What is SCADA ?

SCADA is normally a software package designed to display

information, log data and show alarms.

This can be graphical and tabular and can involve words and pictures
(or mimics).

The software would normally be installed on a computer and all the

various signals would be wired back to the central point (CPU), or
marshalled and gathered using some form of bus system or direct
wired.

SCADA can be used to monitor and control plant or equipment. The

control may be automatic, or initiated by operator commands. The
data acquisition is accomplished firstly by the RTU’s (remote Terminal
Units).

The central host will scan the RTU’s or the RTU’s will report in Data can
be of three main types.

Analogue data (i.e. real numbers) will be trended (ie placed in graphs).
Digital data (on/off) may have alarms attached to one state or the
other. Pulse data (e.g. counting revolutions of a meter) is normally
accumulated or counted

Supervisory control and data acquisition – SCADA refers to ICS

(industrial control systems) used to control infrastructure processes
(Utilities, water treatment, wastewater treatment, gas pipelines, wind
farms, etc), facility-based processes (airports, space stations, ships,
etc,) or industrial processes (production, manufacturing, refining,
power generation, etc).

The following subsystems are usually present in SCADA systems:

 The apparatus used by a human operator; all the processed data

are presented to the operator
 A supervisory system that gathers all the required data about the
process
 Remote Terminal Units (RTUs) connected to the sensors of the
process, which helps to convert the sensor signals to the digital
data and send the data to supervisory stream.
 Programmable Logic Controller (PLCs) used as field devices
 Communication infrastructure connects the Remote Terminal
Units to supervisory system.
Generally, a SCADA system does not control the processes in real time
– it usually refers to the system that coordinates the processes in real
time.

SCADA Systems Concepts

SCADA refers to the centralized systems that control and monitor the
entire sites, or they are the complex systems spread out over large
areas.
Nearly all the control actions are automatically performed by the
remote terminal units (RTUs) or by the programmable logic controllers
(PLCs).

The restrictions to the host control functions are supervisory level

intervention or basic overriding.

For example, the PLC (in an industrial process) controls the flow of
cooling water, the SCADA system allows any changes related to the
alarm conditions and set points for the flow (such as high
temperature, loss of flow, etc) to be recorded and displayed.
Data acquisition starts at the PLC or RTU level, which includes the
equipment status reports, and meter readings. Data is then formatted
in such way that the operator of the control room can make the
supervisory decisions to override or adjust normal PLC (RTU) controls,
by using the HMI.

SCADA systems mostly implement the distributed databases known as

tag databases, containing data elements called points or tags. A point
is a single output or input value controlled or monitored by the
system. Points are either ‘soft’ or ‘hard’.

The actual output or input of a system is represented by a hard point,

whereas the soft point is a result of different math and logic
operations applied to other points.

These points are usually stored as timestamp-value pairs. Series of the

timestamp-value pairs gives history of the particular point.

Storing additional metadata with the tags is common (these additional

data can include comments on the design time, alarm information,
path to the field device or the PLC register).

Human Machine Interface

The HMI, or Human Machine Interface, is an apparatus that gives the
processed data to the human operator. A human operator uses HMI to
control processes.

The HMI is linked to the SCADA system’s databases, to provide the

diagnostic data, management information and trending information
such as logistic information, detailed schematics for a certain machine
or sensor, maintenance procedures and troubleshooting guides.
The information provided by the HMI to the operating personnel is
graphical, in the form of mimic diagrams.

This means the schematic representation of the plant that is being

controlled is available to the operator.

For example, the picture of the pump that is connected to the pipe
shows that this pump is running and it also shows the amount of fluid
pumping through the pipe at the particular moment.

The pump can then be switched off by the operator. The software of
the HMI shows the decrease in the flow rate of fluid in the pipe in the
real time.

Mimic diagrams either consist of digital photographs of process

equipment with animated symbols, or schematic symbols and line
graphics that represent various process elements.

HMI package of the SCADA systems consist of a drawing program

used by the system maintenance personnel or operators to change the
representation of these points in the interface.

These representations can be as simple as on-screen traffic light that

represents the state of the actual traffic light in the area, or complex,
like the multi-projector display that represents the position of all the
trains on railway or elevators in skyscraper.

SCADA systems are commonly used in alarm systems. The alarm has
only two digital status points with values ALARM or NORMAL. When
the requirements of the Alarm are met, the activation will start.

