SCADA System Fundamentals

Course No: E01-007

Credit: 1 PDH

Tracy Adams, P.E.

Continuing Education and Development, Inc.

22 Stonewall Court
Woodcliff Lake, NJ 07677

P: (877) 322-5800
info@cedengineering.com
 SCADA System Fundamentals
INTRODUCTION

Just as different countries have their own languages so do different technologies. The first step
to understanding a new technology is learning the unique language of that technology. This
course is intended to provide you with an understanding of the terms and equipment associated
with Supervisory Control and Data Acquisition (SCADA) systems.

SCADA systems at their fundamental level are Industrial Control Systems. They are computer
based control systems that monitor and control industrial processes that exist in the physical
world. SCADA systems can be found in manufacturing facilities, oil production and processing,
pharmaceuticals, energy, water treatment and distribution, and the list goes on. They are the best
control method for processes that have large amounts of data that need gathering and analyzing,
or are spread over large distances, or require critical control in fast paced processes.

SCADA SYSTEM SIGNALS

The very basic components of a SCADA system are these signals:

• DI – Discrete Input

• DO – Discrete Output

Discrete signals (also called Digital signals) provide an ON or OFF input to a SCADA system.
This is the same binary signal format used in computer processors.

The next basic types of signals are:

• AI – Analog Input

• AO – Analog Output

Analog signals are continuous. A change in signal value reflects change in the parameters being
monitored. Examples of analog signals are temperature and pressure.

The signals generated by the instruments being monitored by a SCADA system are voltage or
current based. Analog signals can be formatted as: 4-20 mA, 0-20 mA, 1-5VDC, 0-5VDC,
-10VDC to 10VDC.

Values (whether discrete or analog), when used in a SCADA system, they need to be seen by
Operators to be of any use.

© Tracy A. Adams 2014

SCADA SYSTEM DATA GATHERING

The Operator’s access into a SCADA system is by:

• OIT – Operator Interface Terminal or an

• HMI – Human Machine Interface

OIT’s provide a local interface, typically in a remote location or into an isolated system like skid
mounted equipment. Screens to display information have a simple layout since displays are not
large; anywhere from 4 inches to 14 inches.

HMI software is used at the Central Control location. Software is installed on computers with
faster processors and larger monitors so the screens display more information. They also make
use of animation to emphasize critical data or focus operator attention to important areas of a
process or annunciate an alarm.

The work horse of the SCADA system that effectively grabs data from instruments, converts the
information to a format a computer program can understand, and handles high speed
communication is the:

• PLC – Programmable Logic Controller

The Programmable Logic Controller (PLC) was invented in 1968 to support the automobile
industry by Bedford Associates’ engineer Dick Morley. The first PLC was called a MOdular
DIgital CONtroller, aka MODICON.

Over time variations of the PLC have developed. The two primary ones are:

• RTU – Remote Telemetry Unit

• PAC - Programmable Automation Controller

The Remote Telemetry Unit (RTU) was developed to gather data and then transmit that data to a
remotely located processor. A RTU has communication capabilities of a PC and the IO
capability of a PLC, as well as being industrial hardened. However, it does not control processes
using an internal program. It functions as a Data logger that can transmit data at a certain time to
Central or when polled. A hybrid version of the RTU contains a PLC that does control local
processes and performs the communication functions of a RTU.

A PAC is the next generation of a PLC. It has the same form and function as a PLC but its
processor is more related to a computer in its speed and computing methods. Its greatest
advantage is the communication function which allows it to work more effectively with modern
communication networks that are Ethernet based.

© Tracy A. Adams 2014

SCADA SYSTEM TYPES

Data gathering and system control at the highest level is broken into two basic systems:

• SCADA – Supervisory Control and Data Acquisition

• DCS – Distributed Control System

Definition of SCADA is a Monitoring and/or Control System that utilizes a central computer for
storing information, and onsite/remote hardware to monitor facilities and processes. Control may
be automatic or manual and may occur at the remote units or the central computer.

Definition of DCS is a Monitoring and/or Control System that utilizes a central computer for
storing information and onsite/remote hardware to monitor facilities and processes. Control may
be automatic or manual and may occur at the remote units or the central computer.

While a SCADA system and a DCS system are essentially the same at all levels, there is a very
basic difference. A SCADA system is event driven and operator concentric. It is data gathering
orientated. Data is stored in database and control is usually remotely originated. Whereas, a
DCS is process state driven. It is directly connected with field devices and control is done
locally and automatically. The operator is just informed of what has happened.

