BASIC OF SCADA SYSTEM…

AND ITS APPLICATION TO PROCESS INDUSTRIES

 OBJECTIVE

❑ INTRODUCTION OF INDUSTRIAL CONTROL SYSTEM

❑UNDERSTAND THE DEFINITION OF SCADA

❑ FUNCTIONALITY OF SCADA

❑ ARCHITECTURE OF SCADA

❑ COMPONENT OF SCADA

❑ DATA FLOW

❑ DEMO. CONFIGURATION AND SIMULATION SOFTWARE

INDUSTRIAL CONTROL SYSTEM (ICS)
❑ ELECTRONIC CONTROL SYSTEM AND ASSOCIATED
INSTRUMENTATION USED FOR INDUSTRIAL PROCESS CONTROL
❑ RANGE IN SIZE FROM MODULAR TO A LARGE SCALE CONTROL SYSTEM
❑ USES IT AND INDUSTRIAL PROTOCOLS

❑ LEGACY SYSTEMS (15 – 20 YEARS)

❑ OPEN ARCHITECTURE TO OTHER “OT” SYSTEMS

OPERATIONAL TECHNOLOGY (OT)

❑ ALL ELECTRONIC AND COMPUTER SYSTEMS UTILIZED BY
INDUSTRIAL FACILITIES TO OPERATE SAFELY

❑ CONTINUOUS OPERATION

❑ RESPONSE IS TIME CRITICAL

❑ HIGHER FAULT TOLERANCE

EXAMPLES OF OPERATIONAL TECHNOLOGY (OT) SYSTEMS
❑ DISTRIBUTED CONTROL SYSTEM (DCS)
❑ SAFETY INSTRUMENTED SYSTEM (SIS)
❑ EMERGENCY SHUTDOWN SYSTEM (ESD)
❑ SCADA (SUPERVISORY CONTROL AND DATA ACQUISITION)
❑ PLC’’s / RTU’s
❑ FIRE & GAS (F&G)
❑ FIRE ALARM CONTROL PANEL (FACP)
❑ TANK GUAGING SYSTEM (TGS)
❑ SUBSTATION AUTOMATION SYSTEM
❑ POWER CONTROL SYSTEM
❑ ELECTRICITY METERING SYSTEM
❑ ELECTRICAL POWER MONITORING SYSTEM
❑ COMPRESSOR CONTROL SYSTEM
❑ VIBRATION MONITORING SYSTM
❑ BURNER MANAGEMENT CONTROL SYSTEM
❑ ENERGY MANAGEMENT SYSTEM
 EVOLUTION OF INDUSTRIAL CONTROL SYSTEM

MANUAL CONTROL PNEUMATIC CONTROL PANRL

MIMIC PANEL

RELAY CONTROL
PANEL

ALARM WINDOW RECORDER STANDALONE SINGLE CONTROLLER ALARM MONITOR

 EVOLUTION OF INDUSTRIAL CONTROL SYSTEM
FOURTH INDUSTRIAL REVOLUTION
(INDUSTRY 4.0)

COMPUTER HARDWARE MULTIPLE DISPLAYS AND DESKTOP CONSOLE

MOBILE APP

WEB BROWSER SCADA SERVER

 DEFINITION OF SCADA

ACRONYM MEANING

SUPERVISORY SCADA IS A SYSTEM OF SOFTWARE AND HARDWARE

ELEMENTS THAT ALLOWS INDUSTRIAL ORGANIZATIONS TO:

CONTROL ❑ CONTROL INDUSTRIAL PROCESSES LOCALLY OR

REMOTELY
❑ DIRECTLY INTERACT WITH DEVICES SUCH AS SENSORS,

AND METERINGS, VALVES, PUMPS, MOTORS, AND MORE

THROUGH HUMAN MACHINE INTERFACE (HMI)
SOFTWARE

DATA
❑ MONITOR, GATHER, AND PROCESS REAL-TIME DATA
❑ DISPLAYS ALARMS AND RECORDS EVENTS INTO A LOG
FILE

ACQUISITION FLOW / LEVEL / PRESSURE / TEMPERATURE / CURRENT / SPEED /

FREQUENCY / VOLTAGE / VIBRATION / ANALYZERS
Ref: https://inductiveautomation.com/resources/article/what-is-scada
 DEFINITION OF SCADA
WHY DO WE NEED SCADA?
❑ ABILITY TO REMOTELY COLLECT DATA FROM DIFFERENT PLANTS ON DIFFERENT PLACES

❑ ABILITY TO CONTROL PROCESS FROM A DISTANCE.

❑ ABILITY TO CREATE LOGS AND REPORTS ABOUT SYSTEM’S PRESENT AND PREVIOUS STATES

❑ ABILITY TO SEND INFORMATION TO ENGINEERS AND OPERATORS IN REAL TIME USING INSTANT
MESSAGING AND SMS.

