1.

0 Introduction to Supervisory Control and Data Acquisition (SCADA)

Often referred to as a Telemetry System, Supervisory Control and Data Acquisition (SCADA)
systems are very similar to a DCS. The primary difference is that a SCADA system can monitor
and control many industrial processes or facilities over a larger geographical area; where as, a
DCS is typically confined to single processing or manufacturing facility. A SCADA system may
integrate other systems such as DAS and/or DCS as part of a SCADA system.

1.0.1 SCADA System Applications

Typical SCADA system applications include, but are not limited to, the following examples;
1. Monitoring and control of electric power grids, switching and distribution
stations.
2. Monitoring and control of oil, gas, water or other pipeline systems, including the
production and metering facilities, compression and or pumping stations,
mainline control stations and distribution facilities.
3. Monitoring and Control of irrigation systems

SCADA systems can be used to provide connectivity where physical access is restricted or
dangerous, or where manpower is limited.

Unlike a DAS or DCS that are typically supplied as an integrated hardware/software package by
a single vendor; SCADA systems generally consist of multi-vendor hardware and software
components, which are integrated into a working system.

Most SCADA systems are organized in a hierarchical structure.

Data Integrity, Customer,

Production, Scheduling and Management
Level 4 Information Level
Maintenance Planning,
Business etc.

Data communication links

Operator Interface, Reporting,

Level 3 Supervisory Control Level Archiving etc.

RTU, PLC, SLC, Flow

Level 2 Direct Control Level 2 Computers etc.

Remote I/O, Smart

Level 1 Direct Control Level 1 Instrumentation etc.

Process Measurement &

Controlled Variables

Process / Manufacturing

Figure 1

NAIT #1380 SCADA Systems 9-1

1.0.2 SCADA Operating Systems

Most SCADA systems use one of the common Operating Systems (OS) such as Disk Operating
System (DOS), Windows or UNIX to manage workstation hardware and software components.
Network Operating Systems (NOS) that are specific to the network architecture and OS being
used manage the networked systems. Network Management Systems (NMS) are used to control
and monitor large communication systems that make up a Wide Area Network (WAN).

1.0.3 SCADA Application Software

SCADA application software can be either proprietary or conform to open standards.

Proprietary systems are offered by single vendors providing a “turn key”, single platform
approach to SCADA system installation. Problems often arise when attempting to integrate
other vendor’s devices into the SCADA system. Open software allows the integration of
different vendor products within the same SCADA system. Vendors adhere to the rules and
protocols of open software standards that are established by user or engineering organizations.
Adhering to these rules ensure system interoperability. Object Linking and Embedding (OLE)
for Process Control (OPC) is an example of an open SCADA software guideline for data transfer
and interfacing in a process control environment. Other open standards can be utilized at each
level of a SCADA system. SCADA applications can be found at the Host and Remote
environments (refer to the appropriate area in this section for a detailed description of SCADA
applications).

1.0.4 SCADA System Hardware

There are three main hardware environments that make up a SCADA system, they are;
1. The Front End or Host,
2. The Communication Network,
3. The Remote.

Host Communication The Remote

Environment Environment Environment

Figure 2.

NAIT #1380 SCADA Systems 9-2

1.1 The SCADA Host Environment

The host environment typically consists of a number of hardware and software components
networked together into a Local Area Network (LAN). Services on the LAN will provide
specific functions such as;
 File, Printer, and Application sharing,
 History logging and trending,
 Report generation,
 Network and SCADA system management and engineering,
 Variable display and manipulation,
 SCADA Polling, and
 Data Communications.

Detailed information about LAN concepts are found in the Data Communication and ILAN
sections of this course pack. The LAN will be managed by the Network Operating System
(NOS). Application software and hardware resources will be controlled by the Operating
System.

RAID drive Printer Workstation

Internet

Workstation Workstation Telemetry Web Server /

Server Firewall

The Remote
Process /
Communication Manufacturing
Environment Environment
(Private, Leased, Virtual)

Figure 3.