A SCADA master station generally considers changes of state (both status points and analogue
changes leading to alarms) as the main criteria driving the data gathering and presentation
system. Any undetected changes of state simply cannot be missed. A change of state will cause
the system to generate all alarms, events, database updates and any special processing required
relating to that. Event lists and alarm lists are of major importance to the operator, sometimes
more so than data screens. S is for Supervisory - an Operator takes action.

Conversely, DCS systems are process control systems that are state based and consider the
process variable's present and past states to be the main criteria driving the DCS. PLC protocols
are generally register scanning based, with no specific change of state processing provided.
Should a point toggle between scans, it will not be seen by the DCS. If any change of states are
critical (as some would be for a DCS used for SCADA applications), a point must be latched on
until it is confirmed it has been scanned, which can be difficult and non-deterministic. DCS
software tasks are generally run sequentially, rather than event driven. If a process starts to
move from a set parameter, the DCS responds to maintain that parameter value. Notifying the
Operator is a secondary consideration. Events and alarm lists are secondary in importance to the
process displays, and filtering may not be as complex and flexible. On the up side, the
generation and display of data, especially analogue trends and standard process blocks, is far
more user friendly and easier for both operators and engineers.

© Tracy A. Adams 2014

SCADA systems historically have been broken down into two basic flavors:

Proprietary SCADA System:

• All or most components manufactured by one supplier

• Installation and service from same single source

• Lack of compatibility with other products

• Uses proprietary communications and programming

Mix & Match SCADA System

• Usually supplied by System Integrator

• Usually uses open communication protocols

• Uses off-the-shelf products

• PLC’s program using standard procedures

• Utilizes open HMI Software

Original SCADA systems were proprietary. The Manufacturer built all the hardware, software,
installed the equipment and did all the programming.

As computer technology improved, SCADA systems evolved to take advantage of the

advancement. Hardware components started coming off the shelf. SCADA software started to
be developed to use open protocol communication standards. This led to the rise of System
Integrators, companies that developed custom systems to meet the needs of the end users.

SCADA SYSTEM COMPONENTS

These are the four basic parts of a SCADA system.

• Field Instruments

• PLC/Remote Terminal Unit

• Communications Link – open standard (like MODBUS) and proprietary

• Central Computer Station including HMI Software – Proprietary for specific RTUs or
open including interfacing many products

© Tracy A. Adams 2014

We are going to look at each of these parts and identify the basic components for each:

A. FIELD INSTRUMENTS

Discrete signals are generated by:

a. Limit switches

b. Pushbuttons

c. Float switches

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 d. Flow switches

e. Relay contacts

f. Selector switches

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Discrete signals have three basic configurations that are used:

Form A - Normally Open

Form B - Normally Closed

Form C - Normally Open-Normally Closed combined

Analog signals generally come from instruments and motion controlling equipment. The most
common instrument is the analyzer. Analyzers are test equipment located in the field for
monitoring the quality of a process. Analyzer primary signal output is analog but there are
typically some discrete contacts for alarms. Below are some examples of analyzers:

© Tracy A. Adams 2014

This is a turbidity meter used to measure solids in water.

Below is a Chlorine Analyzer used to measure the level of chlorine in water leaving a treatment
plant to ensure it is safe for humans.

© Tracy A. Adams 2014

While not an instrument, a Variable Frequency Drive (VFD) is a field device that frequently
interfaces with SCADA systems to control process outputs. VFD’s are used to power motors
driving pumps and fans. VFD’s generate analog and discrete signals.

Typical signals from a VFD are:

• Speed Indication (Analog)

• Speed Control (Analog)

• Running (Discrete)

• Fault (Discrete)

• Start Command (Discrete)

© Tracy A. Adams 2014

B. PLC/RTU

PLC’s come in a wide variety of sizes and shapes. They are used from controlling nuclear power
plants to controlling a sump pump in a parking garage.

High end PLC’s can handle multiple racks of IO modules, various communication modules, and
may be installed in a redundant configuration so the loss of a power supply or processor will not
stop control of a facility.

The latest step in the evolution of PLC’s is the Programmable Automation Controller (PAC).

A PAC has a computer processor so it works better with Ethernet networks (routers/switches)
which are becoming prevalent in SCADA systems. Programming can also be done in more main
stream programs (C++, etc)

© Tracy A. Adams 2014

Smaller PLC’s are configured for just a few points. Sometimes they may only have discrete
signals, and function as intelligent relays. They are not typically expandable to add more IO
points.

