SCADA System: What is it?

(Supervisory Control and Data Acquisition)

February 21, 2021 by Vidya Muthukrishnan

Contents
• What is SCADA

• SCADA History

• SCADA Basics

• Objectives of SCADA

• Master Terminal Unit (MTU)

• Remote Terminal Unit (RTU)

• Communication Network

• Functions of SCADA Systems

• SCADA Software

• Citect SCADA – Schneider Electric

• InTouch – Wonderware

• Experion SCADA – Honeywell

• iFIX – General Electric

• Ignition – Inductive Automation

• SIMATIC WinCC V7 – Siemens

• SCADA Applications

• Electric Power Generation, Transmission, and Distribution

• Manufacturing Units

• Mass transit and Railway Traction

• Water, Waste Water Utilities and Sewage

• Buildings, Facilities, and Environments

• Water Security: The Role of the SCADA System

• Thermal Power Plants

• Forestry, Pulp and Paper Industry

• Difference Between PLC and SCADA

What is SCADA
SCADA stands for “Supervisory Control and Data Acquisition”. 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 form a large part of control systems engineering. 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.

Generic SCADA System

Supervisory Control and Data Acquisition systems are essential to a wide range
of industries and are broadly used for the controlling and monitoring of a
process. SCADA systems are prominently used as they have the power to
control, monitor, and transmit data in a smart and seamless way. In today’s data-
driven world, we are always 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 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.
SCADA Architecture
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.

SCADA History

Earlier to the birth of SCADA systems, manufacturing floors and industrial

plants relied on the manual control and monitor using push buttons and analog
equipment. As the size of the industries and manufacturing units grew in size,
they started using relays and timers, that provided supervisory control to a
certain extent.

Unfortunately, relays and timers were able to solve problems only with minimal
automation functionality and reconfiguring the system was difficult. So, a more
efficient and fully automated system was required by all industries.
Computers were developed for industrial control purposes in the early 1950s.
Slowly, the telemetry concept was introduced for virtual communication and
transmission of data. Around the year 1970, the term SCADA was coined along
with the evolution of Microprocessors and PLC concepts. So, this helped for the
development of a fully automated system, that can be used remotely in Industry.
As years rolled by, in the early 2000s, distributed SCADA systems were
developed.

Modern SCADA systems came into existence that allowed us to control and
monitor real-time data anywhere in the world. The real-time interaction boomed
up the business and took the growth of industries to greater heights. Even if the
operator did not have much knowledge of software development, he was able to
manage the modern SCADA systems.

SCADA Basics
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
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)
Functional Units of SCADA
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.
Remote terminal unit
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.
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
SCADA Software

As discussed earlier, SCADA software plays a significant role in the whole

process analysis. There are several big manufacturing companies that work
exclusively on SCADA software. There are many factors to be looked upon
before the SCADA software is selected and implemented. To mention a few,
• The lifespan of the Software: Since you are going to invest a lot in
procuring the software, it is always better to check if the software would last
between 5 to 10 years down the lane.
• Request for Information: It is a business term used to specify details about
vendors and suppliers. If you buy software from a particular vendor, he/she
should be able to give you technical support whenever required.
• Historian Software: The term historian means, the software should save
data with timestamps, that can be used for future reference. So, your software
should be proficient of handling the data from the field and logging the same.
• SCADA technology: As we all know, technology is growing rapidly so as
to meet our needs. When you mean technology, it does not imply that always
you need to use the latest technology that pops up in the market. Rather, you
should choose a technology that can stay stable and secure for a longer time.
• Alarm Supervision and Management: Almost all SCADA systems have an
alarming feature that comes along with software development. Configuration of
alarm is important. There are two types of alarm system namely system defined
alarm managed by the system by itself and user-defined alarm which is
managed by the user.
Let us have a look into software developed by big players in the market.

Citect SCADA – Schneider Electric

A compact, flexible and reliable SCADA software developed by Schneider
Electric. The latest product released by them is Vijeo Citect (version7.10) Citect
SCADA is still one of the commonly used SCADA technologies and you
certainly need to learn about this platform as a SCADA developer. It has actually
become part of the SCADA alternatives for Wonderware.
InTouch – Wonderware
InTouch, which has become one of the largest SCADA suppliers on the market,
comes from Wonderware, now owned by Schneider Electric. Although
Wonderware is relatively new to the market, it is quickly gaining popularity.
The Wonderware system platform is a SCADA system with many “plug-and-
play” parts that is modular and very versatile. Because of the modularity of this
scheme, you can readily customize it to your requirements if you choose this
SCADA software. The benefit of In Touch is that they use open standards of
communication and can operate with most PLC systems.