NAIT #1380 SCADA Systems 9-3

1.2 The SCADA Communication Environment

Utilizing a telemetry system allows industry to connect to industrial processes, utilities and other
applications over a large geographical area. A SCADA system is the integration of a telemetry
system with a data acquisition and control system. Telemetry is used to send commands,
variables and programs and to receive monitoring information from remote locations. The
communication structure, often referred to as a Wide Area Network (WAN), could be made up
of a number of different devices and carrier systems. Common carrier systems will utilize one
or more of the following systems;
 Radio systems
 Microwave
 Satellite
 Fiber optics
 Hard wired cable systems

These carrier systems will utilize devices according to the application and protocols being
implemented. Communication devices could include (but are not limited to);
 Line drivers,
 Modems,
 Radios and antenna systems,
 multiplexors,
 LAN components.

Mux / Demux Mux / Demux

SCADA SCADA
Telephone Telephone
Modem Modem
Network Network
Management Management
Figure 4.

For more information on these systems refer to the appropriate communication section in this
course pack.

The communication structure of a SCADA system will be dictated by a number of factors

including;
 The type of information being transferred
 Hardware device types
 Process Applications
 Hardware/Software application interfaces
 Bandwidth requirements
 Availability and the type of existing communication facilities
 Facility locations
 Installation and maintenance cost

NAIT #1380 SCADA Systems 9-4

Large private or leased communication systems are often managed by a Network Management
System (NMS). A NMS will allow technical staff to monitor and control the data
communication equipment that make up the communication system. The technician can gain
remote or local access to communication devices allowing them to perform functions such as;
 Device diagnostics and configuration
 Circuit diagnostics
 Device resetting
 Alarm and report generation

Large SCADA systems often utilize leased or privately owned communication facilities. Other
systems may use the existing Internet infrastructure. Virtual Private Networks (VPN) provide a
relatively secure method for transferring data over the Internet while avoiding the costs of
leasing or owning private facilities.

1.3 The Remote SCADA Environment

A SCADA system includes a number of devices at remote (in relationship to the Host) industrial
facilities. The primary functions of these devices are to collect field data and send this data, via
the communication link, to the Host system and to perform local control and monitoring tasks.
These devices may be components within a complex DCS or DAS. Other devices may not be
part of a DCS or DAS and only having a communication link to the host. Hardened Computers,
PLCs, RTUs, Loop Controllers, Flow Computers and intelligent instrumentation can be
configured as Remote devices within the SCADA network. Typically, all of these devices or
systems are designed to perform stand-alone operation in case the communication link to the
host is severed.

Communication
The SCADA Host
Environment

Radio/Modem
Radio tower RTU

Radio/Modem Radio tower

PLC PLC Radio/Modem

Radio tower RTU

Flow Computer
PLC

Figure 5.

NAIT #1380 SCADA Systems 9-5

1.4 DAS, DCS and SCADA Remote Hardware Architecture

Generally, remote devices are microprocessor-based devices having their own memory, power
supply, Input/Output (I/O) and communication modules. A Microcontroller can be used to
provide control, monitoring and data acquisition functions within a “Stand-Alone”, DAS, DCS
or a SCADA system. The Microcontroller can be a hardened PC, Remote Terminal Unit (RTU),
Programmable Logic Controller (PLC), Flow Computers, Digital Controller or some other
microprocessor based device. These devices can operate independent of a central or host
computer system in the event of a communication failure. In this configuration, a host can be
limited to providing operator graphic displays and history archiving functions.

Communication Other Microcontrollers,

Modules
Host systems, HMI, etc.

Manipulated Measured
Output Modules CPU / Memory Input Modules
Variables Variables

Power Supply

Uninterruptible
Power Supply

Figure 6.