DESIGN OF A SCADA PROJECT

THE SCADA PROJECT CONTAINS:
❑ DESIGN DOCUMENTS (NETWORK ARCHITECTURE/ HARDWARE SPECIFICATION / SOFTWARE SPECIFICATION)

❑ PROCESS FLOW DIAGRAM (PFD) OR PIPING & INSTRUMENTATION DIAGRAM (P&ID)

❑ DATASHEETS

❑ I/O LIST (INPUT / OUTPUT), ALARM SETTINGS THINGS TO CONSIDER:

BANDWIDTH
❑ METHODOLOGY, PROCEDURES (FAT/SAT)
NETWORK REDUNDANCY
❑ CONTROL PHILOSOPHY, NARRATIVES
 ADVANTAGES AND DISADVANTAGES

ADVANTAGES…
❑ THE SYSTEM PROVIDE FACILITY TO STORE LARGE AMOUNT OF DATA.
❑ THE DATA CAN BE DISPLAYED IN VARIOUS FORMATS AS PER USER REQUIREMENTS.
❑ IMPROVES MAINTENANCE AND OPERATION
❑ IT PROVIDES INTERFACE TO CONNECT THOUSANDS OF SENSORS ACROSS WIDE REGION FOR VARIOUS
MONITORING AND CONTROLLING OPERATIONS.
❑ PROVIDE RAPID RESPONSE TO EMERGENCIES
❑ RELIABLE

DISADVANTAGES…
❑ INSTALLATION COSTS ARE HIGHER.
❑ THE SYSTEM SUPPORTS USE OF RESTRICTED SOFTWARES AND HARDWARE EQUIPMENTS
❑ PLC BASED SCADA SYSTEM IS COMPLEX IN TERMS OF HARDWARE UNITS AND DEPENDENT MODULES.
❑ AS THE SYSTEM IS COMPLEX, IT REQUIRES SKILLED OPERATORS, ANALYST AND PROGRAMMERS TO
MAINTAIN SCADA SYSTEM.
❑ CYBER ATTACKS
 ADVANTAGES AND DISADVANTAGES
CYBER ATTACKS
“Huge Risk to society and environment”
A cyberattack on oil and gas control systems can result
in severe consequences to human safety and the
environment in the form of ruptures, explosions, fires,
releases and spills.
Lack of cybersecurity awareness in the oil & gas industry – a major risk for the environment |
Advenica

Malicious software (a.k.a. Malware)

❑ designed to disrupt, damage, or gain unauthorized
access to a computer system
❑ a file or a code that typically delivered to a network, that infects
explores, steals or conducts virtually any behavior an attacker wants.
Types or Malware
❑ Ransonware - blackmail
❑ Spyware – steals your data
❑ Adware – spams you with ads
❑ Worms – spread across computer Ref: Timeline of Cyberattacks on Oil & Gas Industry | Download Scientific
❑ Trojans – sneak malware into your PC Diagram (researchgate.net)
❑ Botnets – Turn your PC into a zombie
 ADVANTAGES AND DISADVANTAGES
CYBER ATTACKS
Attack on Florida’s Water Treatment Plant Western Ukraine Power BlackOut

One year after the Oldsmar water breach, some experts question the utility's Industrial Cybersecurity Pulse - Throwback Attack: BlackEnergy
cybersecurity | WUSF Public Media attacks the Ukrainian power grid

Manipulation of process variables, excessive amount Start as Phishing email,

of chemicals added to the process and result of BlackEnergy (Trojan malware)
contamination
❑ Weak passwords and web infrastructure ❑ Lack of cyber security awareness
❑ Lack of security features and stronger firewalls
❑ Lack of cyber security skilled workforce
 ADVANTAGES AND DISADVANTAGES