Experion SCADA – Honeywell

Honeywell is commonly used in PLC systems (particularly in the US). They are
also a big player in the SCADA market, providing a software platform for
programming SCADA and HMI software systems. You can either use their
software for a stand-alone SCADA scheme or use it with Honeywell’s PLC
platform (e.g. C200 and C300 platform) as well as RTU’s like Control Edge RTU.

Although Honeywell’s SCADA software works are optimized to communicate

with other Honeywell products (e.g. PLCs and RTUs), it will still work when
paired with non-Honeywell products.
iFIX – General Electric
General Electric (GE) is one of the world’s largest manufacturing businesses, is
also a significant player in the SCADA market. IFIX is one of their software
solutions and it is a very flexible SCADA system. The advantage of using iFIX is
its ability to develop screens quickly with HTML5.
Another reason is the many drivers that allow you to set up networked and
distributed systems, allowing you to connect and exchange information with
most contemporary PLCs. GE also have their own branded PLCs – but a GE
SCADA system does not require these GE PLCs to function correctly.
Ignition – Inductive Automation

Ignition is a SCADA scheme that uses the latest IoT architecture to its full
potential. Ignition from Induction Automation is a very nice option if you want a
system that is up-to-date with all Industry 4.0 norms and techniques. Ignition is
relatively new to the SCADA industry compared to some of the veteran systems.
That said between Ignition’s IoT integrations and the fact that they work with
most PLC systems, Ignition has been chosen by many businesses as their
SCADA solution.
SIMATIC WinCC V7 – Siemens
The Siemens SCADA system has been around for many years, and is known as
“WinCC”. Siemens is one of the largest players in the PLC and SCADA industry,
and many businesses use the Siemens platform. Siemens is a huge company that
has been evolving their PLC and SCADA platforms over the years to adopt
modern technologies. The fact that they are a large and veteran player in the
SCADA industry gives many businesses confidence in entrusting them with
their SCADA applications.
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.
Manufacturing Units
SCADA systems are used to regulate industrial automation and robots, and
monitor process and quality control

Mass transit and Railway Traction

Transit officials use SCADA to regulate electricity for subways, trams and trolley
busses; to automate railway traffic signals; to monitor and identify trains and
busses, and to control railway crossing doors

Water, Waste Water Utilities and Sewage

State and municipal water utilities use SCADA to monitor and control water
flow, tank concentrations, pipe pressure, and other variables
SCADA Applications in Water Pump Station
Buildings, Facilities, and Environments
Facility managers use SCADA to regulate HVAC, cooling, lighting and input
systems.

Water Security: The Role of the SCADA System

A lot of research continues to be performed on how to implement modern
SCADA concepts into water treatment plants whilst minimizing the risk of
unauthorized network access (cyber risk is an ongoing issue in large
enterprises).
The communication network of SCADA is distributed across the water
distribution system as shown in the figure below. Workstations, typically PC-
based are situated at a treatment facility in a control room, enable operators to
view the entire process and take control measures.
Within the plant, programmable logic controllers are used in chemical treatment
and filters. Local Area Network (LAN) is utilized to link the controllers to
workstations. Remote terminal units (RTUs) are used in remote locations and
are generally found in sensitive fields such as pump stations, storage tanks,
valve vaults, and treatment centers.

The RTU communicates on a wide area network typified by the radio scheme
shown in the following figure. A significant benefit of SCADA schemes is the
coordination of safety measures with activities. A SCADA system connected to
perimeter surveillance systems can either decrease the need for manned patrols
considerably or eliminate them.

SCADA Applications in Water Treatment Plant

The SCADA scheme can provide ongoing surveillance of all places, unlike
patrols. You can easily interface security systems or appliances, including video
cameras, motion detectors, contact switches, keypad entry devices, and card
readers, either directly to the SCADA network or via a neighboring remote
terminal unit (RTU). Today’s SCADA systems also give alarm management in
instances where many alarms happen in a brief moment.

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.
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,
which decreases human workers’ mistakes. SCADA system is used to supervise
a complete process
The picture can't be display ed.

Forestry, Pulp and Paper Industry

The forestry, pulp and paper industry also relies on SCADA systems. From
automation & process control, energy management, drive control, power
protection, enclosure systems, and safety – the industry has ample uses for
SCADA.

SCADA systems are used throughout the paper supply chain – including within
the wood yard, to the chippers, evaporators, digestors, refiners, cleaners, drying
& pressing, and of course the paper machines. This complex processing of trees
to paper is automated from end-to-end through the use of established SCADA
systems.

Difference Between PLC and SCADA

SCADA and PLCs can easily be confused when you’re first learning about
control engineering. You will often hear the terms “PLC” and “SCADA” used
within the same breath. Although they are related, they are distinctly different
from one another.
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.

So 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.