SCADA:
SCADA is the abbreviation for Supervisory Control And Data Acquisition. It generally refers to an industrial control system which is meant to function across a wide area with an autonomous Remote Terminal Unit (RTU). The precise definition of SCADA has been muddied somewhat by newer telecommunications technology, enabling reliable, low latency, high speed communications over wide areas, and a tendency by popular media to mistakenly refer to all Industrial Control Systems as SCADA. Despite this confusion, a SCADA system is expected to have open loop controls (meaning that a human operator watches near real time data and issues commands). By comparison, a Distributed control system (DCS) is expected to have closed loop controls (meaning that real-time loop data is applied directly to an industrial controller without human intervention). These differences are primarily design philosophies, not mandates of definition.
The supervisory control system is a system that sends commands to a real-time control system to control a process that is external to the SCADA system (i.e. a computer, by itself, is not a SCADA system even though it controls its own power consumption and cooling). This implies that the system coordinates, but does not control processes in real time, as there is a separate or integrated real-time automated control system that can respond quickly enough to compensate for process changes within the time constants of the process. The process can be industrial, infrastructure or facility based as described below:
a. Industrial processes include those of manufacturing, production, power generation, fabrication, and refining, and may run in continuous, batch, repetitive, or discrete modes.
b. Infrastructure processes may be public or private, and include water treatment and distribution, wastewater collection and treatment, oil and gas pipelines, electrical power transmission and distribution, and large communication systems.
c. Facility processes occur both in public facilities and private ones, including buildings, airports, ships, and space stations. They monitor and control HVAC, access, and energy consumption.
Systems concepts:
SCADA systems, a branch of instrumentation engineering, include input-output signal hardware, controllers, human-machine interfacing ("HMI"), networks, communications, databases, and software.
The term SCADA usually refers to centralized systems which monitor and control entire sites, or complexes of systems spread out over large areas (on the scale of kilometers or miles). Most site control is performed automatically by remote terminal units ("RTUs") or by programmable logic controllers ("PLCs"). Host control functions are usually restricted to basic site overriding or supervisory level intervention. For example, a PLC may control the flow of cooling water through part of an industrial process, but the SCADA system may allow operators to change the set points for the flow, and enable alarm conditions, such as loss of flow and high temperature, to be displayed and recorded. The feedback control loop passes through the RTU or PLC, while the SCADA system monitors the overall performance of the loop.
Data acquisition begins at the RTU or PLC level and includes meter readings and equipment status reports that are communicated to SCADA as required. Data is then compiled and formatted in such a way that a control room operator using the HMI can make supervisory decisions to adjust or override normal RTU (PLC) controls. Data may also be fed to a Historian, often built on a commodity Database Management System, to allow trending and other analytical auditing.
SCADA systems typically implement a distributed database, commonly referred to as a tag database, which contains data elements called tags or points. A point represents a single input or output value monitored or controlled by the system. Points can be either "hard" or "soft". A hard point represents an actual input or output within the system, while a soft point results from logic and math operations applied to other points. (Most implementations conceptually remove the distinction by making every property a "soft" point expression, which may, in the simplest case, equal a single hard point.) Points are normally stored as value-timestamp pairs: a value, and the timestamp when it was recorded or calculated. A series of value-timestamp pairs gives the history of that point. It's also common to store additional metadata with tags, such as the path to a field device or PLC register, design time comments, and alarm information.
Human Machine Interface:
A Human-Machine Interface or HMI is the apparatus which presents process data to a human operator, and through which the human operator controls the process.
The HMI industry was essentially born out of a need for a standardized way to monitor and to control multiple remote controllers, PLCs and other control devices. While a PLC does provide automated, pre-programmed control over a process, they are usually distributed across a plant, making it difficult to gather data from them manually. Historically PLCs had no standardized way to present information to an operator. The SCADA system gathers information from the PLCs and other controllers via some form of network, and combines and formats the information. An HMI may also be linked to a database, to provide trending, diagnostic data, and management information such as scheduled maintenance procedures, logistic information, detailed schematics for a particular sensor or machine, and expert-system troubleshooting guides. Since about 1998, virtually all major PLC manufacturers have offered integrated HMI/SCADA systems, many of them using open and non-proprietary communications protocols. Numerous specialized third-party HMI/SCADA packages, offering built-in compatibility with most major PLCs, have also entered the market, allowing mechanical engineers, electrical engineers and technicians to configure HMIs themselves, without the need for a custom-made program written by a software developer.
SCADA is popular, due to its compatibility and reliability. It is used in small applications, like controlling the temperature of a room, to large applications, such as the control of nuclear power plants.
Hardware solutions:
SCADA solutions often have Distributed Control System (DCS) components. Use of "smart" RTUs or PLCs, which are capable of autonomously executing simple logic processes without involving the master computer, is increasing. A functional block programming language, IEC 61131-3, is frequently used to create programs which run on these RTUs and PLCs. Unlike a procedural language such as the C programming language or FORTRAN, IEC 61131-3 has minimal training requirements by virtue of resembling historic physical control arrays. This allows SCADA system engineers to perform both the design and implementation of a program to be executed on an RTU or PLC.
System components
The three components of a SCADA system are:
1. Multiple Remote Terminal Units (also known as RTUs or Outstations).
2. Master Station and HMI Computer(s).
3. Communication infrastructure
Remote Terminal Unit (RTU)
The RTU connects to physical equipment, and reads status data such as the open/closed status from a switch or a valve, reads measurements such as pressure, flow, voltage or current. By sending signals to equipment the RTU can control equipment, such as opening or closing a switch or a valve, or setting the speed of a pump.
The RTU can read digital status data or analog measurement data, and send out digital commands or analog setpoints.
An important part of most SCADA implementations are alarms. An alarm is a digital status point that has either the value NORMAL or ALARM. Alarms can be created in such a way that when their requirements are met, they are activated. An example of an alarm is the "fuel tank empty" light in a car. The SCADA operator's attention is drawn to the part of the system requiring attention by the alarm. Emails and text messages are often sent along with an alarm activation alerting managers along with the SCADA operator.
Quality SCADA RTUs have these characteristics:
a. Data Networking capability
b. Data Reliability
c. Data Security.
Master Station:
The term "Master Station" refers to the servers and software responsible for communicating with the field equipment (RTUs, PLCs, etc), and then to the HMI software running on workstations in the control room, or elsewhere. In smaller SCADA systems, the master station may be composed of a single PC. In larger SCADA systems, the master station may include multiple servers, distributed software applications, and disaster recovery sites. To increase the integrity of the system the multiple servers will often be configured in a dual-redundant or hot-standby formation providing continuous control and monitoring in the event of a server failure.
The SCADA system usually presents the information to the operating personnel graphically, in the form of a mimic diagram. This means that the operator can see a schematic representation of the plant being controlled. For example, a picture of a pump connected to a pipe can show the operator that the pump is running and how much fluid it is pumping through the pipe at the moment. The operator can then switch the pump off. The HMI software will show the flow rate of the fluid in the pipe decrease in real time. Mimic diagrams may consist of line graphics and schematic symbols to represent process elements, or may consist of digital photographs of the process equipment overlain with animated symbols.
The HMI package for the SCADA system typically includes a drawing program that the operators or system maintenance personnel use to change the way these points are represented in the interface. These represent