Topic 3
Topic 3
2. Communication network / system – used to transfer data between field data interface
devices and control units and the computers in the SCADA host computer (MTU)
- This is intended to provide the means by which data can be transferred between the central
host computer server and field based RTU.
- Communication network refers to the equipments needed to transfer data to and from different
sites.
- The medium used can either be cable, telephone or radio
- The way the SCADA system network (topology) is set up can vary with each system but there
must be uninterrupted, bidirectional communication between the MTU and the RTU for a
SCADA or data acquisition system (DAS) to function properly.
- This can be accomplished in various way i.e private wire lines, underground cables, telephone
radio, modern, microwave dishes, satellite and other atmospheric means and many times,
system employ more than one means of communicating to the remote site.
- Communication systems used for SCADA are often split into two distinct part: WAN and LAN.
- The interface between the two parts is commonly achieved through some form of multiplexing.
- Multiplexing allows different data streams to share single data link. It combines communication
paths to and from many RTUs into a single bit stream, usually using Time Division Multiplexing
(TDM).
- It may itself be a SCADA processing device that manages the local network and not only
combines data, but also reduces the amount of data that be interchanged within the central
host.
5. SCADA software
- SCADA software can be divided into two types: open and proprietary.
- Proprietary software often is configured for a specific hardware platform and may not
interface with the software or hardware produced by competing vendors.
- Commercial off-the shelf (COTS)/open software are more flexible, and will interface with
different types of hardware and software.
- The focus of proprietary software is on process and control functionality while COTS software
emphasizes on compatibility with a variety of equipment and instrumentation.
- Software products typically used within a SCADA system are as follows:-
• Central host computer operating system:- software used to control the central
host computer hardware.
• Operator terminal operating system – Software used to control the central host
computer hardware at the operators terminal. It contributes to the networking of the
central host and operator’s terminal.
• Applications – They are of two types; central host computer application and
operator terminal applications. These handles transmitted and reception of data to
and from the RTU and central computer. It also provides the GU/ which offers mimic
screens, alarm pages trend.
• Communication protocol drives: - required to control the translation and
interpretation of the data between ends of the communication links in the systems.
Data acquisition
- This is the process of sampling signals that measure real world physical conditions and
converting the resulting samples into digital numerical values that can be manipulated by a
computer.
- Data acquisition within SCADA system is accomplished first by the RTU scanning the field
data interface devices connected to the RTU.
- The time to perform this task is called the scanning internal. The MTU scans RTU to access
data in the process referred to as polling the RTU.
- Some systems allow the RTU to transmit field values and alarms to the central host without
being processed by the central host.
- The components of data acquisition systems include:
• Sensors that converts physical parameters to electrical signals
• Signal conditioning circuitry to convert sensor signals into a form that can be converted
to digital values e.g implication, alternation multiplexing.
• Analog to digital converters, which converts conditioned signals to digital values.
• Data acquisition hardware acts as the interface between the computer and the outside
world. It primarily functions as a device that digitizes incoming signal so that the computer
can interpret them.
Benefits of SCADA
i) Improved operation of the plant or process resulting in savings due to optimization of the
system.
ii) Reduces the operating and maintenance cost hence maximize the profits.
iii) Maximize productivity, ensure continuous production and increased productivity of the
personnel.
iv) Improved safety of the system due to better information and improved control.
v) Protection of the plant equipment.
vi) Safeguarding the environment from a failure of the system.
vii) Enhances reliability and robustness of critical industrial processes.
viii) Improved energy savings due to optimization of the plant.
ix) Improved and quicker receipt of data so that clients can be invoiced more quickly and
accurately.
x) Government regulations for safety and metering of gas (for royalties & tax etc).
a) Local b) Centralized
Defence in Depth
- Where a single protection measure has been deployed to protect a system, there is a risk that
if a weakness in that measure is identified and exploited there is effectively no protection
provided.
- No single security measure itself is foolproof as vulnerabilities and weaknesses could be
identified at any point in time. In order to reduce these risks, implementing multiple protection
measures in series avoids single points of failure.
- In order to safeguard the process control system from electronic attacks (e.g. hackers, worms
and viruses), it may be insufficient to rely on a single firewall, designed to protect the corporate
IT network.
- A much more effective security model is to build on the benefits of the corporate firewall with
an additional dedicated process control firewall and deploy other protection measures such
as anti-virus software and intrusion detection
Remote access
- Maintain an inventory of all remote access connections and types (e.g. virtual private network
or modems).
- Ensure that a valid business justification exists for all remote access connections and keep
remote connections to a minimum.
- Implement appropriate authentication mechanisms (e.g. strong authentication) for remote
access connections.
- Implement appropriate procedures and assurance mechanisms for enabling and disabling
remote access connections.
- Ensure that remote access computers are appropriately secured (e.g. anti-virus, anti- spam
and personal firewalls).
Anti-virus:
- Protect process control systems with anti-virus software on workstations and servers.
- Where anti-virus software cannot be deployed other protection measures should be
implemented (e.g. gateway anti-virus scanning or manual media checking)
System hardening
- Undertake hardening of process control systems to prevent network based attacks.