I/O modules provide the interface between the Microcontroller that execute the programmed
tasks and the end-devices that measure and control the process variables. I/O modules will vary
between DAS, DCS and SCADA systems and may include;
 Analog Input modules,
 Analog Output modules,
 Discrete Input modules,
 Discrete Output modules,
 Pulse Input or Counter modules.

Microcontrollers typically have communication modules or ports that provide access to read or
write information. Typical uses for this access are to;
 Monitor data variables (Measured Variables, Calculated Variables, Historical Data, etc.)
 Change data variables (Controlled Variables, Setpoints, Tuning Parameters, Alarm
Points, Configuration, etc.)
Communication ports provide a connection to;

NAIT #1380 SCADA Systems 9-6

  Local display panels or terminals,
 Engineering stations,
 Other networked PLCs, RTUs, Controllers, Instrumentation, etc., and
 Telemetry equipment.

Communication protocols such as Ethernet, Modbus, DH +, Profibus, HART, to name a few,

dictate the method of communicating. Other physical standards such as EIA-RS232 and RS485
determine how the ports are connected.

1.4.1 Centralized Control

Control and monitoring functions are concentrated into a single large-scale computer. Typically
there is little or no decentralized processing functions done in remote microcontrollers or
instrumentation devices. I/O modules plug into the backplane or directly into the motherboard
of the computer. The main disadvantage of a centralized approach is that all the processing
capability is concentrated into one computer system. The consequences of a single component
failure can be very high.

From the centralized computer many services are provided including;

 front end processing and scanning of the I/O points
 task execution
 operator interfacing
 history logging and trending
 communications

Centralized systems are not as common in modern applications as they once were. A high
degree of flexibility can be achieved by decentralized control and monitoring systems and
distributing them in close proximity to the process. Control and monitoring functions may be
distributed among other microcontrollers, I/O chassis and/or smart instruments.

1.4.2 Distributed Microcontrollers

Distributing Microcontroller throughout a process environment allows for greater system

flexibility and is common in modern applications. A networked approach to control, monitoring
and data acquisition is a core function of a Distributed Control System (DCS). A DCS can be a
sub-component of a SCADA system.

NAIT #1380 SCADA Systems 9-7

 Control Room
Gas Plant
Inlet Control & Gas
Monitoring Processing
Operator Console

PLC PLC

Flow Computer
PLC

Gas Gas Plant

Compression Sales Metering

Figure 7.

Advantages of the decentralized Microcontroller approach include;

 High data acquisition speeds are possible. This is limited only by the scan rate of the
module and by the execution time of the program.
 System modularity - The affect on the system is limited if one component (a host or
Microcontroller) fails.
 The host is relieved of local control functions, which gives it more time for running
its operator and database services.
 Most microcontrollers support one or more network protocols (Modbus, A-B Data
Highway) that provide good data reliability.
 Many vendors provide flexible software solutions that meet the needs of many
different applications.

I/O modules plug into the chassis backplane or directly into the motherboard of the
Microcontroller. Either way, there is a bus connecting all the I/O modules to the processor and
the power supply. The main disadvantages of this approach is that the number of data points can
be limited by the board density (the number of I/O points per module) and the number of plug-in
slots available for I/O modules on the Microcontroller. A common approach to overcoming the
limited I/O count is to use Remote I/O and/or Fieldbus instruments.

NAIT #1380 SCADA Systems 9-8

1.4.3 Remote I/O

Distributed or Remote I/O can be connected to a Microcontroller by using serial data

communication links. Remote modules may support a variety of communication protocols
including (but not limited to) Ethernet, Modbus, DH+, HART, Profibus and DeviceNet.
Modules are often multifunctional providing analog, digital, counter and encoded data. Their
modular approach allows for easy system expansion. Remote I/O often has the ability to process
its own program and provide specific functions and diagnostics in the case of a communication
failure to the primary Microcontroller.

PLC w/ Local I/O

HMI

Programmer/Operator
Station
Remote I/O

Field Instruments

Serial communication
links

Field Instruments

Figure 8.