WAYS TO PREVENT CYBER ATTACKS

❑ ANTIVIRUS

❑ FIREWALLS / WHITELISTING

❑ SOFTWARE UPDATES / PATCH UPDATES / FIRMWARE UPDATES

❑ NETWORK SECURITY AND MONITORING

❑ DO NOT CLICK ON LINKS IN SPAM EMAIL OR UNTRUSTED WEBSITES

❑ USE STRONG PASSWORDS

KNOWN CYBER SECURITY VENDORS IN INDUSTRIAL CONTROL SYSTEM

DRAGOS CISCO FORESCOUT
NOZOMI MCAFEE FORTINET
 APPLICATION….
SCADA IN ELECTRICAL SYSTEMS

MONITOR
✓ LINE VOLTAGE
✓ CURRENT FLOW
✓ FREQUENCY
✓ POWER

CONTROL
✓ START/STOP
✓ SPEED CONTROL
✓ SETPOINTS
 APPLICATION….
SCADA IN ELECTRICAL SYSTEMS

POWER SYSTEM GRID

EQUIPMENT STATE
✓ STATUS
✓ OPEN/CLOSE THE
BREAKERS
 APPLICATION….
SCADA SYSTEMS IN OIL AND GAS

BASIC PROCESS CONTROL

 APPLICATION….
SCADA SYSTEMS IN WATER TREATMENT

MONITOR AND REGULATE WATER FLOW, RESERVOIR LEVELS, PIPE PRESSURE

 APPLICATION….
SCADA SYSTEMS IN MASS TRANSIT

REGULATE ELECTRICITY TO SUBWAYS AND TRAMS, CONTROL TRAFFIC FLOW

 APPLICATION….
SCADA SYSTEMS IN DISTRIBUTION METERING SYSTEM

FUEL GAS METERING CONTROL SYSTEM Ref: Reliance scada

 APPLICATION….
SCADA SYSTEMS IN OTHER INDUSTRIES

INDUSTRIES………
❑ PHARMACEUTICAL
❑ PULP AND PAPER
❑ FOOD AND BEVERAGES
❑ TEXTILE INDUSTRIES
❑ DISCREET MANUFACTURING PROCESSES
 SCADA… DCS… PLC…
SCADA…Supervisory Control and Data Acquition System
❑ A SYSTEM THAT COLLECTS DATA FROM VARIOUS SENSORS AT A FACTORY, PLANT OR IN REMOTE LOCATIONS AND THEN
SEND THIS DATA TO CENTRAL COMPUTER WHICH THEN MANAGES AND CONTROLS DATA.
❑ IT INCLUDES HARDWARE (INPUT AND OUTUT), CONTROLLERS, NETWORKS, HMI, COMMUNICATION EQUIPMENTS AND
SOFTWARE.
❑ IT COVERS LARGER GEOGRAPHICAL AREA AND RELY ON VARIETY OF COMMUNICATIONS SYSTEMS.

DCS…Distributed Control System

❑ PROVIDES A WIDE VARIETY OF FEATURES AND FUNCTIONS, SUCH AS CONTROL AND MONITORING, AN INTERFACE TO
OPERATIONS, MAINTENANCE PROGRAMMERS AND ADVANCED APPLICATION SOFTWARE.
❑ DCS CONTROLLER PROVIDES CONTROL FUNCTIONS FROM THE SIMPLEST LOOPS TO COMPLEX STRATEGIES INVOLVING
INTERRELATED LOOPS AND ADVANCED PROCESS CALCULATIONS
❑ DCS APPLICATION SOFTWARE CAN DO MORE THAN PROVIDE ADVANCED CONTROL AND MONITORING OF A PROCESS
PLANT. IT IS ABLE TO INTEGRATE THE CONTROL SYSTEM WITH PLANT AND BUSINESS COMPUTERS.

PLC…Programmable Logic Controller

❑ ALSO REFERRED TO AS A PROGRAMMER CONTROLLER IS A TYPE OF COMPUTER COMMONLY USED IN
COMMERCIAL AND INDUSTRIAL CONTROL APPLICATIONS. PLC MONITOR INPUTS AND OTHER VARIABLE VALUES,
MAKE DECISIONS BASED ON STORED PROGRAM, AND CONTROL OUTPUTS TO AUTOMATE A PROCESS OR
MACHINE.
 DCS ARCHITECTURE AND COMPONENT
DOSS - Supervisory Station/Engineering Station.
DCS…Distributed Control System Large Screen and High resolution graphics.
Windows OS. Plant operating and monitoring task.
DOPC - Process Controller. CPUs in a 2oo3 Engineering environment.
redundancy architecture.
Performs advanced control functions, DOHS - History Station. Windows Server
algorithms, control logics, control language. OS. Collect and store process data.
Connected to the I/O Module that connects to History data to be retrieved in HMI
the field devices. through Alarm & Events, Trends, and
Reports.
DEONET - Communication
System: Redundant
Ethernet.
10Mbps/100Mbps/1Gbps

DOGS - Gateway Station. Retrieves process data

from process contoller and PLC linker. Performs data
exchanges with other systems via network or with
the system on an information network.

DOPL/DGPL - Connectivity to Programmable Logic Controller

(PLC)/Safety Instrumentented Systems (SIS).

Azbil Harmonas-DEO
 DCS ARCHITECTURE AND COMPONENT
DCS…OTHER VENDORS

❑ HONEYWELL EXPERION/TDCS3000

❑ YOKOGAWA CENTUM

❑ SIEMENS SIMATIC PCS7

❑ EMERSON DELTA V

❑ ABB SYMPHONY PLUS

❑HARMONAS-DEO AZBIL (YAMATAKE)

 PLC ARCHITECTURE AND COMPONENT
BASIC ELEMENTS OF THE PLC
A PLC SYSTEM CONTAINS FOUR MAIN
PARTS, WHICH ARE:

▪ CPU MODULE
▪ INPUT AND OUTPUT
MODULES(I/O MODULES)
▪ A POWER SUPPLY MODULE
▪ PROGRAMMING DEVICE
Programming Language Standard: IEC61131-3
LADDER DIAGRAM (GRAPHICAL)
FUNCTIONAL BLOCK DIAGRAM (GRAPHICAL)
STRUCTIRED TEXT (TEXTUAL)
INSTRUCTION LIST (TEXTUAL)
SEQUENTIAL FUNCTION CHART
 PLC ARCHITECTURE AND COMPONENT

