3

ACADEMIC YEAR 2023-24

III B.TECH II SEM EIE (R18)
INDUSTRIAL AUTOMATION
UNIT – V
SCADA Basics

P.Srinivas
Assistant Professor
 CONTENTS
 Computer Process interface for Data Acquisition and

control
 Computer control loops
 Supervisory Digital Control (SCADA)
• Introduction and brief history of SCADA – SCADA
Hardware and software
• Landlines for SCADA
• use of modems in SCADA
• SCADA with LAN
Computer Process interface for Data
Acquisition and Control
 Samplers
• Flow rates, pressures, liquid levels,
provided
temperatures,continuously
etc, are by the various sensors and
transducers.
• The computer can handle information on a discrete time
basis.
• Sampler is a switch which closes at specific time intervals
within which the continuous signal is converted into
sampled values. Each sampled value is used by the computer
control algorithm to give output result within the specific
time interval of sampling.
• If during this period
(reading value,
calculating error and
making a control action)
measured value changed, Cont.
it is not recognized by the
computer.
 Hold element
• Most of the final control elements (pneumatic valves
particularly) are actuated by continuous time signals (e.g.,
compressed air).
• The discrete time signal from computer output (computed
by program) is converted into continuous signal by hold
element.
 Analog-to-digital converter
• A/D converters convert an analog voltage signal lying within
a specific range (such as ± 10 V, 0 to 5 V, etc.) to an integer
number.
• The range of the integer I is given by Irange = 2N, where N is
the number of bits.
• For a 12 bit converter, maximum integer is 212 = 4096.
• So the range is 2048 ≤I ≤+ 2047, I=0 exists between +ve and
–ve integers.
• For the positive range (2047), the resolution of the converter
is the voltage range divided by the intervals between
integers, Resolution = (10/2047) V = 0.00489 V.
• This gives an expected error of ± 1/2 of the resolution, or±
0.00244 V, Relative error = 0·00244 V/│measured voltage│
• The throughput speed of A/D converters is routinely 50,000
-
100,000 conversions/s.
Cont.
Ex: As an illustration of A/D conversion, suppose the 12-bit
converter measure voltages and reports the integer 1261
and 21 as a result of the conversion. Determine the actual
measured voltage for I=1261 and 21. Assume expected error
is ± 1/2 of the resolution.
Ans: For I=1261, Vmeasured = (10 ×1261/2047) = 6.16023 V
Relative error = ± 0·00244/6.16023 = ± 0.000397 =± 0.0397%
 Digital-to-analog converter
• D/A converters are the reverse of A/D conversion. An integer
with range 2N is converted to an analog voltage output.
• Ex: For output of 3.5 V determine the input integer for a D/A
converter.
• Iinput =2047× Voutput/10 = (2047) (3.5) /10=716.45 ≈716
• It is rounded to Iinput = 716. The actual output voltage of V
output = 716 X 10 /2047 = 3.49780 V≈3.5 V
 Multiplexer
• Multiplexers multiplex several
similar measurements from a
remote location and sequentially
• transmit
Consider 10these thermocouple
over only ameasurements
few from a process,
lines.
each with a voltage signal of – 10 mV. First of all, one may
not wish to run 10 lines and use 10 channels of our A/D
converters just for these signals, so multiplexing is
necessary.
• This is an electronic switch with several ports, which can
serve sequentially several lines carrying analog signals.

A/D converter with

multiplexer
Computer control loops (multiple)
 Operation cycle in the PLC
• The operation cycle of a PLC is made up of two separate modes; these are
the I/O scan mode, followed by the execution mode.
• I/O scan mode is the period when the processor updates the output
control signals, based on the information received from the previous I/O
scan cycle after its evaluation of the signals. The processor then scans the
inputs in a serial mode and updates its internal memory as to the status of
the inputs.
• Execution mode follows the I/O scan mode. In this mode, the processor
evaluates the input data stored in memory against the data programmed
into the CPU. The processor then can determine the actions to be taken by
the output modules, and puts the data into memory for transfer to the
output modules during the next I/O scan mode.
• Scan time is the time required for the PLC to complete one I/O scan plus
the execution cycle. This time depends on the number of input and output
channels, the length of the ladder instruction sets, and the speed of the
processor. A typical scan time is between 5 and 20 ms.
Computer based digitally controlled process
PROCESS/INDUSTRIAL INSTRUMENTS AND CONTROLS HANDBOOK by Gregory
K. McMillan and Douglas M. Considine.
Fig: Typical arrangement between the DCS and the Data Reconciliation,
Simulation, and Optimization procedures (from Simulation Sciences, Inc.,
1989) presented by Romagnoli & Sanchez, DATA PROCESSING AND
RECONCILIATION FOR CH EM ICAL PROCESS OPERATIONS
Presented by Romagnoli & Sanchez, DATA PROCESSING AND RECONCILIATION FOR CH
EM ICAL PROCESS OPERATIONS.
Presented by Romagnoli & Sanchez, DATA PROCESSING AND RECONCILIATION
FOR CHEMICAL PROCESS OPERATIONS.
 SCADA