1.4.4 Fieldbus Devices

These are field devices such as transmitters or valve positioners which are designed to
communicate digitally with controllers, workstations and servers. They are designed using
different communication protocols such as HART, FOUNDATION Fieldbus H1, PROFIBUS
PA. These protocols are based on the OSI reference model. When these devices are properly
networked, data can be sent directly to the controllers and stored in the information system for
processing. Field data can hence be easily accessed by management systems using host-level
communication protocols.

NAIT #1380 SCADA Systems 9-9

1.4.5 Remote Terminal Units (RTU)

Early devices had little intelligence and were primarily used as a device for remotely gathering
analog or discrete signal data. When polled, the RTU transmitted the data to a central host
where control calculations were performed.

RTUs are currently found within DAS, DCS, and SCADA systems. Modern RTUs can operate
within a stand-alone or networked environment while performing most of the functions provided
by earlier central host computers. RTUs have the processing power, memory and I/O
capabilities to be used in a variety of complex applications. RTUs can support local and remote
I/O. Some of the more notable applications for RTUs include;
 PID control,
 Complex flow computations (i.e. American Gas Association (AGA) methods),
 History logging and trending,
 Data concentration and switching.

RTUs normally have extensive digital communication capabilities including;

 Asynchronous and synchronous communication,
 Dial up or radio modem,
 Protocol emulation and data conversion for networking,
 Multiple communication ports.

1.4.6 Programmable Logic Controllers (PLC)

Early Programmable Logic Controllers (PLC) were primarily designed to replace

electromechanical relay circuits. The programming language for the PLC was developed to
represent logic diagrams used by electricians within the plant facility. PLCs are currently found
within DCS, and SCADA systems.

PLCs have the capabilities to be used in a variety of complex applications similar to a RTU.
With the increased capabilities in hardware and software the description that separates a PLC
from a RTU is based more on historical application then present capabilities. RTU and PLC
systems support programming languages such as IEC-61131, and object linking protocols such
as OPC. Modern PLCs can operate within a stand-alone or networked environment. PLCs can
support local and remote I/O. Some of the more notable applications for PLCs include;
 PID control
 Logical control
 Position control

For more information on PLCs, refer to the PLC section in this manual.

NAIT #1380 SCADA Systems 9-10

Flow Computers

Flow computers were designed to replace chart recorders. The primary function of a Flow
Computer is to perform complex flow calculations. Having a computer calculating flow has
many advantages including;

 increased accuracy and repeatability

 speed, as the manual integration of charts is no longer required
 memory, information can be archived on the computer or a mass storage device
 maintenance is reduced to routine calibration and verification
 data can be communicated directly to the users via a telemetry systems

Disadvantages may include;

 Flow computers can be relatively expensive

 Power is required
 Technical complexity is increased
 Data can be lost or corrupted if it is not handled properly

The flow calculations can demand a large amount of processing time from the microprocessor
and therefore the number of tasks performed is limited. Tasks typically performed by a flow
computer will include;

 reading process variables from devices such as;

- Flow meters (mass or volume)
- DP cells
- Pressure transmitters
- Temperature transmitters
- density transmitters
- gas chromatographs

 Performing standard flow calculations (AGA 8, AGA 7, AGA 3,)

 Archiving flow accumulations
 Communicating to host computers or analytical instruments

NAIT #1380 SCADA Systems 9-11

1.4.7 Hardened Personal Computer (PC)

A hardened PC is a computer which has been ruggedized to enable installation on the factory
floor or in other harsh environments. Hardening is accomplished in a variety of ways:
 By enclosure
- Several manufactures offer PC type computers in NEMA 2 and 4 enclosures
 By improved card edge connector systems
- Several manufactures offer PCs, which plug into bus back planes
- Numerous PLC manufactures offer entire PC ATs which plug into PLC chassis's
 By using ruggedized I/O
- VGA and EGA screens have been enclosed in NEMA enclosures
- Keyboards can be sealed and "spill proof"
- Disk storage is replaced by:
- Solid state disks
- Bubble memory modules
- Analog and digital inputs with protection against over voltage