- Remove or disable unused services and ports in the operating systems and applications to
prevent unauthorized use.
- Understand what ports are open and what services and protocols used by devices (especially
embedded devices such as PLCs and RTUs). This could be established by a port scan in a
test environment. All unnecessary ports and services should be disabled (e.g. embedded web
servers).
- Ensure all inbuilt system security features are enabled.
- Where possible restrict the use of removable media (e.g. CDs, floppy disks, USB memory
sticks etc.) and if possible removable media should not be used. Where it is necessary to use
removable media then procedures should be in place to ensure that these are checked for
malware prior to use.
Physical security
- Deploy physical security protection measures to protect process control systems and
associated networking equipment from physical attack and local unauthorized access.
- A combination of protection measures is likely to be required which could include, drive locks,
tamper proof casing, secure server rooms, access control systems and CCTV.
Security patching
- Implement processes for deployment of security patches to process control systems.
- These processes should be supported by deployment and audit tools.
- The processes should make allowance for vendor certification of patches, testing of patches
prior to deployment and a staged deployment process to minimize the risk of disruption from
the change.
- Where security patching is not possible or practical, alternative appropriate protection
measures should be considered.
Introduction
- Industrial communication refers to the wide range of hardware and software products and
protocols used to communicate between standard computer platforms and devices used in
industrial automation.
- Although a communication circuit can involve only two pieces of equipment with a circuit
between them, the term network typically refers to connecting many devices together to permit
sharing of data between devices over a single or redundant circuit.
- The industrial automation systems are often implemented as an open distributed architecture
with communication over digital communication networks.
- It is now common for users connected to a local area network to communicate with computers
or automation devices on other local area networks via gateways linked by a wide area
network.
- As the industrial automation systems becomes large and the number of automation devices
increases, it has become very important for industrial automation to provide standards which
make it possible to interconnect many different automation devices in a standard way.
- Considerable international standardization efforts have been made in the area of local area
networks. The Open Systems Interconnection (OSI) standards permit any pair of automation
devices to communicate reliably regardless of the manufacturer.
- By definition, an industrial network requires geographical distribution of the physical
measurement I/O and sensors or functional distribution of applications. Most industrial
networks transfer bits of information serially.
- Serial data transfer has the advantage of requiring only a limited number of wires to exchange
data between devices. With fewer wires, we can send information over greater distances.
Because industrial networks work with several devices on the same line, it is easier to add a
new device to existing systems.
- To make all this work, our network must define a set of rules – a communication protocol -
- to determine how information flows on the network of devices, controllers, PCs, and so on.
- With improved communication protocols, it is now possible to reduce the time needed for the
transfer, ensure better data protection, and guarantee time synchronization, and real-time
deterministic response in some applications.
- Industrial networks also ensure that the system sends information reliably without errors and
securely between nodes on the network.
Network levels
- The industrial automation systems can be very complex, and it is usually structured into
several hierarchical levels. Each of the hierarchical level has an appropriate communication
level, which places different requirements on the communication network.
- Industrial networks may be classified in several different categories based on functionality:
field-level networks (sensor, actuator or device buses), control-level networks (control buses)
and information-level networks
Field level
- The lowest level of the automation hierarchy is the field level, which includes the field devices
such as actuators and sensors.
- The elementary field devices are sometimes classified as the element sublevel. The task of
the devices in the field level is to transfer data between the manufactured product and the
technical process.
- The data may be both binary and analogue. Measured values may be available for a short
period of time or over a long period of time. For the field level communication, parallel, multi-
wire cables, and serial interfaces such as the 20mA current loop has been widely used from
the past.
- The serial communication standards such as RS232C, RS422, and RS485 are most
commonly used protocols together with the parallel communication standard IEEE488.
- Those point-to-point communication methods have evolved to the bus communication
network to cope with the cabling cost and to achieve a high quality communication.
- Field-level industrial networks are a large category, distinguished by characteristics such as
message size and response time.
- In general, these networks connect smart devices that work cooperatively in a distributed,
time-critical network. They offer higher-level diagnostic and configuration capabilities
generally at the cost of more intelligence, processing power, and price.
- At their most sophisticated, fieldbus networks work with truly distributed control among
intelligent devices like FOUNDATION Fieldbus.
- Common networks included in the devicebus and fieldbus classes include CANOpen,
DeviceNet, FOUNDATION Fieldbus, Interbus-S, LonWorks, Profibus-DP, and SDS.
- Nowadays, the fieldbus is often used for information transfer in the field level. Due to timing
requirements, which have to be strictly observed in an automation process, the applications
in the field level controllers require cyclic transport functions, which transmit source
information at regular intervals.
- The data representation must be as short as possible in order to reduce message transfer
time on the bus.
Control Level
- At the control level, the information flow mainly consists of the loading of programs,
parameters and data.
- In processes with short machine idle times and readjustments, this is done during the
production process. In small controllers it may be necessary to load subroutines during one
manufacturing cycle.
