UNIT-01

SCADA AND DCS

SCADA
SCADA is the short abbreviation of Supervisory Control and Data Acquisition.
As the name suggests SCADA mainly does three operations:

 Supervise real-time data in the form of graphical presentation

 Control industrial processes locally or through Remote locations
 Acquire real-time data as well as logs data
SCADA system is an important factor of the industrial organization as they help to
monitor process data as well as control the processes and easily detect any issue
within the process thus reduce downtime.

Basic Overview of SCADA Software

Generally, SCADA is completely a software package that helps to monitor the entire
area of the plant. The basic architecture of the SCADA begins with a Programmable
Logic Controller(PLC) or Remote Terminal Units(RTUs).

As we know, PLC or RTUs are microprocessors that communicate with the field
devices such as valves, pumps, sensors, HMIs, other end devices, etc. These
devices route all this collected data from end devices to SCADA computers.
Then SCADA software processes distribute and display the data on the monitor to
better understand the operator about the field condition.

SCADA displays the real-time process value of each weighing feeder and also logs
the data.

SCADA Architecture
Advantages of SCADA System
 Reduce Breakdown time by continuous monitoring of
equipment status.
 Reduce manpower costs required for operating and monitoring
equipment in different areas.
 Flexibility to give report generation in an auto manner as well
as manual.
 Provide remote access to the real-time display, alarm, trend,
and report generation.
 Provide flexibility to choose equipment and system based on
performance.

Features of SCADA System

1) Control Feature using Graphical Representation
2) Real-time/Historical Trend Feature
3) Alarm Handling
4) Report Generation
DCS
Basic Overview of Distributed Control System(DCS)
“A distributed control system (DCS) is a computerized 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. The DCS concept increases reliability and
reduces installation costs by localizing control functions near the process
plant, with remote monitoring and supervision.”
Distributed Control System Architecture
In the DCS, a dedicated controller is assigned for each machine or group of
machines to control the process. Here the smart field devices or
instruments are directly connected with the dedicated controller as well as
operator station via high-speed communication.

In the DCS, we have seen that the distribution of control systems, which
are very small sets of control systems is connected as a subsystem. These
subsystems are connected with high-speed communication buses. Some of
the subsystems are divided to do,

 Data Acquisition
 Data Presentation
 Process Control and Supervision
 Report Generation
Components of Distributed Control System
Engineering Station
This is the main station from where all the distributed controllers, as well as
field devices and operator stations, can be configured. This station can be
a PC or any other system.

This station is additionally used to configure a new controller, modifying the

control logic of the controller, configure smart field devices, to create a new
logic, to store the information, create a new input or output point, etc.

Operator Station or HMI

This is the station from where an operator can monitor the entire plant
equipment in a graphical illustration. An operator can also operate the
equipment as well as see the trends, alarms, and reports.

Sometimes multiple stations are used to perform this task like Trends,
Alarms, Report, Recipe in a different station.
Process Control Unit or Local Control Unit
This is also called a distribution controller or process station. It is placed
near to the field devices or a suitable location from where all the field
devices can connect with it.

The field devices like sensors, actuators, transmitters are directly

connected with the I/Os of this unit.
The controller receives the instructions from the engineering station like set
point and other parameter and also acquire the information from the
various input devices.

The CPU analyzes all the inputs and processes them based on the user
program and then sends the output signal via output modules to control the
devices.

It can sense and control both analog and digital inputs/outputs by analog
and digital I/O modules. These modules are extendable according to the
number of inputs and outputs.

It collects the information from discrete field devices and sends this
information to operating and engineering stations.

Communication System
The communication system is the most important part of the Distributed
Control System or DCS System, which is used to connect all the
engineering stations, process stations, control units, and smart field
devices.

The common protocol used in DCS as communication protocols are

Ethernet, Profibus, Modbus, DeviceNet, etc.

However it is not compulsory that only a single protocol can be used in

DCS, we can use a different protocol for different levels.
Advantages of DCS
Handle complex structure
System redundancy
HMI
Scalable platform
System security
Difference between DCS and SCADA
DCS SCADA

Not capable of handling

Capable of handling communication failure
communication failure

Faster communication Slower communication when compared to DCS

Short distance communication Long-distance communication

Really costly Not as much costlier as DCS

Less downtime and

Maintenance and downtime would be more than DCS
maintenance

Distributed type of control Supervisory level control

SCADA would be composed of a data network,

Dependent on instrumentation
computer network, graphical interface

Pre-programmed Not pre-programmed

Process safety can be ensured Not as safe as the DCS

Process related Data gathering

Remote Terminal Unit (RTU) in SCADA

Definition: Remote Terminal Unit (RTU) in SCADA systems is a

microprocessor-based electronic device present at geographically distributed
remote locations in order to facilitate communication of various devices within
the distributed SCADA system. It consists of input-output hardware and
communication interface for remote sensing and controlling of ongoing
processes.