supervisory control and data

acquisition
4 Types of SCADA 7
systems
• First Generation: Monolithic or Early SCADA systems(1950-70),
• Second Generation: Distributed SCADA systems(1980-90),
• Third Generation: Networked SCADA systems(1990-2000) and
• Fourth Generation: Internet of things technology, SCADA
systems(2000)
Monolithic or Early SCADA Systems 8

• Minicomputers are used earlier for computing the SCADA systems.

In earlier times, the common network services were not available.
Hence, these are independent systems without having any
connectivity to other systems.
• The functions in the early first generation were limited to
monitoring sensors in the system and flagging any operations in
case of surpassing programmed alarm levels.
SCAD A
Master
Distributed SCADA Systems 9

• The sharing of control functions is distributed across the multiple

systems connected to each other using Local Area Network (LAN).
• These individual stations were used to share real-time information for
performing control tasks to trip the alarm levels of possible problems.
• 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(proprietary).
Networked SCADA Systems 11

• The current SCADA systems are generally networked

and communicate using Wide Area Network (WAN) Systems over
mobile network, Ethernet or Fiber Optic Connections for
transmitting data between the nodes frequently.
• These SCADA systems use Programmable Logic Controllers
(PLC)
for monitoring and adjusting the system parameters.
• Open system architecture and communication protocols
 SCADA hardware
On a more complex SCADA system there are
essentially five levels or hierarchies:
 Field level instrumentation and control devices
 Organized terminals and RTUs
 Communications system
 The master station(s)
 The commercial data processing department
computer system
 Introduction and brief history of SCADA
 SCADA (supervisory control and data acquisition) has
been around as long as there have been control systems.
 The first ‘SCADA’ systems utilized data acquisition by
means of panels of meters, lights and strip chart recorders.
 The operator manually operating various control knobs
exercised supervisory control.
 These devices were and still are used to do supervisory
control and data acquisition on plants, factories and power
generating facilities.
Introduction and brief history of SCADA
The sensor to panel type of SCADA system has the
following advantages:

 It is simple, no CPUs, RAM, ROM or software programming needed

 The sensors are connected directly to the meters, switches and

lights on the panel
 It could be (in most circumstances) easy and cheap to add a simple
device like a switch or indicator
The disadvantages of a direct panel to sensor system are:
 The amount of wire becomes unmanageable after the installation of
hundreds of sensors
 The quantity and type of data are minimal and simple
 Installation of additional sensors becomes progressively harder as
the system grows
 Re-configuration of the system becomes extremely difficult
 Simulation using real data is not possible
 Storage of data is minimal and difficult to manage
 No off site monitoring of data or alarms
 Someone has to watch the dials and meters 24 hours a day
 Introduction and brief history of SCADA

• The sensor to panel type of

SCADA system has the following
advantages:
– It is simple, no CPUs, RAM, ROM
or software programming needed
– The sensors are connected
directly to the meters, switches
and lights on the panel
– It could be (in most
circumstances) easy and cheap to
add a simple device like a switch
or indicator
 Fundamental principles of modern SCADA
systems
 SCADA refers to the combination of telemetry
and data acquisition.
 SCADA encompasses the collecting of the
information, transferring it back to the central
site, carrying out any necessary analysis and
control and then displaying that information on
a number of operator screens or displays.
 The required control actions are then conveyed
back to the process.
Fundamental principles of modern SCADA
systems
 Fundamental principles of modern SCADA
systems
• The advantages of the PLC / DCS SCADA system are:
– The computer can record and store a very large amount of
data
– The data can be displayed in any way the user requires
– Thousands of sensors over a wide area can be connected to
the system
– The operator can incorporate real data simulations into the
system
– Many types of data can be collected from the RTUs
– The data can be viewed from anywhere, not just on site
 Fundamental principles of modern
SCADA systems
• The disadvantages are:
– The system is more complicated than the sensor
to panel type
– Different operating skills are required, such as
system analysts and programmer
– With thousands of sensors there is still a lot of
wire to deal with
– The operator can see only as far as the PLC
Fundamental principles of modern SCADA
systems
Fundamental principles of modern
SCADA systems
 Fundamental principles of modern SCADA
systems
• The advantages of the PC to IED fieldbus system are:
– Minimal wiring is needed
– The operator can see down to the sensor level
– The data received from the device can include information such as
serial numbers, model numbers, when it was installed and by whom
– All devices are plug and play, so installation and replacement is easy
– Smaller devices means less physical space for the data acquisition
system
• The disadvantages of a PC to IED system are:
– More sophisticated system requires better trained employees
– Sensor prices are higher (but this is offset somewhat by the lack of
PLCs)
– The IEDs rely more on the communication system
 SCADA hardware
• A SCADA system consists of
– a number of remote terminal units (RTUs) collecting field data and sending
that data back to
– a master station, via
– a communication system.
• The master station displays the acquired data and allows the operator
to perform remote control tasks.
• On a more complex SCADA system there are essentially five levels or
hierarchies:
– Field level instrumentation and control devices
– Marshalling terminals and RTUs
– Communications system
– The master station(s)
– The commercial data processing department computer system
 The RTU

