules, a Programming Device & essential components like MTU, RTU,
Power Supply and HMI

There are different types of PLC like fixed The different types of a SCADA system
or compact & modular. are monolithic, distributed, networked &
IoT

The i/p & o/ps are signified in NO (normal The input & outputs of SCADA are
open), NC (normal close) & coil contacts. represented through images.

In PLC, every component can be defined In SCADA, each component can be

through an address. defined through the name.

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.

Block Diagram of Temperature Control Industrial Plant

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.

SCADA for Remote Industrial Plant

Advantages

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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2 Comments

SCADA Says: REPLY

at
Supervisory Control and Data Acquisition mechanism plays an important role in determining the
processes and control system. It further sends processed information to supervising unit for
analytics. Schneider Electric India has helped businesses have a clear vision of machinery
operations with SCADA.

Tarun Agarwal Says: REPLY

at
Hi SCADA
Thank you so much for your response.

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