For example, when the fuel tank of a car is empty, the alarm is
activated and the light signal is on. To alert the SCADA operators and
managers, text messages and emails are sent along with alarm
activation.

SCADA Hardware
SCADA system may have the components of the Distributed Control
System. Execution of easy logic processes without involving the master
computer is possible because ‘smart’ PLCs or RTUs.IEC61131-
39(Ladder Logic) is used, (this is a functional block programming
language, commonly used in creating programs running on PLCs and
RTUs.)

IEC 61131-3 has very few training requirements, unlike procedural

languages like FORTRAN and C programming language.

The SCADA system engineers can perform implementation and design

of programs being executed on PLC or RTU. The compact controller,
Programmable automation controller (PAC), combines the capabilities
and features of a PC-based control system with a typical PLC.

’Distributed RTUs’, in various electrical substation SCADA applications,

use station computers or information processors for communicating
with PACs, protective relays, and other I/O devices.

Almost all big PLC manufacturers offer integrated HMI/SCADA

systems, since 1998.

Many of them are using non-proprietary and open communication

protocols. Many skilled third party HMI/SCADA packages have
stepped into the market, offering in-built compatibility with several
major PLCs, which allows electrical engineers, mechanical engineers or
technicians to configure HMIs on their own, without requiring
software-developer-written custom-made program.

Remote Terminal Unit (RTU)

The RTU is connected to the physical equipment. Often, the RTU
converts all electrical signals coming from the equipment into digital
values like the status- open/closed – from a valve or switch, or the
measurements like flow, pressure, current or voltage.

By converting and sending the electrical signals to the equipment, RTU

may control the equipment, like closing or opening a valve or a switch,
or setting the speed of the pump.

Supervisory Station
A ‘supervisory Station’ refers to the software and servers responsible
for communication with the field equipment (PLCs, RTUs etc), and after
that, to HMI software running on the workstations in the control room,
or somewhere else.

A master station can be composed of only one PC (in small SCADA

systems). Master station can have multiple servers, disaster recovery
sites and distributed software applications in larger SCADA systems.

For increasing the system integrity, multiple servers are occasionally

configured in hot-standby or dual-redundant formation, providing
monitoring and continuous control during server failures.

SCADA Operational Philosophy

The costs resulting from control system failures are very high. Even
lives may be lost. For a few SCADA systems, hardware is ruggedized,
to withstand temperature, voltage and vibration extremes, and
reliability is increased, in many critical installations, by including
communications channels and redundant hardware.

A part which is failing can be identified and the functionality taken

over automatically through backup hardware. It can be replaced
without any interruption of the process.

Communication Methods and Infrastructure

SCADA systems initially used modem connections or combinations of
direct and radio serial to meet communication requirements, even
though IP and Ethernet over SONET/SDH can also be used at larger
sites like power stations and railways. The monitoring function or
remote management of the SCADA system is called telemetry.

SCADA protocols have been designed to be extremely compact and to

send information to the master station only when the RTU is polled by
the master station. Typically, the legacy of SCADA protocols consists of
Conitel, Profibus, Modbus RTU and RP-570.

These protocols of communication are specifically SCADA-vendor.

Standard protocols are IEC 61850, DNP3 and IEC 60870-5-101 or 104.
These protocols are recognized and standardized by all big SCADA
vendors. Several of these protocols have extensions for operating
through the TCP/IP.

The development of many automatic controller devices and RTUs had

started before the advent of industry standards for the
interoperability.
For better communication between different software and hardware,
PLE for Process Control is a widely accepted solution that allows
communication between the devices that originally weren’t intended
to be part of the industrial network.

SCADA Architectures
Monolithic: The First Generation
In the first generation, mainframe systems were used for computing.
At the time SCADA was developed, networks did not exist.

Therefore, the SCADA systems did not have any connectivity to other
systems, meaning they were independent systems. Later on, RTU
vendors designed the Wide Area Networks that helped in
communication with RTU.

The usage of communication protocols at that time was proprietary. If

the mainframe system failed, there was a back-up mainframe,
connected at the bus level.

Distributed: The Second Generation

The information between multiple stations was shared in real time
through LAN and the processing was distributed between various
multiple stations.

The cost and size of the stations were reduced in comparison to the
ones used in the first generation. The protocols used for the networks
were still proprietary, which caused many security issues for SCADA
systems.
Due to the proprietary nature of the protocols, very few people
actually knew how secure the SCADA installation was.