• The RTU provides an

interface to the field
analog and digital
sensors situated at each
remote site.
 The Communication System
• The communications system provides the
pathway for communication between the
master station and the remote sites.
• This communication system can be wire, fiber
optic, radio, telephone line, microwave and
possibly even satellite.
• Specific protocols and error detection
philosophies are used for efficient and
optimum transfer of data.
 The Master Station
• The master station (or sub-masters) gather
data from the various RTUs and generally
provide an operator interface for display of
information and control of the remote sites.
• In large telemetry systems, sub-master sites
gather information from remote sites and act
as a relay back to the control master station.
 SCADA software
• SCADA software can be divided into two types,
proprietary or open.
• Companies develop proprietary software to
communicate to their hardware. These systems are sold
as ‘turn key’ solutions.
– The main problem with this system is the overwhelming
reliance on the upplier of the system.
• Open software systems have gained popularity because
of the interoperability they bring to the system.
– Interoperability is the ability to mix different manufacturers’
equipment on the same system.
 SCADA software
• Key features of SCADA software are:
– User interface
– Graphics displays
– Alarms
– Trends
– RTU (and PLC) interface
– Scalability
– Access to data
– Database
– Networking
– Fault tolerance and redundancy
– Client/server distributed processing
Typical SCADA System
 Landlines for SCADA
• Even with the reduced amount of wire when using a PC to
IED system, there is usually a lot of wire in the typical SCADA
system. This wire brings its own problems, with the main
problem being electrical noise and interference.
• The use of twisted pair shielded cat5 wire is a requirement on
most systems.
– Using good wire coupled with correct installation techniques
ensures the system will be as noise free as possible.
• Fiber optic cable is gaining popularity because of its noise
immunity.
– At the moment most installations use glass fibers, but in some
industrial areas plastic fibers are increasingly used.
Landlines for SCADA
 SCADA and local area networks
• A LAN is a communication path between computers, file-servers,
terminals, workstations, and various other intelligent peripheral
equipments, which are generally referred to as devices or hosts.
• A LAN allows access for devices to be shared by several users, with full
connectivity between all stations on the network.
• A LAN is usually owned and administered by a private owner and is
located within a localized group of buildings.
• Ethernet is the most widely use LAN today because it is cheap and easy to
use.
• Connection of the SCADA network to the LAN allows anyone within the
company with the right software and permission, to access the system.
– Since the data is held in a database, the user can be limited to reading the
information.
– Security issues are obviously a concern, but can be addressed.
Ethernet used to transfer data on a SCADA
system
Modem use in SCADA systems
Typical SCADA system
 Key features of SCADA software are:
• User interface
• Graphics displays
• Alarms
• Trends
• RTU (and PLC) interface
• Scalability
• Access to data
• Database
• Networking
• Fault tolerance and redundancy
• Client/server distributed processing
 SCADA and local area networks

• Local area networks (LAN) are all about

sharing information and resources.

• A LAN is a communication path between

computers, file-servers, terminals,
workstations, and various other intelligent
peripheral equipment's, which are generally
referred to as devices or hosts.
SCADA and local area networks

Ethernet used to transfer data on a SCADA system

 Modem use in SCADA systems
• Often in SCADA systems the RTU (remote terminal unit (PLC, DCS or
IED)) is located at a remote location.
• This distance can vary from tens of meters to thousands of kilometers.
• One of the most cost-effective ways of communicating with the RTU
over long distances can be Line modems.

• Line modems are used to communicate to RTUs when RS-232 or RS-

485 communication systems are not practical. The bit rates used in this
type of system are usually slow, 1200 to 9600 bps.
• The bandwidth of landline communication systems is typically 300
Hz to 3400 Hz for telephone cable.

• A conversion device, called a modem (modulator/demodulator)

• A modulator is thus required to convert the digital signals into an
analog form suitable for transmission over a telephone network.
• The demodulation portion of the modem receives this analog
information and converts it back into the original digital
information generated by the transmitting computer.