NAIT #1380 SCADA Systems 9-12

 Appendix A – SCADA Examples

A large natural gas transmission SCADA system

A large gas transmission system may have hundreds, even thousands of facilities that are
monitored and/or controlled, in some capacity, by a SCADA system. These facilities may
include receipt and sales metering stations, compressor stations and control stations. The
geographic span of a pipeline system can be intercontinental, reaching (as an example) from
Alaska to Mexico. The pipeline system will gather gas from a number of producers at different
receipt facilities and blend it with the other producer’s gas in the mainline. Compression
facilities “draft” and “pack” the gas as it moves from the receipt facilities to the delivery point
where it is measured again.

A pipeline system as described above would be unable to operate safely or efficiently without
SCADA system. Implementing a SCADA system on the above system would provide functions
including the following;
 Gas delivered from the pipeline to end users (utilities or large industrial users) and gas
received from producers into the pipeline must be measured and controlled.

 Real time, load forecasting allows for efficient pipeline balancing. Supply is balanced
with customer demands. A prediction of customer demand is based on information
gathered from sources such as weather forecasts and actual customer requests.

 Control and monitoring of gas transmission facilities ensures safe and efficient pipeline
operations. These facilities will include;
 metering stations (inlet, mainline and outlet)
 compressor stations (series and parallel units)
 routing of gas flow (pipeline cross-overs and inter-connects)
 from storage or suppliers
 to users or storage
 to parallel pipelines or compression facilities

 Hydraulic analysis of gas flow characteristics can ensure systems are operated in the most
efficient manner. Dangerous operating conditions can be avoided and pipeline leakage
can be detected.

 Information related to gas volumes, pressures, flow rates and facility status could be
archived for future analysis or trending.

 Information gathered from the SCADA system is used to create customer-billing

information. Special precautions are implemented to ensure that the information is of the
highest integrity.

NAIT #1380 SCADA Systems 9-13

The Host Environment

A large pipeline system is typically controlled from a central hub or operations center.
Contingency facilities will provide limited to complete back-up control of the pipeline
operations center. These contingency facilities may be a redundant, on line system or a hot
standby system requiring a logical switch-over in order to be activated. The contingency
facilities may be located at one facility or distributed in strategic locations within the SCADA
network.

The operations center will typically take advantage of a Local Area Network (LAN) to distribute
the processing requirements to different nodes or servers. The application of these nodes may be
distributed as follows:
 A polling server acts as the front end to the SCADA system. This node provides an
interface between the LAN and the communication environment that connects to the
remote SCADA facilities. A requirement to poll beyond 10,000 variables/minute
from remote locations is not unusual.
 A database/historical server will store large amounts of data that is gathered from the
polling server. This node allows many application servers to access this information
for their specific requirements.
 Operator stations display the information gathered by the SCADA system to
operators. The operators use this information to operate and control the pipeline,
create reports and troubleshoot technical and operational problems.
 Engineering Stations provide a means for technical staff to modify, control and
troubleshoot the SCADA system.
 Other nodes often include accounting, engineering and management applications.

The Communication Network

The communication networks topology and architectures will be influenced by considerations

such as;
 The type and number of applications being carried by the communication network.
In addition to SCADA, applications such as voice (radio trunks & telephone) network
management, e-mail and other data transfers between office LAN’s and facility
security may require bandwidth on the communication channels.
 The number of field locations will effect the amount of traffic on the network and the
path routing.
 The geographic distribution of these locations will effect the path routing and the
type of carrier system selected. Carrier systems may include one, or a combination of
the following methods;
 VHF/UHF or microwave radio,
 leased or dial-up telephone lines,
 privately owned field wiring,
 fiber optics,
 Satellite (Very Small Aperture Terminal - VSAT).