- This determines the timing requirements. It can be divided into two: cell and area sublevels.
i) Cell sublevel:
- For the cell level operations, machine synchronizations and event handlings may require short
response times on the bus. These real-time requirements are not compatible with time
excessive transfers of application programs, thus making adaptable message segmentation
necessary.
- In order to achieve the communication requirements in this level, local area networks have
been used as the communication network. After the introduction of the CIM concept and the
DCCS concept, many companies developed their proprietary networks for the cell level of an
automation system.
- The Ethernet together with TCP/IP (transmission control protocol/internet protocol) was
accepted as a de facto standard for this level, though it cannot provide a true real-time
communication.
- Many efforts have been made for the standardization of the communication network for the
cell level.
- The IEEE standard networks based on the OSI layered architecture were developed and the
Mini-MAP network was developed to realize a standard communication between various
devices from different vendors. Some fieldbuses can also be used for this level.
- Control-level networks are typically used for peer-to-peer networks between controllers such
as programmable logic controllers (PLCs), distributed control systems (DCS), and computer
systems used for human-machine interface (HMI), historical archiving, and supervisory
control.
- Control buses are used to coordinate and synchronize control between production units and
manufacturing cells.
- Typically, ControlNet, PROFIBUS-FMS and (formerly) MAP are used as the industrial
networks for controller buses.
- In addition, we can frequently use Ethernet with TCP/IP as a controller bus to connect upper-
level control devices and computers.
Information level
- The information level is the top level of a plant or an industrial automation system.
- The plant level controller gathers the management information from the area levels, and
manages the whole automation system.
- At the information level there exist large scale networks, e.g. Ethernet WANs for factory
planning and management information exchange.
- Ethernet networks are used as a gateway to connect other industrial networks.
- With respect to management Information System Communication in automated system, there
are three types of networks used:
o Local Area Network (LAN)
o Wide Area Network (WAN)
o Metropolitan area network (MAN)
Networks Models/Layers
- Network model defines a set of network layer and how they interact. There are several
different network models depending on what organization/industry want.
- The most important are:
i) The TCP / IP model
ii) OSI network model
1. The TCP/IP model
- TCP/IP (Transmission Control Protocol/Internet Protocol) is the basic communication
language or protocol of the Internet. It can also be used as a communications protocol in a
private network (either an intranet or an extranet).
- TCP/IP is the de facto global standard for the Internet (network) and host–to–host (transport)
layer implementation of internet work applications because of the popularity of the Internet.
- The TCP/IP (Transmission Control Protocol / Internet) is a layer protocol where it defines 4
layers’
i) Physical layer
- This is the lowest layer which describes the way actual data in the form of symbols that are
sent over a medium such as copper wire or fibre optic cabling. Item like signal level symbol
representation and connector pinout are defined at this layer. The main functions are
a) Hardware specification – the details of the physical cables, network interface cards,
wireless radios etc are part of this layer.
b) Encoding and signaling – How are the bits encoded in the medium is also decided by
this layer.
c) Data transmission and reception: the transfer of each bit of data and assures the
transmission of each bit with a high probability.
d) Topology and network design: the type of network topologies to be used and which part
of the network in the routes going to be placed, where the switches will be used etc.
v) Session layer
- The layer is concerned with the establishment and termination of communication sessions
between processors in host computers.
- It also ensures that the data transfer starts from where it breaks, keeping it transparent to the
end user.
- Strictly speaking, a network requires only layers 1, 2, and 7 of the protocol model to operate.
- In fact, many device bus networks use only these three layers. The other layers are added
only as more services are required (e.g., error-free delivery, routing, session control, data
conversion, etc.).
- Most of today’s local area networks contain all or most of the OSI layers to allow connection
to other networks and devices.
Advantages:
• It provides wide variety of choice.
• It does not depend or rely on a specific computer system.
• It interprets the product functionality at each-stage.
• It encrypts the data for security purpose.
• It is easy to add multiple-network models.
Disadvantages:
• Many applications do not require/need the data integrity, which is provided by OSI-model.
• In order to fast set up OSI requires agreement between three-parties: users & service
provider.
• Complex.
• This model is not adapted at all to telecommunication applications on computer.
3. Field bus model
- Due to complexity of the OSI model, modification has been done on the industrial networks,
where only three layers are left.
- The resulting fieldbus is referred to as a 3 – layer architecture. These layers are:-
o Application layer
o Data link layer
o Physical layer
- Several characteristics and functions in the data link layer are key to the distributed real time
control capabilities of fieldbus.
a) The data link layer is based on a token passing protocol.
b) The Link Active Scheduler (LAS) is a centralized device that acts as the arbitrator of the
bus.
c) The LAS executes a schedule that makes possible deterministic communication.
d) The LAS distributes time to the network to permit all devices to share the same sense of
time.
- The user application layer defines blocks that represent the functions and data available in a
device.
- Rather than interface to a device through a set of commands as commonly used with
communication protocols, fieldbus user interacts with device through a set of blocks that
define device capabilities in a standardized way.
- The data link layer has important aspect which is medium access control.