EIA 22526 unit 5 SKKBPP EE

SCADA System Overview

The task of supervision of machinery and industrial processes on a routine basis

can be an excruciatingly tiresome job. Always being by the side a machine or being
on a 24x7 patrol duty around the assembly line equipment checking the
temperature levels, water levels, oil level and performing other checks would be
considered a wastage of the expertise of the technician on trivial tasks. But, to get
rid of this burdensome task, the engineers devised equipment’s and sensors that
would prevent or at least reduce the frequency of these routine checks. As a result
of that, control systems and it’s various off springs like SCADA systems were
formed. Supervisory Control and Data Acquisition (SCADA) offers the ease of
monitoring of sensors placed at distances, from one central location.

History

Supervisory control first evolved in electric utility systems when a need to operate
remote substation equipment without sending in personnel or line crew at the
remote site was felt. In 1940s, a pair of wires for every unique equipment was used
between sites. The potential of multiplexing on one pair of lines was soon put to
use taking ideas from the Magnetic Stepping Switch developed by telephone
companies in the 30s. Security being an issue, a select-check-operate procedure
was adopted where the operator waited for acknowledgement from device before

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finally operating it. Taking further cues from the telephone relay systems and its
coding schemes, Westinghouse and North Electric Company developed the
Visicode supervisory control.

General Electric and Control Corporation too developed their own independent
supervisory control programs. These were used in pipelines, gas companies and
even airports for runway landing lights. These systems became popular during
1950 and 1965. By that time, i.e. in 1960s Telemetry was developed for monitoring
purposes. Before 1970’s equipment was generally hard wired as solid state devices
were in birth and infancy stages. But with the advent of low cost computer
technology, software and computers enabled the performing of the functions
previously done by technicians and operators sitting besides panel instruments and
tone telemetry.

The first push was given by the 8 and 16 bit computers called minicomputers. The
second was the microprocessors, several years later. Computers offered flexibility
in programming and communicating with field data acquisition units that was
previously being done by hard wired equipments. This was the dawn of SCADA.
Many organizations have been involved with the standardization of SCADA
systems since then, including the IEEE, American National Standards Institute,
Electric Power Research Institute, International Electrotechnical Commission,
DNP3 Users group etc.

Q: Elements of SCADA Systems

SCADA monitors, controls and alarms the plant and/or regional facilities’
operating systems from a centralized location. It includes the communication of
information between a SCADA central host computer, many scattered units and/or
Programmable Logic Controllers. For example, in a water filtration plant, the
remote units measure the pressure in pipes and report the readings to the central
computer located somewhere in the control tower. In case of any anomaly, the

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SCADA system would alert the main station of the problem apprising it of other
details like the severity of the anomaly and measurement values in an organized
fashion. The systems may vary from simple, like temperature reporting in a
building to complex like monitoring the traffic on many traffic lights. The system
consists of the following elements:

1. SCADA Master Station Computer Systems: It is the repository of the real-

time or near real-time reported data collected from the remote terminal units
connected to it. It is generally standard computer hardware equipment and very
few SCADA system suppliers have ventured out to make their own computer
equipment. A few companies like IBM and CDC did try making hardware for it,
but the effort was short lived and commercial off-the-shelf computer products
continue to be the main stay. The back end SCADA software must be able to
repeatedly poll the RTUs for data values, should have software for their retrieval,
storage and processing. The processing may include unit conversion, cataloguing
into tables etc.

2. Human-Machine Interface: This is the eye candy part on the host station.
The values that have been stored in the host computers are presented to the human
operator in an understandable and comprehensible form using HMIs. These may
provide trending, diagnostic or management information and detailed schematics
and animations representing the current states of the machines under its control.
Pictorial representation being more understandable to humans is the preferred form
in SCADA HMIs.

Q2: Explain block diagram of SCADA. Identify different components of it.

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RTU: Remote Terminal Unit [sensors, transducers interface terminal located in

plant.

MTU: Mater Terminal Unit [Controller, PLC]

Data Telemetry System: Transmission and reception.

Data Acquisition: multiple data collection

Server: Computers

HMI: SCADA software operating terminal.

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 RTUs (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

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6. Automation: It helps for automatic transmission and functionality

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)

Q3: Functions of SCADA Systems

In a nutshell, we can tell 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

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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.

Communication Network
In general, network means connection. When you tell a communication network,
it 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.

Q5: 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

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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.

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.

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.

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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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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.

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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Q6: Human-machine Interface (HMI)

It is an input-output device that presents the process data to be controlled by a

human operator. It is used by linking to the SCADA system’s software programs
and databases for providing the management information, including the scheduled
maintenance procedures, detailed schematics, logistic information, trending and
diagnostic data for a specific sensor or machine. HMI systems facilitate the
operating personnel to see the information graphically.