PLC…OTHER VENDORS
❑ ROCKWELL AUTOMATION (ALLEN BRADLEY)

❑ SIEMENS (SIMATIC)

❑ SCHNEIDER (MODICON / TRICONEX)

❑ HONEYWELL SAFETY MANAGER

❑ HIMA (HIMATRIX / HIMAX)

 COMPONENT OF SCADA

SCADA…MAIN COMPONENTS
❑ FIELD INSTRUMENTATIONS (Sensors/Transmitters/Meters)

❑ FIELD CONTROLLERS (RTUs / PLCs / IEDs)

❑ HUMAN MACHINE INTERFACE (HMI)

❑ COMMUNICATION NETWORK

❑ SERVER COMPUTER
 COMPONENT OF SCADA
FIELD INSTRUMENTATIONS…
❑ Sensors/Transducers

Temperature Pressure Level Flow Vibration Probe Current Transducer

- RTD - Diaphragm - Radar - Vortex
- Thermocouple - Bellows - Float - Pressure
- Capacitance - Pulses
❑ Switches

Push Buttons Float Switch Proximity Switch Flow Switch

 COMPONENT OF SCADA
FIELD INSTRUMENTATIONS…
❑ Transmitters

Level
Pressure Wireless Temperature
Transmitter
Transmitter Press. Transmitter Transmitter

Position Frequency-Voltage/Current Signal

Flow
Transmitter Converter Converter
Transmitter
 COMPONENT OF SCADA
FIELD INSTRUMENTATIONS…
❑ Outputs…. Final Control Device/Equipment

Motor Breaker Alarm Horn Relays

Motorized Valve Shutdown Valve Solenoid Valve Control Valve

 COMPONENT OF SCADA
CONTROLLERS…
❑ Intelligent Electronic Devices (IED) 4-20mA Signals / Digital Signals / Modbus RTU /DNP3 / IEC60870-5 / IEC61850

Protection Relay Universal Motor Controller Energy Meter

Flow Computer Fire & Gas System Ultrasonic Flow Meters Gas Chromatograph
(Custody Transfer) Analyzers
 COMPONENT OF SCADA
CONTROLLERS…
❑ REMOTE TELEMETERY UNITs (RTUs)

❑ A MICROPROCESSOR BASED THAT MONITORS AND CONTROLS FIELD DEVICES

❑ MULTIPLE DIFFERENT TYPES OF I/O, AND COMMUNICATION MODULES
❑ CAN BE PROGRAMMED THROUGH SIMPLE WEB INTERFACE
❑ MOST RTU’s HAVE PRE-PROGRAMMED MODULE
❑ USED IN ENVIRONMENT WITH EXTREME TEMPERATURES AND LOCATED IN REMOTE LOCATIONS
❑ BACKUP BATTERY AND CHARGING CIRCUIT, SUCH AS SOLAR POWER
 COMPONENT OF SCADA
CONTROLLERS…
❑ PROGRAMMABLE LOGIC CONTROLLERS (PLCs)

SAFETY PLCs……
❑ TMR (TRIPLE MODULAR REDUNDANCY)
❑ IT SUPPORTS ALL THE APPLICATIONS THAT A STANDARD PLC DOES.
❑ IT IS ONE OF THE COMPONENT OF THE SAFETY INSTRUMENTED SYSTEMS (SIS). IT CAN
REFERRED ALSO AS THE SAFETY SHUTDOWN SYSTEM. THE SAFETY INSTRUMENTED SYSTEM
MONITORS THE EQUIPMENT OR PROCESS AND IF UNACCEPTABLE CONDITION OCCURS IT
REACTS BY THE SHUTDOWN OF THE EQUIPMENT OR PROCESS.
❑ USE IN APPLICATION THAT COULD POSE HARM TO ENVIRONMENT, BUSINESS,
EQUIPMENT, AND PEOPLE
 COMPONENT OF SCADA
HUMAN MACHINE INTERFACE
❑ A COMPUTER THAT RUNS ON OPERATING SYSTEM

❑ ONE-TO-ONE RELATIONSHIP BETWEEN THE OPERATOR AND THE

MACHINE . IT REPRESENTS IN A GRAPHICAL DISPLAYS IN ORDER
FOR THE OPERATOR TO SEE WHAT IS HAPPENING TO THE
PROCESS AND EXECUTE COMMAND TO START/STOP THE
MACHINE AND OTHER FUNCTIONS. source: aispro.com
HMI TOUCH PANEL
❑ LOW LEVEL OF MONITORING AND CONTROL IT SUPPORTS WITH
INFORMATION ABOUT THE PROCESS VALUES, SETPOINTS, STATUS OF
THE MACHINES, LOADS AND USUFULL INFORMATION.