NAIT #1380 SCADA Systems 9-14

The Remote

The remote location must have a device that will store the measured variables and package them
into a format that can be transmitted over the communication network. In addition to this form
of data concentration, it may be required to receive information such as control setpoints or
logical commands. The remote can typically perform stand-alone functions should the
communication channel or host fail. Typical remote locations may have one or more of the
following devices;
- Remote Terminal Units,
- Programmable Logic Controllers,
- Flow computers,
- Single Loop (SLDC) and Multi-Loop Digital Controllers (MLDC),
- Hardened P.C.,
- Motor controllers,
- Smart Instrumentation and Analyzers.

The remote location may be as complex as a DCS or DAS.

A small oil and gas field SCADA System

This example of a small SCADA system allows for the monitoring and control of a gas field that
consists of;
- 3 remote compressor sites, and
- 6 to 10 gas wells per compressor.

The Host could be located at the company’s regional office location or at one of the compressor
stations.

- system requirements
- monitor and control compressors
- monitor and control alarms
- do production accounting including
- gas flow calculations
- automatic report generation (daily, weekly, monthly production reports)

- system hardware
- HP Vectra (80386 based personal computer)with:
- 80387 math co-processor
- 100 MB Harddisk
- EGA display
- the PC acts as the
- system host
- gathers field data
- acts as the operator interface
- generates reports

NAIT #1380 SCADA Systems 9-15

- remote stations consist of:
- 2 to 3 RTUs (HP 49050)
- used as data communication concentrators and for point measurement and
valve control
- Daniel flow computers
- do AGA gas flow calculations on gas pipelines
- Microgard Controllers
- control compressors
- handle ESD (emergency shutdown)

NAIT #1380 SCADA Systems 9-16

Honeywell’s Local Control Network (LCN)

- An example of an industrial network used in a large scale DCS (Distributed Control

System).

- In this case, the DCS is Honeywell’s TDC 3000

- Note the architecture of the TDC 3000 in a previous handout.

- The LCN forms the main DCS backbone

- The devices which connect to the LCN are control room devices (Example:
Computing Module (C.M.), Application Module (A.M.), History Module (H.M.),
Universal Station (U.S.) and Universal Workstations (U.S.W.)) and bridges and
gateways to other systems (Processor Gateway, Highway Gateway and Network
Interface modules).

- Process oriented devices (example: Multifunction Controllers, Process Managers etc)

are connected to one of two or more sub networks (Data Highway or Universal
Control Network (UCN)).

- This architecture enables process control and monitoring functions to be physically

distributed throughout the plant.

o In this way, a problem or disaster in one area should have minimal effect on the
control equipment in other areas.

o The networks allow control devices and operator stations to share process related
information for display purposes or to form complex control strategies.

Example:

- sequential controls for start ups/shut down

- multivariable schemes
- feed forward

LCN Details

- Structured using ISO/OSI layer model and is based on IEEE 802.4

NAIT #1380 SCADA Systems 9-17

 LCN Physical Layer

- A dual-redundant multidrop bus

o The devices periodically switch from Cable A to Cable B.

o If one cable fails, communications are automatically moved to the alternate cable.

- Signal type is Manchester at 5Mbps

- Also a 12.5 kHz sine wave is transmitted over the bus. This signal is used for Real
Time synchronization by all of the network devices.

- Upt o 40 (or 64, references have conflicting data) can be connected to an LCN
segment (of these 40, up to 20 can be HGs’ or NIUs’)

- Cable is a 75Ω coaxial

- Maximum cable length is approx. 1000 ft (300m)

LCN Data Link Layer

- The LCN is based on IEEE 802.4

- Netowrk access method is token passing

- Has a 32 bit CRC

NAIT #1380 SCADA Systems 9-18

NAIT #1380 SCADA Systems 9-19