Programming is usually simple. Sometimes the programming can even be done with the keys on
the front of the PLC. Relay Ladder Logic was the first programming language for PLC’s. It
mimicked the wiring diagrams electricians were used to seeing in control panels in software. In
fact, electricians were the first PLC programmers.

As hardware and software changed, the companies making the products started diverging. It
became apparent that standards had to be developed so the software and hardware could work
together. There also started to be programmers who were familiar with multiple high level
programming languages and never saw the inside of a control panel. In Europe IEC developed
standard 61131 which specified five styles of programming to be used in PLC’s:

• Relay Ladder Logic

• Function Block Diagram

• Structure Text

• Instruction List

• Sequential Function Chart

© Tracy A. Adams 2014

In addition to these standards, PLC’s can have specialty modules installed that use C++ or Basic
for special program requirements.

PLC’s cannot be mounted to a wall and left unprotected. They are mounted in enclosures that
protect them from hostile environments. A typical PLC panel is shown below with high end
PLC’s configured with redundant processors and power supplies.

© Tracy A. Adams 2014

Shown below is an RTU configured with a PAC that can provide local control in case
communications are lost. This panel communicates via leased line using the modem in the lower
left corner of the panel.

This is an example of a control panel that shows the customized approach taken to building
control panels. This is designed for a site with a large number of physical IO. A radio will be

© Tracy A. Adams 2014

installed in the upper right hand corner for communication. Note the batteries in the lower right
corner for backup power. A Remote IO panel (an RTU) interfaces with field devices but has no
processors for local control. It is equipped with a communication module instead.

This style reflects the original design on RTU’s. It has a processor to handle communications
via the radio mounted on the door. It receives signals from field devices which it passes through
to Central for display by the SCADA HMI. It then passes any commands from Central to the
field devices.

Autodialers (shown below) are a very basic form of RTU. This device receives site alarms as
Digital Input signals. It then calls a Duty Operator over a standard telephone line (POTS) or a
cell phone. The Operator can acknowledge the alarm using the telephone keyboard. Higher end
Autodialers also allow the Operator to do basic controls via the keyboard such as starting a
backup pump or operate valves.

© Tracy A. Adams 2014

C. Communication

Radios are the most common communication method in large SCADA systems. Licensed radios
were originally used. Then in 1987 the FCC marked a radio frequency band segment for
Industrial Scientific Medical (ISM) use. This was an unlicensed segment that was opened for
use and did not require a license. The ISM is in the low 900MHz range.

The ISM band is limited to a maximum of 1 Watt transmitting power. This was the method
selected to reduce interference by limiting the range of the transmissions. Licensed radios are
still used in SCADA systems for operators who have a long distance that needs to be covered
between sites.

Characteristics of most frequently used frequencies are:

1) Licensed VHF – 132-174 Mhz, 400Mhz

• Up to 5 Watts Power

• Very Good Signal Transmission

2) Licensed UHF – 380-512 Mhz

• Good Signal Transmission

3) Unlicensed Spread Spectrum – 900 Mhz

• 1 Watt max. Power

• Line-of-Sight, weather dependent

• Ethernet protocol versions are available in all frequencies.

A recent trend in SCADA system has been the incorporation of video cameras and still cameras
to provide Operators real time images of what is happening at remote sites. The need for
increased security was the driving force behind this trend.

Images contain a lot of data. In order to transmit images over a radio link and make them
practical, frequencies in the 2.4 GHz and 5.8 GHz are used.

© Tracy A. Adams 2014

Above is the basic radio form that was originally selected for industrial use and is still a very
popular and functional form used today.

As electronics improved, radios became smaller while still keeping the same performance
capabilities. This style of radio is designed to be mounted on DIN rail.

© Tracy A. Adams 2014

One of the areas that a radio link loses transmission power is the cable connecting the radio with
the antenna. The above radio is a weatherized unit that can be mounted on the mast just below
the antenna. This eliminates signal power lost during transmission through the antenna cable.
Typically an Ethernet connection is provided to interface with PLC’s or computers.

The two basic workhorse antennas of SCADA systems are YAGI and Omni.

YAGI OMNI

© Tracy A. Adams 2014

The yagi is for directional transmission and the omni provides 360 degrees of transmission.

An omni antenna will be used at a SCADA Central site to broadcast to RTU’s at many different
locations. The yagi antenna transmits radio signals in the direction the antenna is pointing.

As higher radio frequencies (2.4 GHz and 5.8 GHz) have come into use for transmitting more
data (e.g. video signals), panel and parabolic antennas are now common in SCADA Systems.