❑ IT REQUIRES A COMMUNICATION HARDWARE / DRIVERS TO TALK TO THE

CONTROLLERS.
 COMPONENT OF SCADA

❑ GRAPHIC DISPLAY

DISTILLATION UNIT GAS TURBINE GENERATOR

✓ EQUIPMENT / PIPING ✓ CONTROL SELECTION

✓ REAL TIME PROCESS VALUES ✓ ANIMATION
✓ CONTROLLERS (SETPOINTS/OUTPUT) ✓ SETPOINTS
✓ VALVE STATUS
 COMPONENT OF SCADA

❑ GRAPHIC DISPLAY

ALARM WINDOW
✓ EQUIPMENT OR DEVICE STATUS
✓ PROCESS ALARM STATUS
✓ RECEIVES SIGNAL THROUGH MODBUS TCP
PROTOCOL
✓ REAL TIME VOLTAGE/CURRENT/POWER VALUES
✓ LINE VOLTAGE / PHASE CURRENTS / ACTIVE POWER
 COMPONENT OF SCADA

❑ TREND DISPLAY

COMPRESSOR CONTROL TREND/CURVE PROCESS TREND

✓ REAL TIME TREND ✓ HISTORY DATA FOR ANALYSIS
✓ HISTORY TREND ✓ INVESTIGATION OF TRIPS
✓ COMPRESSOR OPERATING POINT ✓ PROCESS OPTIMAZATION
 COMPONENT OF SCADA

❑ ALARM DISPLAY

PROCESS ALARM SEQUENCE OF EVENTS

✓ ACTIVE ALARM ✓ ALARMS AND EVENTS FOR FAILURE ANALYSIS
✓ PRIORITY (TIME/LEVEL/AREA)
✓ ALARM & EVENT HISTORY
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ CABLES AND CONNECTORS RS232 (RECOMMENDED STANDARD 232)

COMPUTER DEVICE
TD RD
DTE DCE
RD TD
DATA DATA
TERMINAL COMMUNICATION
EQUIPMENT EQUIPMENT
RS232 CABLE

❑ COPPER MULTI-CONDUCTOR WITH 9-PIN CONNECTOR OR TERMINAL CONNECTION

❑ POINT TO POINT
❑ TRANSMISSION SPEED FROM 100 TO 20KBPS

❑ MAXIMUM LENGTH OF 50FT/15METERS

 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ CABLES AND CONNECTORS RS485 - TIA-485(-A) OR EIA-485

❑ COPPER UTP OR STP

❑ POINT TO POINT / MULTIPOINT

❑ TRANSMISSION SPEED UP TO 10MBPS

❑ MAXIMUM LENGTH OF 4000FT/1.2KMS

EXAMPLE OF MULTIDROP CONFIGURATION

2-WIRE CABLE
RS485
MULTI DROP
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ CABLES AND CONNECTORS ETHERNET CABLE (CAT5/CAT5E/CAT6)

STRAIGHT-
DTE THROUGH DCE

CROSSOVER
DTE DTE

CROSSOVER
DCE DCE

❑ COPPER UTP TO STP

❑ POINT TO POINT
❑ TRANSMISSION SPEED UP TO 10GBPS
❑ MAXIMUM LENGTH OF 180FT/55METERS
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ CABLES AND CONNECTORS CO-AXIAL CABLE

CO-AXIAL CONTROL TAPS SPLITTER

(WITH BNC CONNECTOR) (ALLEN BRADLEY) (MODICON)

❑ COPPER COAXIAL
❑ MULTI-DROP
❑ TRANSMISSION SPEED UP TO 10MBPS
❑ MAXIMUM LENGTH OF 3280FT/1000M
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ CABLES AND CONNECTORS FIBER OPTIC CABLE / CONNECTORS

SINGLE MODE FIBER OPTIC FIBER OPTIC CONNECTORS

SINGLE MODE OPTICAL FIBER (SMF) MULTIMODE OPTICAL FIBER (MMF)

❑ POINT TO POINT ❑ POINT TO POINT
❑ SMALLER DIAMETER 8.3 TO 10microns ❑ DIAMETER 50 TO 100microns
❑ MAXIMUM LENGTH OF 10km ❑ MAXIMUM LENGTH OF 1km

❑ TRANSMISSION SPEED OF 10Gbps ❑ TRANSMISSION SPEED OF 1GBps

 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ MEDIA CONVERTERS / COMMUNICATION MODULES

SERIAL RS232/422/485 TO SERIAL RS232/422/485 ETHERNER TO FIBER OPTIC DH+ TO ETHERNET

FIBER OPTIC CONVERTER TO ETHERNET CONVERTER CONVERTER CONVERTER (ALLEN BRADLEY)

RTU COMMUNICATION PLC ETHERNET PLC CONTROL NET (CO-AXIAL)

MODULE COMMUNICATION MODULE COMMUNICATION MODULE
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ ETHERNET SWITCH / GATEWAYS

