SCADA is a type of process control system architecture that uses computers,

networked data communications and graphical Human Machine Interfaces (HMIs) to

enable a high-level process supervisory management and control.

SCADA systems communicate with other devices such as programmable logic

controllers (PLCs) and PID controllers to interact with industrial process plant and
equipment.

SCADA systems gather pieces of information and data from a process that is analyzed
in real-time (the“DA”in SCADA). It records and logs the data, as well as representing
the collected data on various HMIs.

This enables process control operators to supervise (the “S” in SCADA) what is going
on in the field, even from a distant location. It also enables operators to control (the
“C” in SCADA) these processes by interacting with the HMI.

SCADA systems are essential to a wide range of industries and are broadly used for
the controlling and monitoring of a process and prominently used as system has the
power to control, monitor, and transmit data in a smart way. In modern world
everyone is looking for ways to increase automation and make smarter decisions
through the proper use of data and SCADA systems are a great way of achieving this.

SCADA systems can be run virtually, which allows the operator to keep a track of the
entire process from his place or control room. Time can be saved by using SCADA
efficiently. One such excellent example is, SCADA systems are used extensively in
the Oil and Gas sector. Large pipelines will be used to transfer oil and chemicals
inside the manufacturing unit.

Hence, safety plays a crucial role, such that there should not be any leakage along the
pipeline. In case, if some leakage occurs, a SCADA system is used to identify the

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leakage. It infers the information, transmits it to the system, displays the information
on the computer screen and also gives an alert to the operator.

Generic SCADA systems contain both hardware and software components. The
computer used for analysis should be loaded with SCADA software. The hardware
component receives the input data and feds it into the system for further analysis.

SCADA system contains a hard disk, which records and stores the data into a file,
after which it is printed as when needed by the human operator.

SCADA systems are used in various industries and manufacturing units like Energy,
Food and Beverage, Oil and Gas, Power, Water, and Waste Management units and
many more.

Objectives of SCADA
1. Monitor: SCADA systems continuously monitor the physical parameters
2. Measure: It measures the parameter for processing
3. Data Acquisition: It acquires data from Remote Terminal Units, data
loggers, etc
4. Data Communication: It helps to communicate and transmit a large amount
of data between MTU and RTU units
5. Controlling: Online real-time monitoring and controlling of the process
6. Automation: It helps for automatic transmission and functionality

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The SCADA systems consist of hardware units and software units. SCADA
applications are run using a server. Desktop computers and screens act as an HMI
which are connected to the server. The major components of a SCADA system
include:

 Master Terminal Unit (MTU)

 Remote Terminal Unit (RTU)
 Communication Network (defined by its network topology)

Master Terminal Unit (MTU)

MTU is the core of the SCADA system. It comprises a computer, PLC and a network
server that helps MTU to communicate with the RTUs. MTU begins communication,
collects and saves data, helps to interface with operators and to communicate data to
other systems.

Remote Terminal Unit (RTU)

Being employed in the field sites, each Remote Terminal Unit (RTU) is connected
with sensors and actuators. RTU is used to collect information from these sensors and
further sends the data to MTU.

RTUs have the storage capacity facility. So, it stores the data and transmits the data
when MTU sends the corresponding command. Recently developed units are
employed with sophisticated systems, that utilize PLCs as RTUs. This helps for direct
transfer and control of data without any signal from MTU.

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Communication Network
In general, network means connection. The communication network is defined as a
link between RTU in the field to MTU in the central location. The bidirectional wired
or wireless communication channel is used for networking purposes. Various other
communication mediums like fiber optic cables, twisted pair cables, etc. are also used.

Functions of SCADA Systems

In a nutshell, the SCADA system is a collection of hardware and software
components that allows the manufacturing units to perform specific functions. Some
of the important functions include

 To monitor and gather data in real-time

 To interact with field devices and control stations via Human Machine
Interface (HMI)
 To record systems events into a log file
 To control manufacturing process virtually
 Information Storage and Reports

SCADA Applications
SCADA has made comprehensive use of features such as Flexibility, Reliability, and
Scalability in Automating complex systems.

There are countless applications in the real world where SCADA has already been
effective in providing surveillance and control alternatives across a broad spectrum of
sectors, from energy production to agricultural systems.

SCADA is widely used in different areas from chemical, gas, water, communications,
and power systems.

Electric Power Generation, Transmission, and Distribution

Using SCADA systems, electrical utilities detect current flow and line voltage,
monitor circuit breaker operation (e.g. a vacuum circuit breaker or SF6 circuit
breaker), and take sections of the power grid online or offline.

Thermal Power Plants

Most operational inspections of Thermal Power Plants are Automatic. However,
manual action may be necessary at times. The plant is therefore equipped with
Monitoring and Alarm systems that alert plant operators when certain working para
counter deviates significantly from their normal range.

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The demand for greater reliability and effectiveness is growing in Thermal Power
plants. After periodic intervals, the power plant needs continuous inspection and
tracking. There may be chances of mistakes when human employees measure at
different phases.

To improve Reliability, Automation is required to improve the general power plant

efficiency. Automation is established through the use of PLC & SCADA, resulting in
decreasing human mistake. SCADA system is used to supervise a complete process.

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 PLC and SCADA
A PLC is a “Programmable Logic Controller”. This is essentially a ruggedized
mini-computer that sits out in the field within a panel, with a bunch of inputs and
outputs leading from devices in the field into the PLC. The PLC will monitor the state
of these inputs (e.g. the speed of a motor) and depending on the program inside,
programmatically output various signals to control these field devices (e.g. stop the
motor).

SCADA systems sit “on top” of programmable logic controllers. PLCs are almost
always part of a SCADA network and form an interface between the field and
SCADA. The data that is logged and stored in a SCADA system is typically acquired
through communication with the PLC. The PLC will continue to execute its program,
reading inputs, and writing outputs.