HMI :

Human machine interface (HMI) –also

known as User Interface (UI), Operator
Interface Terminal (OIT) or Man
Machine Interface (MMI) –
encompasses hardware and software
solutions for information exchange and
communication between
systems/machines and a human
operator.

In simple terms, the Human Machine Interface, commonly known as HMI, is the
means by which humans engage with machines to monitor, control and/or carry
out processes. Simple examples of Human Machine Interfaces are keyboards and
touchscreens.

HMIs enable control, management and/or visualization of device processes and

can range from simple inputs on a touch display to control panels for highly
complex industrial automation systems.

HMIs can be found in multiple locations such as portable handheld devices, on

machines, centralized control rooms, as well as factory floor machine and process
control. Applications include industrial and building automation, digital signage,
vending machine, medical, automotive, and appliances.

They have innumerable uses, but in essence HMIs enable operators to make sure
processes run smoothly, identify problems, and maintain and improve efficiencies.

HMIs come with integrated software that allow operators to manage the
information that appears on the screen or dashboard. The software is essential to

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execute commands, control the machinery, and manage manufacturing and

production processes. Operators interact with these processes and machinery
through a graphic user interface (GUI). A GUI is a visual information system that
communicates with HMIs at both supervisor and machine level. HMI software
generally allows operators to view information through a series of diagrams, photos
and schematics. Depending on its technical capabilities, HMI software can
communicate on multiple networks, and enables operators to control processes and
machinery in different locations.

Q7: A distributed control system (DCS) is a computerised control system for a

process or plant usually with many control loops, in which autonomous controllers
are distributed throughout the system, but there is no central operator supervisory
control.

This is in contrast to systems that use centralized controllers; either discrete

controllers located at a central control room or within a central computer.

The DCS concept increases reliability and reduces installation costs by localising
control functions near the process plant, with remote monitoring and supervision.

Distributed control systems first emerged in large, high value, safety critical
process industries, and were attractive because the DCS manufacturer would
supply both the local control level and central supervisory equipment as an
integrated package, thus reducing design integration risk.

Today the functionality of Supervisory control and data acquisition (SCADA) and
DCS systems are very similar, but DCS tends to be used on large continuous
process plants where high reliability and security is important, and the control room
is not geographically remote.

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EIA 22526 unit 5 SKKBPP EE

The key attribute of a DCS is its reliability due to the distribution of the control
processing around nodes in the system.
This mitigates a single processor failure. If a processor fails, it will only affect one
section of the plant process, as opposed to a failure of a central computer which
would affect the whole process.
This distribution of computing power local to the field Input/Output (I/O)
connection racks also ensures fast controller processing times by removing
possible network and central processing delays.
The accompanying diagram is a general model which shows functional
manufacturing levels using computerised control.
Referring to the diagram;

• Level 0 contains the field devices such as flow and temperature sensors,
and final control elements, such as control valves
• Level 1 contains the industrialised Input/Output (I/O) modules, and their
associated distributed electronic processors.
• Level 2 contains the supervisory computers, which collect information
from processor nodes on the system, and provide the operator control
screens.
• Level 3 is the production control level, which does not directly control
the process, but is concerned with monitoring production and monitoring
targets
• Level 4 is the production scheduling level.

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EIA 22526 unit 5 SKKBPP EE

Levels 1 and 2 are the functional levels of a traditional DCS, in which all equipment
are part of an integrated system from a single manufacturer.
Levels 3 and 4 are not strictly process control in the traditional sense, but where
production control and scheduling takes place.
Application of DCS:
Distributed control systems (DCS) are dedicated systems used in manufacturing
processes that are continuous or batch-oriented.
Processes where a DCS might be used include:

• Chemical plants
• Petrochemical (oil) and refineries
• Boiler controls and power plant systems
• Nuclear power plants
• Water management systems
• Water treatment plants
• Sewage treatment plants
• Food and food processing
• Agrochemical and fertilizer
• Metal and mines
• Automobile manufacturing
• Metallurgical process plants
• Pharmaceutical manufacturing
• Sugar refining plants
• Agriculture applications
• Q4: Develop a generalised DCS architecture for control of a plant.

•
• Level 0: It consists of the field devices such as temperature sensors, flow,
and final control elements such as control valves.

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EIA 22526 unit 5 SKKBPP EE

• Level 1: It consists of the industrialized Input / Output (I/O) modules, and

their associated distributed electronic processors.
• Level 2: It is included with supervisory computers that help to gather
information from processor nodes on the system, and provide the operator
control screens.
Level 3: It is the production control level, which does not directly control
the process, but is concerned with monitoring production and monitoring
targets.
Level 4: It is the production scheduling level.