HIGH SPEED ETHERNET SWITCH

MODBUS TCP GATEWAY

HUB

FIREWALL

ROUTER
DATA DIODE
 COMPONENT OF SCADA
COMMUNICATION PROTOCOL
Protocol Level Common Applications
Modbus Device Manufacturing, Electric Utility
ModbusPlus
ModbusTCP
Profibus Device Process Industry
DeviceNet Device Manufacturing
DNP 3.0 Device Electric Utility, SCADA
BACNet Control HVAC Control, Building Automation
ControlNet Control Manufacturing
ARCNet Supervisory Office Automation, Gaming
Ethernet I/P Supervisory Office Automation, Internet
Source: instrumentationtools.com
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ NETWORK TOPOLOGY
BUS TOPOLOGY
ADVANTAGE
✓ LESS EXPENSIVE
✓ NODE FAILURE DOES NOT AFFFECT OTHERS
✓ SUITED FOR SMALL NETWORK

DISADVANTAGE
✓ NOT FAULT TOLERANCE (NO REDUNDANCY)
✓ LIMITED CABLE LENGTH
✓ NO SECURITY

❑ CONNECTS NETWORK COMPONENT IN A

SINGLE CABLE OR SERIES OF CABLE SEGMENT
❑ MULTI-DROP / DAISY CHAIN
2-WIRE CABLE
RS485
MULTI DROP
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ NETWORK TOPOLOGY
STAR TOPOLOGY

ADVANTAGE
✓ EASY TO DESIGN AND IMPLEMENT
✓ CENTRALIZED ADMINISTRATION (SWITCH)
✓ SCALABLE

DISADVANTAGE
✓ SINGLE POINT OF FAILURE
✓ BOTTLENECKS DUE TO OVERLOAD SWITCH/HUB
✓ INCREASED COST DUE TO SWITCH/HUB
❑ NETWORK COMPONENT IS PHYSICALLY
CONNECTED TO A CENTRAL NODE
(HUB / SWITCH / ROUTER)
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ NETWORK TOPOLOGY
RING TOPOLOGY

ADVANTAGE
✓ BETTER PERFORMANCE THAN BUS TOPOLOGY
✓ CAN CAUSE BOTTLENECK DUE TO WEAK LINK
✓ ALL NODES WITH EQUAL ACCESS

DISADVANTAGE
✓ UNIDIRECTIONAL. SINGLE POINT OF FAILURE
✓ NO SECURITY
✓ HIGH LOAD WILL DECREASE THE PERFORMANCE
❑ NETWORK STATIONS ARE CONNECTED ALONG
A SINGLE PATH WHOSE ENDS ARE JOINED TO
FORM A CIRCLE
❑ TOKEN RING PASSING PROTOCOL
❑ UNIDIRECTIONAL
 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ NETWORK TOPOLOGY
MESH TOPOLOGY ADVANTAGE
✓ EACH CONNECTION CAN CARRY ITS OWN DATA LOAD
✓ ROBUST
✓ FAULT DIAGNOSED EASILY
✓ PROVIDES SECURITY AND PRIVACY
✓ REDUNDANCY
DISADVANTAGE
✓ EXPENSIVE TO IMPLEMENT
✓ HIGH MAINTENANCE AND TIME CONSUMING
❑ NETWORK DEVICES ARE INTERCONNECTED
WITH EACH OTHER

HONEYWELL WIRELESS NETWORK

 COMPONENT OF SCADA
COMMUNICATION NETWORK
❑ NETWORK TOPOLOGY
TREE TOPOLOGY HYBRID TOPOLOGY

❑ ALSO KNOWN AS STAR BUS TOPOLOGY ❑ COMBINATION OF TWO OR MORE TOPOLOGIES

❑ INTEGRATION OF BOTH BUS AND STAR TOPOLOGY ❑ MIXTURE OF RING, TREE, BUS, STAR TOPOLOGY

❑ USE NETWORK ROUTERS AND BRIDGES

 ARCHITECTURE OF SCADA
OSI MODEL (OPEN SYSTEMS INTERCONNECTION)
7 LAYERS OF NETWORK ARCHITECTURE

• END USER LAYER EXAMPLES:

APPLICATION LAYER SAFARI / FIREFOX / OUTLOOK
DATA • HTTP/WWW/DNS/SMTP/FTP/TELNET

• SYNTAX LAYER / DATA CONVERSION/ DATA ENCRYPTION/DATA COMPRESSION

SOFTWARE PRESENTATION LAYER • SSL/SSH/MPEG/FTP/JPEG
DATA
LAYER
• SYNC AND SEND TO PORT
SESSION LAYER • API/SOCKET/WINSOCK
DATA

• END TO END CONNECTION

TRANSPORT LAYER
SEGMENTS
• TCP/UDP/PORT NUMBERS

• PACKETS EXAMPLES:
NETWORK LAYER • IP LOGICAL ADDRESSING/ ROUTING (PATH) IPv4/IPv6/
PACKETS
• FRAMES
HARDWARE DATA LINK LAYER • MAC ADDRESS/SWITCHES/BRIDGES/ETHERNET(802.3)
LAYER FRAMES