Networked: The Third Generation

The SCADA system used today belong to this generation. The
communication between the system and the master station is done
through the WAN protocols like the Internet Protocols (IP).

Since the standard protocols used and the networked SCADA systems
can be accessed through the internet, the vulnerability of the system is
increased.

However, the usage of security techniques and standard protocols

means that security improvements can be applied in SCADA systems.

SCADA Trends
In the late 1990s instead of using the RS-485, manufacturers used
open message structures like Modbus ASCII and Modbus RTU (both
developed by Modicon). By 2000, almost all I O makers offered fully
open interfacing like Modbus TCP instead of the IP and Ethernet.

SCADA systems are now in line with the standard networking

technologies. The old proprietary standards are being replaced by the
TCP/IP and Ethernet protocols. However, due to certain characteristics
of frame-based network communication technology, Ethernet
networks have been accepted by the majority of markets for HMI
SCADA.
The ‘Next Generation’ protocols using XML web services and other
modern web technologies, make themselves more IT supportable. A
few examples of these protocols include Wonderware’s SuiteLink, GE
Fanuc’s Proficy, I Gear’s Data Transport Utility, Rockwell Automation’s
FactoryTalk and OPC-UA.

Some vendors have started offering application-specific SCADA

systems that are hosted on remote platforms all over the Internet.
Hence, there is no need to install systems at the user-end facility.
Major concerns are related to the Internet connection reliability,
security and latency.

The SCADA systems are becoming omnipresent day by day. However,

there are still some security issues.

SCADA Security Issues

Security of SCADA-based systems is being questioned, as they are
potential targets to cyberterrorism/cyberwarfare attacks.

There is an erroneous belief that SCADA networks are safe enough

because they are secured physically. It is also wrongly believed that
SCADA networks are safe enough because they are disconnected from
the Internet.

SCADA systems also are used for monitoring and controlling physical
processes, like distribution of water, traffic lights, electricity
transmissions, gas transportation and oil pipelines and other systems
used in the modern society. Security is extremely important because
destruction of the systems would have very bad consequences.
There are two major threats. The first one is unauthorized access to
software, be it human access or intentionally induced changes, virus
infections or other problems that can affect the control host machine.
The second threat is related to the packet access to network segments
that host SCADA devices.

In numerous cases, there remains less or no security on actual packet

control protocol; therefore, any person sending packets to SCADA
device is in position to control it.

Often, SCADA users infer that VPN is sufficient protection, and remain
oblivious to the fact that physical access to network switches and jacks
related to SCADA provides the capacity to bypass the security on
control software and control SCADA networks.

SCADA vendors are addressing these risks by developing specialized

industrial VPN and firewall solutions for SCADA networks that are
based on TCP/IP. Also, white-listing solutions have been implemented
due to their ability to prevent unauthorized application changes.

APPLICATIONS OF SCADA:
1)Application In Power Plants:
A group of Hydro and Gas generation plants when the load demand
exceeds the generating capacity, These plants are considered as peak
load plants because these plants can start in no time and deliver
power to the grid.

These plants are located in the romote locations. These plants are
controlled by opening and closing the valves of turbines so that they
can deliver the power in peak conditions and can be kept on standby
during normal load conditions.

2)Application In Oil & Gas Plants:

Many process control parameters, motors, pumps, valves are spread
over the wide area in the field.

Control and monitoring applications include turning on and off

motors, pumps, valves and gathering information of process
parameters(like flow rate, pressure, temperature) continuously and
taking certain decisions can be done through SCADA systems.

3)Applications In Pipelines:
Pipelines carrying oil, gas, chemicals and water which are located at
varying distances from the plant needs continuous monitoring and
control.

Control includes opening and closing the valves, starting and stopping
the pumps. Monitoring the flowrate and other parameters to avoid
leakage in the pipelines by acquiring the data and carrying out
suitable controls is done through SCADA systems.

4)Applications In Power Transmission:

Electrical power transmission which is spread over thousands of
kilometers can be controlled by opening and closing the circuit
breakers and other functions, This is done in master control substation
which can control the other substations through SCADA systems.

5)Applications In Irrigation Systems:

Irrigation systems which are spread over wide area can be controlled
by closing and opening the valves, gathering the meter values of
amount of water supplied and taking the control actions can be done
through SCADA systems.