The sole purpose of an RTU present at the remote site of the SCADA system
is to send all the collected data and information to the central station with the
help of sensors, monitors, production processes, etc. so that it can be stored
and monitored.

Basics of Remote Terminal Unit

We have discussed in the previous content of the introduction to SCADA

systems that SCADA systems permit the interconnection of various units
which are dispersedly present at various remote locations to handle industrial
control processes.

The remote terminal unit acts as a crucial component of SCADA systems. It

establishes and maintains the connection between the different elements of
the system to facilitate communication where a wired connection cannot be
established. As it supports the communication of remote field equipment thus
it is named so.

 It is to be noted here that PLCs that hold the ability to

communicate through radio waves can act as a substitute for
RTUs.
RTU Architecture
 1. CPU

The inbuilt central processing unit nowadays uses 16-bit or 32-bits

microprocessor with the memory capacity of 256 kilobytes. It consists of 3
communication ports with ethernet links and the real-time clock is used for the
overall controlling of the system.

The use of watchdog timer provides real-time checking of regular execution of

processes. This watchdog timer gets reset on regular basis and in case the
resetting is delayed then the timer flags error.

2. Power Supply Module

For the uninterrupted operation, continuous supply of power is required by the

RTU, but the unit is separated with a large distance from the point where
supply is actually present. So, to facilitate uninterrupted operation in case of
power failure, an alternate power source with battery backup is provided to the
unit. For low power RTUs, solar panels are mostly used while sometimes
thermoelectric generators are used according to the availability of gas
pipelines.

Generally, lead-acid or nickel-cadmium batteries are used.

3. Analog Input Module

The applied analog input is generally a variable voltage or current, varying in

direct proportion to the process under measurement. The different analog
inputs are 0-1 mA, 0-10 V, ± 1.5 V, 5 V, etc.

The basic features of analog output modules are:

 There are 8, 16 or 32 analog inputs,

 It usually offers 8 to 12 bits of resolution,
 Generally, 4 to 10 mA range,
 The offered conversion rate is about 10 microseconds to 30
milliseconds.
 4. Analog Input Module

The applied analog input is generally a variable voltage or current, varying in

direct proportion to the process under measurement. The different analog
inputs are 0-1 mA, 0-10 V, ± 1.5 V, 5 V, etc.

The basic features of analog output modules are:

 It has 8, 16, 32 analog outputs,

 It offers a resolution of 8 or 12 bits,
 The provided conversion rate is between 10 microseconds to 30
milliseconds,
 The output ranges between 4-10 milliampere or 0 to 10 V.
5. Communication Interfaces

A remote terminal unit can be interfaced to multiple control stations and

intelligent electronic devices using different communication media like RS485,
RS232, ethernet, microwave and satellite, etc. When a communication
interface is maintained between two ends then either side can initiate the data
transfer so as to have synchronized data transfer with the least possible traffic
issues.

Also, if the multiple RTUs within the SCADA system wants to share a common
communication line then using multi-drop scheme this can be done. As unique
addressing is provided to each unit and response will be understood
depending on their polls and commands.
Master Terminal Units (MTU) role
Master terminal units (MTU) in SCADA system is a device that issues
the commands to the Remote Terminal Unit (RTUs) which are located
at remote places from the control, gathers the required data, stores the
information, and process the information and display the information
in the form of pictures, curves and tables to human interface and helps
to take control decisions. This is the operation of the Master Terminal
Unit (MTU) located in the control center.

1. Communication between the MTU and RTU is bidirectional,

however, the major difference is RTU cannot initiate the
conversation, an RTU simply collects the data from the field and
stores the data.

2. Communication between the MTU and RTUs are initiated by the

programs within the MTU which are triggered either by operator
instructions or automatically triggered.

3. 99% of the instructions and messages to the RTUs from MTUs are
automatically triggered.

4. When Master Terminal Unit (MTU) asks the desired information

RTU sends it. So MTU is considered as master and RTU is the Slave.

5. after receiving the data required MTU communicates to the

printers and CRTs which are operator interface through necessary
protocols.

6. Thus in SCADA system, Master Terminal Unit (MTU) acts as the

heart of the system.
EDITORS USED IN SCADA
In SCADA (Supervisory Control and Data Acquisition) systems, there are
several software tools and editors commonly used for configuring and
designing the system. These editors allow users to create and modify the
graphical user interface (GUI), define communication protocols, set up data
acquisition parameters, and configure alarms and events. Here are some
commonly used editors in SCADA:

1. HMI/SCADA Editors: Many SCADA systems provide their own integrated

development environments (IDEs) or editors for creating human-machine
interfaces (HMIs). These editors allow users to design the visual
representation of the SCADA system, including process displays, alarms,
trends, and control elements.