PHYSICAL LAYER • PHYSICAL STRUCTURE (CABLING, CONNECTORS)

BITS • COAX/FIBER/RJ45/NIC/HUBS/WIRELESS(802.11)/REPEATERS
 ARCHITECTURE OF SCADA
INDUSTRIAL AUTOMATION & CONTROL SYSTEM SECURITY (IEC62443/ISA-99)
IEC 62443 (FORMERLY KNOWN AS ISA-99) IS A SET OF SECURITY STANDARS FOR THE SECURE DEVELOPMENT OF INDUSTRIAL AUTOMATION AND CONTROL SYSTEM (IACS).
IT PROVIDES A THOROUGH AND SYSTEMATIC SET OF CYBER SECURITY RECOMMENDATIONS. IT’S USED TO DEFEND INDUSTRIAL NETWORKS AGAINST CYBER SECURITY
THREATS.

IT

OT

Yokogawa Cyber Security

 ARCHITECTURE OF SCADA
OT and IT…
OT IT
INDUSTRIAL AUTOMATION & GENERAL PURPOSE
CONTROL SYSTEMS INFORMATION TECHNOLOGY
SYSTEMS

AVAILABILITY CONFIDENTIALITY

INTEGRITY INTEGRITY

CONFIDENTIALITY AVAILABILITY

PRIORITY
SAFETY SECURITY
 ARCHITECTURE OF SCADA
TYPES OF SCADA SYSTEM
1st : MONOLITHIC OR STAND ALONE 2nd: DISTRIBUTED SCADA

4TH: INTERNET OF THINGS

3rd: NETWORK SCADA
 ARCHITECTURE OF SCADA
SAMPLE SCADA NETWORK AND ARCHITECTURE

SCADA INTEGRATION OF VARIOUS PLANT

PROCESS AREAS AND UTILITIES
 ARCHITECTURE OF SCADA
SAMPLE SCADA NETWORK AND ARCHITECTURE

SCADA INTEGRATION OF SUBSTATION AND

POWER PLANT TO THE CONTROL CENTER
 COMPONENT OF SCADA
SERVER COMPUTER
❑ A COMPUTER THAT RUNS ON OPERATING SYSTEM.
(WINDOWS SERVER/MS SQLSERVER, RDBM)
* RELATIONAL DATABASE MANAGER

❑ CAN BE CONFIGURED AS REDUNDANT SERVERS FOR

SYSTEM RELIABILITY

❑ COLLECT AND STORE PROCESS DATA FOR ALARM AND EVENTS

RETRIEVAL AND HISTORY TRENDS. SERVE AS AN HISTORIAN OF
SCADA SYSTEM.

❑ IT PROVIDES AN EXTENDED DATA ARCHICE, TYPICALLY

MINIMUM OF ONE YEAR AND CAN BE EXTENDED
❑ PHYSICAL SERVER
DEPENDING ON THE CONFIGURATION OF THE SYSTEM.
❑ VIRTUAL SERVER
❑ APPLICATION SERVER
❑ WEB SERVER ❑ IT ALSO PROVIDE REPORT FUNCTION WHICH CAN BE SAVED IN
❑ DATABASE SERVER MSEXCEL.
❑ MONITORING AND MANAGEMENT SERVER
❑ ALARM MANAGEMENT SERVER
❑ HISTORY SERVER

SERVER ROOM
COMMUNICATION SETTINGS (SERIAL: RS232, RS485) OBJECT DATA TYPE PROVIDED BY MODBUS SLAVE TO A MASTER DEVICE
Parameters Values Object Function Access Size Address Space
Baud Rate 2400 - 115200 Type Code

Parity Even, Odd, None Coil 1 Read-write 1bit 00001-09999

Stop Bit 1 or 2 Discrete 2 Read-only 1bit 10001 - 19999

Input
Data Bit 3,4,5,6,7,8
Input 3 Read-only 16 bits 30001 - 39999
Parameters Values Register
Device ID 1 - 247 Holding 4 Read-write 16 bits 40001- 49999
Register
COMMUNICATION SETTINGS (ETHERNET)
Parameters Values
IP Address Class A : 0.0.0.0 to 127.255.255.255
Class B : 128.0.0.0 to 191.155.255.255
Class C : 192.0.0.0 to 223.255.255.255
Class D : 224.0.0.0 to 239.255.255.255
Class E : 240.0.0.0 to 255.255.255.255
Subnet Class A : 255.0.0.0
Class B : 255.255.0.0
Class C : 255.255.255.0
Gateway 1 or 2
 CONNECTIVITY OF SCADA
CLIENT MASTER CLIENT MASTER
HMI
HMI SERVER SCADA SOFTWARE
SCADA SOFTWARE HISTORIAN ENGINEERING STATION
I/O SERVER/ DASERVER / OPC / DRIVERS I/O SERVER/ DASERVER / OPC / DRIVERS I/O SERVER/ DASERVER / OPC / DRIVERS