The SCADA system is used to keep a log of the historical state of these inputs and
outputs, which can be used for data analysis or auditing. Programmable logic
controllers have a limited capacity for long-term data storage.

Although SCADA systems can be programmed to control certain aspects of the field
this is usually an unwanted situation. Ideally, your PLC would run autonomously,
able to programmatically handle any situation it encounters. Due to the complexity of
the Real World, this is often not the case. In these cases, operator input is required for
the correct functioning of these semi-autonomous systems.

Hence the level of “control” to the SCADA screen (i.e. HMI software) that the
operator interacts with is generally much less than the control executed by a PLC.
Anything that can be easily programmed into logic (e.g. IF the flow rate exceeds 100
meters/second, STOP the pump) will be programmed into the PLC.

The SCADA systems are primarily used for Monitoring and Data acquisition, with
control capabilities used under irregular or complex circumstances. SCADA allows
operators (and control systems engineers) to see an overview of the plant from a
distance, giving them the ability to respond to any abnormal states. It should be noted
that a SCADA system technically includes PLCs, which SCADA will communicate
with.

A PLC sits in the field and will read field inputs (e.g. conveyor belt has stopped) and
write outputs (e.g. start conveyor belt) depending on how it is programmed. A PLC
forms part of a SCADA network, asynchronously receiving and executing certain
commands from SCADA (e.g. operator commands to stop the pump), as well as being
read by a SCADA network as a source of data.

SCADA, is a system comprised of hardware and software components used to

monitor and control industrial processes. With a SCADA system, manufacturers are
able to collect and analyze real time production data, monitor and manage alarms, and

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program automatic control responses triggered by certain events or system
parameters.

To perform functions, SCADA integrates with sensors and other measuring devices,
which can be in either digital or analog form, to collect data. The collected data is
then sent to remote terminal unit (RTU) or programmable logic controller (PLC) to
be translated to usable information. Finally, the information is relayed to a human
machine interface (HMI) or other types of displays for operators to analyze and
interact with.

SCADA systems also enable the ability to automate the control of industrial processes
and machines that would otherwise be too complex for manual human control.
Through the use of sensors and measuring devices, SCADA systems can detect
abnormal parameters or alarms and automatically respond with a programmed control
function. For example if an Alarm occurred signaling to much pressure in a line, the
SCADA system would trigger a programmed response to open a pressure relief valve
to return pressure levels to a normal amount.

There are numerous SCADA platforms around the world such as Rockwell Factory
Talk, Siemens, Wonderware Systems Platform, and Ignition. Each of these platforms
can be programmed with modern web languages such as HTML5, Python, and PHP,
and integrated with generalized database software such as SQL (Structured Query
Language is a programming language designed for managing data in relational
database management systems).

The SCADA system is a collection of both software and hardware components that
allow supervision and control of plants, both locally and remotely. The SCADA also
examines, collects, and processes data in real time.

Human Machine Interface (HMI) software facilitates interaction with field devices
such as pumps, valves, motors, sensors, etc. Also within the SCADA software is the
ability to log data for historical purposes.

The structural design of a standard SCADA system starts with Remote Terminal Units
(RTUs) and/or Programmable Logic Controllers (PLCs). The RTUs and PLCs are
microprocessors that communicate and interact with field devices such as valves,
pumps, and HMIs.

That communication data is routed from the processors to the SCADA computers,
where the software interprets and displays the data allowing for operators to analyze
and react to system events.

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Before SCADA, plant personnel had to monitor and control industrial processes via
selector switches, push buttons, and dials for analog signals. This meant that plants
had to maintain personnel on site, during production, in order to control the processes.

As manufacturing grew and sites became more remote in nature, relays and timers
were used to assist in the supervision and control of processes. With these devices
employed, fewer plant personnel were required to be on site in order to oversee and
control operations.

While relays and timers did provide some level of automation, the panels required for
these devices took up valuable real estate, troubleshooting was a nightmare, and
re-configuring was difficult at best.

These issues, in conjunction with the need to grow even larger industrial plants,
helped to facilitate the birth of automation.

A SCADA system works by operating with signals that communicate via channels to
provide the user with remote controls of any equipment in a given system. It also
implements a distributed database, or tag database, that contains tags or points
throughout the plant. These points represent a single input or output value that is
monitored or controlled by the SCADA system in the centralized control room.

The points are stored in the distributed database as value-time stamp pairs. It is very
common to set up the SCADA systems to also acquire data, such as programmable
logic controller (PLC) register paths and alarm statistics.
While these systems simplify a given infrastructure, their components are quite
complex. There are Five essential composing parts of a SCADA system:

 Human Machine Interface (HMI)

 supervisory system
 Remote Terminal Units (RTUs)
 Programmable Logic Controllers (PLCs)
 communication infrastructures

The HMI processes data from each tag and sends it to a human operator, where he or
she then can monitor or control the system.
The supervisory system gathers the data sent from each tag and sends commands or
operations to the process. The RTUs connect sensors and convert their signals to
digital data and send it to the supervisory system, where it can be stored in a
distributed database.

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PLCs are used as field devices because they are much more versatile and economical
than process-specific RTUs.
Finally, the communication infrastructure delivers connectivity to the supervisory
system and then to the RTUs and PLCs for the user to command.
The communication infrastructure is necessary to relay data from remote RTU/PLCs,
which run along electric grids, water supplies, and pipelines.
Communication is the absolute most essential link for a SCADA system to operate
properly; however, how well the system manages communication from HMI to RTUs
and PLCs fundamentally determines how successful a SCADA system can be. The
basic infrastructure of SCADA system is shown.