2. Tag/Variable Editors: SCADA systems typically use tags or variables to

represent process data points. Tag editors allow users to define and
configure these data points, including their names, addresses, data types,
scaling, and other properties.

3. Communication Protocol Editors: SCADA systems communicate with

various field devices, controllers, and data sources using different protocols.
Protocol editors enable users to configure the communication parameters,
such as protocol type, baud rate, IP addresses, and port numbers.

4. Alarm Configuration Editors: SCADA systems generate alarms based on

predefined conditions or events. Alarm configuration editors allow users to
define alarm thresholds, priorities, notifications, and associated actions.

5. Event Log Editors: SCADA systems often maintain event logs to record
system activities, alarms, and other relevant events. Event log editors enable
users to view, filter, and manage these logs, providing insights into system
performance and troubleshooting capabilities.

6. Scripting Editors: Some advanced SCADA systems provide scripting

capabilities for implementing custom logic, calculations, or automation
tasks. Scripting editors allow users to write and edit scripts using specific
programming languages or scripting frameworks.
COMMUNICATION PROTOCOLS FOR SCADA-
1. MODBUS

 MODBUS is a widely used serial communication protocol designed for

communication between electronic devices in industrial environments. It was
developed by Modicon (now Schneider Electric) in 1979
 MODBUS supports both serial (RS-232/RS-485) and Ethernet (TCP/IP) communication
and is known for its simplicity and versatility.
 It enables communication between a master device (such as a programmable logic
controller or a supervisory control and data acquisition system) and multiple slave
devices (such as sensors, actuators, or other controllers) in a network.
 MODBUS uses a simple request/response model and supports various data types,
making it suitable for a wide range of applications.

2. DNP3(DISTRIBUTED NETWORK PROTOCOL)

 DNP3 is a robust and reliable communication protocol used in the utility and energy
sectors.
 DNP3 is specifically designed for remote monitoring and control of devices in SCADA
(Supervisory Control and Data Acquisition) systems.
 It supports both serial and IP-based communication and provides features such as
data prioritization, time synchronization, event reporting, and secure authentication.
 DNP3 is known for its high performance, scalability, and fault tolerance, making it
suitable for large-scale deployments in critical infrastructure systems like power grids,
water treatment plants, and oil refineries.

3. IEC 60870-5: IEC 60870-5 is an international standard for telecontrol protocols

used in SCADA systems. It defines protocols for communication between remote
terminal units (RTUs) and control centers. IEC 60870-5 supports various
communication media, such as serial, Ethernet, and TCP/IP.

4. ICCP (Inter-Control Center Communications Protocol): ICCP is a protocol used for

communication between control centers in electric power systems. It enables the
exchange of real-time data, such as system status, control commands, and
measurements, between SCADA systems in different control centers.
5. OPC
 It stands for OLE (Object Linking and Embedding) for Process Control.
 OPC was initially developed to overcome the challenges of integrating diverse
hardware and software systems. It defines a common interface and communication
protocol to enable data exchange between different industrial devices and software
applications.
 OPC uses Microsoft's Component Object Model (COM) technology for
communication and provides a standardized way to access real-time data, historical
data, and alarms/events from various industrial sources, such as PLCs, DCSs
(Distributed Control Systems), and SCADA systems.
 OPC has evolved over time, and OPC Unified Architecture (OPC UA) is the latest
version, offering enhanced security, scalability, and platform independence.

INTERFACING SCADA SYSTEM WITH PLC

Connection of PLC System with SCADA via OPC UA
OPC is a client-server-based communication. OPC client is a software
program that is installed on a computer in which SCADA is installed or
which is directly connected with the process hardware like HMI.

OPC clients use the OPC server to collect data from the process control
hardware devices.
Architecture of OPC applications:

OPC ™ - OLE for Process Control, implements two large modules:

OPC Server and OPC Client. While the OPC Server specifies
standard interfaces for direct access to equipment or applications,
the OPC Client specifies the default interface for applications to
access the collected data.

There are three types of OPC data servers:

Data Access Server: direct access to equipment data;

Alarm & Event Server: notification mechanism for OPC clients for
specific events and alarm conditions;

Historical Data Server: reading, processing and editing historical

data.
Steps to establishing a connection between PLC system with SCADA:

1) Create a New Project in TIA Portal. Select the PLC system with
firmware version above v2.5 and which provides OPC UA server data
access.