Another application using radios is wireless IO. This is a paired set of radios that have terminals
for connecting physical IO signals (discrete or analog). One radio is for connecting field
devices: a pressure transmitter or a high level float. The second radio receives the signals with
the field devices values and retransmits the signals over wires connected to a PLC.

The two radios are paired to work together. They cannot communicate to any other radios. This
system eliminates all the conduits and wires that would have been installed to connect the field
devices to the PLC. No special communication configuration had to be designed to allow the
radio to talk to the PLC. This is a way to save money when needing to pick up a single point and
tie it into a SCADA system.

© Tracy A. Adams 2014

Within SCADA systems multiple protocols are available for communication. Protocols are the
methodology used to encapsulate data for transmission between SCADA components. Designers
just need to select the method best suited for the system.

Originally serial communications were conducted over special cables with various protocols
(Fieldbus, ControlNET, Modbus RTU, etc). These were the standards for many years and they
are still used frequently.

The late comer Ethernet has recently made big move into the field. As the electronics became
industrialized, the ability to use the same communication in a SCADA system (that the IT
Department was familiar with) became a money saver.

It also streamlined the interface between PLC and SCADA computers. It has simplified SCADA
communications by allowing the gathering of data from “smart” devices such as VFD’s, power
monitors, analyzers, etc. with just a single cable.

In addition to the traditional radio and serial cable communications, SCADA systems also use:

• Cellular – PCS, CDPD

• Telephone Lines – Dedicated leased and Dial-up

• Wireless Internet

• DSL Broadband

• Fiber Optic – supports Ethernet protocol

• Satellite – Geosynchronous LEO

© Tracy A. Adams 2014

Designers just need to find the right method to solve the communication problem. For example,
satellites are used for accessing remote sites in mountainous terrain where it is impossible to get
a radio signal out or run a cable.

D. Central Computers

One of the first steps in designing a SCADA system is to determine which Communication
Protocol will be used. The most common protocols used are:

• MODBUS RTU or MODBUS ASCII (original protocol used)

• DEVICENET

• CONTROLNET

• Profibus

• Foundation Fieldbus

• DH+, DF1

• DNP3

• Ethernet (MODBUS TCP, ETHERNET IP)

Protocols are the languages that the equipment uses to communicate. Just as people speak
English, French, German, etc., so have different protocols been developed by different
manufacturers. These different protocols are intended to maximize the hardware benefits of their
equipment. Some of these protocols are open for anyone to use and some are proprietary.

The second step is determining the hardware:

• Computer Hardware inc. UPS – Off-the-shelf

• Central RTU – Sometimes for polling

• Communication Interface – Radio/Antenna, Telephone Modem, DSL Modem

• HMI – Human Machine Interface

• Common HMIs – Intellution, Wonderware, Citec, Trihedral Engineering VT-Scada

• Internet Based – Mission

• Web based - Inductive Automation

© Tracy A. Adams 2014

At the high level end of a SCADA system, you see the equipment and software that the
Operators use to interface with the system. At this level communication is the key process.
There is the hardware and software to interface with all the field components.

Also, there is hardware and software to interface with the operators. This side of the process is
very graphic oriented.

• SCADA Fundamentals

• Alarm Annunciation

• Remote Control

• Trending – Real Time/Historical

• Data Logging / History

• Alarming

• Reporting

• Security

• High Level Optimization Strategies

• Auto-Dialer / Pager

• Remote Monitoring

The SCADA HMI software is written to provide these services to the Operators for their day to
day operations:

• SCADA Fundamentals

• Analog Summary

• Radio Error Analysis

• Log Report – All Data

• Detail Report

• Pump Activity – Total & Ave Run Times, Starts

• Pump Discrepancy – Excessive changes

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 • Flow

• Water Quality

Another very important feature of SCADA HMI software is documentation for historical
purposes. The data collected is achieved and then distributed in various formats. This
information helps with maintenance as well as reporting to supervisory organizations.

A typical graphics screen allows the operator in a quick glance to see the status of all the critical
equipment and processes in an area.

© Tracy A. Adams 2014

Trending is data spread over a period of time and presented in a graph. This is a useful tool for
improving processes.

CONCLUSION

SCADA systems are a vital tool for keeping our society going. As electronics and
communications have improved, so have the capabilities of SCADA systems. SCADA systems
make controlling large and small processes easier for Operators whether they are in
telecommunications, water treatment, manufacturing, energy production, oil production,
transportation, etc.

© Tracy A. Adams 2014