Introduction to SCADA System | Supervisory Control and Data Acquisition

System | What is SCADA? - YouTube

SCADA tutorial for beginners in thermal electric power distribution system - part
02 - YouTube

SCADA tutorial for beginners in process control for automatic bottle filling
machine - part 04 - YouTube

HMI (209) HMI Programming Tutorial using mitsubishi e designer simulation

software - YouTube

DCS:

https://www.youtube.com/watch?v=jXRksET5vNo

https://www.youtube.com/watch?v=eUZZuZb8UWA

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 SCADA Basics

Before discussing about the architecture of SCADA and different types of SCADA systems,
primarily we must know a few SCADA basics. Consider the block diagram of SCADA
system shown in the figure which consists of different blocks, namely Human-machine
Interface (HMI), Supervisory system, Remote terminal units, PLCs, Communication
infrastructure and SCADA Programming.

Basics of SCADA

1. Human-machine Interface (HMI)

It is an input-output device that presents the process data to be controlled by a human

operator. It is used by linking to the SCADA system’s software programs and databases for
providing the management information, including the scheduled maintenance procedures,
detailed schematics, logistic information, trending and diagnostic data for a specific sensor or
machine. HMI systems facilitate the operating personnel to see the information graphically.
 Human-Machine Interface

2. Supervisory System

Supervisory system is used as server for communicating between the equipment of the
SCADA system such as RTUs, PLCs and sensors, etc., and the HMI software used in the
control room workstations. Master station or supervisory station comprises a single PC
in smaller SCADA systems and, in case of larger SCADA systems, supervisory system
comprises distributed software applications, disaster recovery sites and multiple
servers. These multiple servers are configured in a hot-standby formation or dual-
redundant, which continuously controls and monitors in case of a server failure for
increasing the integrity of the system.

3. Remote Terminal Units

Physical objects in the SCADA systems are interfaced with the microprocessor
controlled electronic devices called as Remote Terminal Units (RTUs). These units are
used to transmit telemetry data to the supervisory system and receive the messages
from the master system for controlling the connected objects. Hence, these are also
called as Remote Telemetry Units.

4. Programmable Logic Controllers

In SCADA systems, PLCs are connected to the sensors for collecting the sensor output
signals in order to convert the sensor signals into digital data. PLCs are used instead of
RTUs because of the advantages of PLCs like flexibility, configuration, versatile and
affordability compared to RTUs.

Programmable Logic Controllers

5. Communication Infrastructure

Generally the combination of radio and direct wired connections is used for SCADA
systems, but in case of large systems like power stations and railways SONET/SDH are
frequently used. Among the very compact SCADA protocols used in SCADA systems –
a few communication protocols, which are standardized and recognized by SCADA
vendors – send information only when the supervisory station polls the RTUs.

6. SCADA Programming

SCADA programming in a master or HMI is used for creating maps and diagrams
which will give an important situational information in case of an event failure or
process failure. Standard interfaces are used for programming most commercial
SCADA systems. SCADA programming can be done using derived programming
language or C language.

Architecture of SCADA

Generally the SCADA system includes the following components: local processors,
operating equipment, PLCs, instruments, remote terminal unit, intelligent electronic
device, master terminal unit or host computers and a PC with human machine
interface.

Architecture of SCADA

The block diagram of SCADA system shown in the figure represents the basic SCADA
architecture. The SCADA (supervisory control and data acquisition) systems are different
from distributed control systems that are commonly found in plant sites. When distributed
control systems cover the plant site, SCADA system cover much larger geographic areas.

Above figure depicts an integrated SCADA architecture which supports TCP/IP, UDP and
other IP based communication protocols as well as industrial protocols like Modbus TCP,
Modbus over TCP or Modbus over UDP. These all work over cellular, private radio or
satellite networks.
In complex SCADA architectures, there are a variety of wired and wireless media &
protocols involved in getting data back to the monitoring site. This allows implementation of
powerful IP based SCADA networks over landline, mixed cellular and satellite systems.
SCADA communications can utilize a diverse range of wired and wireless media.

The choice of the existing communication depends on the characterization of a number of

factors. The factors are remoteness, available communications at the remote sites, existing
communications infrastructure, polling frequency and data rates. These factors impact the
final decision for SCADA architecture. Therefore, a review of SCADA systems evolution
allows us to better understand many security concerns.

4 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.

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.

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.

Distributed SCADA Systems

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.

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.

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.

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. 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.

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.
 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.

Wireless SCADA Block Diagram

In this project 2.4 GHz wireless transmitter and USB receiver are used for sending and
receiving the data collected from the temperature sensors which interface with 8051
microcontroller. If the temperature goes beyond the set limit whether the low limit or high
limit, then the microcontroller sends commands to the relays to turn on or off based on the
command signal.

Monitoring and controlling of multiple operations in maximum number of industries are

being automatically controlled by most advanced SCADA technology implementations.
Already we are observing that many industrial operations are automatically controlled using
the application of SCADA system technology, but still many researchers are working to
develop more efficient SCADA systems for adopting full automatic control of all types of
industrial operations. Having any queries and ideas? Post your comments in the comment
section below for any technical help for implementing your ideas to develop real time
projects.