2) Activate OPC Server in the PLC System.

3) Select Runtime License

4) Prepare a sample ladder program to check the OPC connection.

5) Open PLCSIM Advanced and create an instance with PLCSIM Virtual

Ethernet Adapter as a normal PLCSIM does not provide the simulation for
the OPC UA server.

6) Download the user program into the PLC system.

7) Create a new project in WinCC.

8) Add a driver into Tag Management as OPC UA WinCC Channel.

9) Define a connection parameter for the OPC UA Connections.

10) Add a server address that we have already assigned in the PLC
system.

11) Select security policy and mode as per the given in the PLC system.

12) Browse OPC Server.

13) Select the input, output, and memory tags from the server.

14) Prepare a graphic to on and off the motor in the Graphics

Manager and give all the properties and actions as per the requirement.

15) When we press the start button it will start the motor as per the user
program.

16) We can monitor the user program status in the TIA portal as well.
simple traffic light control system using SCADA

1. System Design: Determine the requirements and design of your traffic

light control system. Identify the number of traffic lights, their locations, the
desired traffic flow patterns, and any specific rules or timings to be
implemented.

2. SCADA Software Selection: Choose a SCADA software platform that

suits your needs.

3. Create Tags: In SCADA, tags represent the real-world data points you
want to monitor or control. Create tags for each traffic light, including their
status (red, yellow, green), timers, and any other relevant parameters.

4. HMI (Human Machine Interface) Design: Develop an intuitive and user-

friendly interface for operators to interact with the traffic light control
system. Design the HMI screens to display the status of traffic lights, allow
manual control, and provide feedback on system performance.

5. Communication Setup: Establish communication between the SCADA

software and the traffic light hardware. This typically involves configuring
communication protocols such as Modbus, OPC (OLE for Process Control),
or MQTT (Message Queuing Telemetry Transport) to exchange data
between the SCADA software and the traffic light controller.

6. Programming Logic: Implement the necessary programming logic in the

SCADA software to control the traffic lights. This may include timers for the
green, yellow, and red phases, coordination between adjacent traffic lights,
and handling special scenarios such as pedestrian crossings or emergency
vehicle prioritization.

7. Alarms and Event Handling: Set up alarms and event notifications within
the SCADA software to alert operators in case of faults or abnormal
conditions, such as a traffic light malfunction or power failure.
8. Testing and Commissioning: Conduct thorough testing of the system to
ensure proper functionality and compliance with the specified requirements.
Collaborate with the appropriate stakeholders, including traffic engineers
and local authorities, to validate the system before deployment.

9. Deployment and Maintenance: Once the system is tested and approved,

deploy it in the desired traffic intersections. Monitor the system's
performance, provide regular maintenance, and address any issues or
updates as necessary.
Maintaining a SCADA-based PLC
Maintaining a SCADA-based PLC (Programmable Logic Controller) system
involves several important steps to ensure its optimal performance and
reliability. Here's a general procedure to help you maintain a SCADA-based
PLC system:

1. Regular Inspections:
- Perform visual inspections of the hardware components, such as PLCs, I/O
modules, and communication devices, to check for any physical damage,
loose connections, or signs of wear and tear.

2. Software Updates:
- Stay up-to-date with the latest firmware and software updates provided by
the PLC and SCADA system manufacturers. These updates often contain bug
fixes, security patches, and performance improvements.
- It's recommended to test software updates in a non-production
environment before deploying them in your live SCADA system.

3. Backup and Disaster Recovery:

- Regularly back up your SCADA system configuration, PLC programs, and
historical data. This ensures that critical information can be restored in case of
system failure, hardware malfunction, or cyber-attacks.
- Store backups in secure locations, preferably off-site or in the cloud, and
ensure that they are easily accessible when needed.

4. Cybersecurity Measures:
- Implement robust cybersecurity measures to protect your SCADA-based
PLC system from unauthorized access and potential cyber threats.
- Keep your antivirus and firewall systems up to date.
5. Performance Monitoring:
- Monitor the performance of your SCADA-based PLC system using built-in
diagnostics, log files, and performance monitoring tools.
- Keep an eye on key performance indicators such as CPU usage, memory
utilization, network traffic, and response times.
- Set up alarms and notifications to alert you of any abnormal conditions or
potential issues.

6. Staff Training:
- Provide regular training to your system operators and maintenance
personnel to ensure they are knowledgeable about the SCADA-based PLC
system.
- Train them on routine maintenance procedures, troubleshooting
techniques, and emergency response protocols.

7. Documentation and Documentation:

- Maintain comprehensive documentation of your SCADA-based PLC
system, including system architecture, network diagrams, hardware
specifications, software versions, and configuration details.