COMMUNICATION INTERFACE COMMUNICATION INTERFACE COMMUNICATION INTERFACE

(EX. NETWORK INTEFACE CARD, NIC) (EX. NETWORK INTEFACE CARD, NIC) (EX. NETWORK INTEFACE CARD, NIC)

CONTROL NETWORK

CONVERTER
SERIAL TO ETHERNET BRIDGE / GATEWAY
COMMUNICATION INTERFACE COMMUNICATION INTERFACE
(EX. ETHERNET, COMM MODULE) (EX. ETHERNET, COMM. MODULE)
COMM. PORT COMM. PORT
DEVICE CONFIGURATION SETTINGS
MODBUS REGISTERS DEVICE CONFIGURATION SETTINGS COMM. SETTINGS COMM. SETTINGS
GLOBAL VARIABLES MODBUS REGISTERS DEVICE ADDRESS DEVICE ADDRESS
TAGNAMES MODBUS REGISTERS MODBUS REGISTERS

DEVICE DEVICE
PLC SLAVE
RTU SLAVE SLAVE SLAVE
 INTELLIGENT DEVICE INTEGRATION
DIAGNOSTIC VIEW
Parameters Values
HMI IP Address 192.168.3.2
HMI
IO Server Protocol ModbusTCP or Modbus
OR
Ethernet (DASMBTCP)
ENGINEERING
STATION Bridge IP Address 192.168.3.10
Type ModbusPLC
ID 21

NETWORK
MODBUS MAPPING

Parameters Values
IP Address: 192.168.3.10
SERIAL TO ETHERNET
CONVERTER Protocol Modbus/RTU, Slave
Serial Interfce 9600, 8, N, 1, RS485
Modbus Port No 502

Parameters Values
Comm. RS485
Baud Rate 9600
DEVICE
MODSCAN / Parity None
MODSIM Stop Bit 1
Device ID 21 SCADA: WONDERWARE INTOUCH
 INTELLIGENT DEVICE INTEGRATION
MODBUS MAPPING

MODBUS VERIFICATION
USING MODSCAN32 / MODSCAN64 / MODSIM SOFTWARE
 PLC INTEGRATION

Parameters Values
HMI IP Address 192.168.3.12
HMI
Communication Driver RLinx
OR
ENGINEERING IO Server Protocol DASABCIP
STATION
Module Type: Ethernet 192.168.3.114
CONTROLLER
TOPIC
MODULE
NAMEVIEWER
DIAGNOSTIC CONFIG
CONFIG
Communication
Processor Type Control Logix

NETWORK

Parameters Values
IP Address: 192.168.3.114

ETHERNET I/P
ROCKWELL AUTOMATION BRIDGE MODULE
CONTROL LOGIX PLC
PROGRAMMABLE LOGIC CONTROLLER RSLINX
(PLC)
PROGRAMMING SOFTWARE
SCADA: WONDERWARE INTOUCH
 CONNECTIVITY OF SCADA
HMI
SCADA Tagname Configuration SCADA SOFTWARE
I/O SERVER OR DASERVER

DASMBTCP

RS485

BRIDGE DEVICE
IP: 192.168.3.82 ID: 21

SCADA: WONDERWARE INTOUCH

 CONNECTIVITY OF SCADA
SCADA Tagname Configuration HMI
SCADA SOFTWARE
I/O SERVER OR DASERVER

DASABCIP

RSLINX
PROGRAMMING
CONTROL LOGIX PLC SOFTWARE
SCADA Graphics Configuration
LIBRARIES

❑ SYMBOL LIBRARIES
❑ ISA STANDARD (2D OR 3D) SYMBOLS
❑ CUSTOMIZED SYMBOL, TEXT, BACKGROUNDS, AND ANIMATIONS
SCADA: WONDERWARE INTOUCH
SCADA Graphics Configuration

PROCESS FLOW DIAGRAM SCADA GRAPHICS

SCADA Graphics Configuration
SCADA Graphics Configuration
 SCADA Graphics Configuration
BREAKER STATUS
OPEN CLOSE FAULT

MOTOR STATUS
RUN STOP

HVHV
RELAY NORMAL
RELAY TRIP
TRANSFORMER
TRANSFORMERT101
T101
VALVE STATUS

OPEN FAULT CLOSE MOVING

FACEPLATE
POP WINDOW

SCADA: WONDERWARE INTOUCH

 SCADA VENDORS
❑ SIMATIC WinCC V7 (Siemens)
❑ Wonderware Intouch (AVEVA)
❑ Wonderware System Platform (AVEVA)
❑ Factory Talk View (Rockwell Automation)
❑ Experion (Honeywell)
❑ Simplicity (General Electric)
❑ Citect SCADA (Schneider)
❑ OPC DataHub – Web SCADA (Cogent Real-Time
Systems)
❑ FAST/TOOLS (Yokogawa)
THANK YOU AND GOD BLESS US ALL