“ DCS VS SCADA”

Made By: Azeem Sajid

Electrical Engineer |HSE | Instrument & Controls

linkedin.com/in/azeemsajid53

 azeemsajid53@gmail.com
 Content
1. DCS INTRODUCTION

2. DCS SYSTEM ARCHITECTURE

3. HOW DOES A DCS WORK?

4. DCS APPLICATIONS

5. SCADA INTRODUCTION

6. WHERE IS SCADA USED?

7. SCADA HARDWARE ARCHITECTURE

8. SCADA SOFTWARE ARCHITECTURE

9. HOW SCADA SYSTEMS WORK?

10. DCS VS. SCADA IN MODERN ENVIRONMENTS

DCS (DISTRIBUTED CONTROL SYSTEM)
INTRODUCTION
❖ Digital Control Systems(DCS) also known as Distributed Control System is the brain of the
control system.
❖ It is generally, since the 1970s, digital, and normally consists of field instruments, connected via
wiring to computer buses or electrical buses to multiplexer/de multiplexers and A/D's or analog
to digital and finally the Human-Machine Interface (HMI) or control consoles. A DCS is a
process control system that uses a network to interconnect sensors, controllers, operator
terminals and actuators. A DCS typically contains one or more computers for control and
mostly use both proprietary interconnections and protocols for communications.
❖ Control Systems are collectively named as "ICSS" Integrated Control and Safety System.
Distinctly identified as "BPCS" Basic Process Control System. "SIS" Safety Instrumentation
System. "F&G" Fire and Gas System.
❖ DCS is employed in BPCS as well as used and prevalent control system
DCS (CONT..)

❖ The DCS is a control system which collects the data from the field and decides what to do with them. Data from the
field can either be stored for future reference, used for simple process control, use in conjunction with data from
another part of the plant for advanced control strategies.
❖ A distributed control system (DCS) is part of a manufacturing system.
❖ Distributed control systems (DCS) are used in industrial and civil engineering applications to monitor and control
distributed equipment with remote human intervention.
WHAT MUST BE IN THE DCS FOR IT TO
BE ABLE TO DO SO MUCH?
❖ Operator Console:
These are like the monitors of our computers. They provide us with the feedback of what they are
doing in the plant as well as the command we issue to the control system. These are also the places
where operators issue commands to the field instruments.
❖ Engineering Station:
These are stations for engineers to configure the system and also to implement control algorithms.
❖ History Module:
This is like the hard disk of our PCs. They store the configurations of the DCS as well as the
configurations of all the points in the plant. They also store the graphic files that are shown in the
console and in most systems these days they are able to store some plant operating data.
CONT..
❖ Data Historian
These are usually extra pieces of software that are dedicated to store process variables, set points and output
values. They are usually of higher scanning rates than that available in the history module.
❖ Control Modules
These are like the brains of the DCS. Specially customized blocks are found here. These are customized to do
control functions like PID control, ratio control, simple arithmetic and dynamic compensation. These days,
advanced control features can also be found in them.
❖ I/O
These manage the input and output of the DCS. Input and output can be digital or analogues. Digital I/Os are
those like on/off, start/stop signals. Most of the process measurements and controller outputs are considered
analogue. These are the points where the field instruments are hard-wired to.
✓ All above mentioned elements are connected by using a network, nowadays very often used is Ethernet.
HOW DOES A DCS WORK?
In the field you have sensors and gauges that give and receive information. They
convert this information into a electric signal that is sent to a control room somewhere
in the field. This control room has programmed logic that is able to converts the signal
into a pressure, flow rate, concentration, temperature, or level. This logic also contains
the information that controls the process and takes the signal compares it with the set
point sent from the operator may or may not be in the field and sends a signal to the
manipulated variables in the field. The DCS covers all of the computer logic from the
operator screen to the field box that contain the logic.
SHUTDOWN SYSTEMS
Shutdown system are the emergency setting of the logic to make sure the process can
be contained and is environmentally safe. These setting are important for emergency
response of the system. It is the job of the DCS to contain the logic for the shutdown
system and be able to operate when a process exceed a certain limit.
 DCS is a very broad term that describes
solutions across a large variety of industries,
including:
 Electrical power grids and electrical generation
plants
 Environmental control systems
 Traffic signals
 Water management systems
 Refining and chemical plants
 Pharmaceutical manufacturing.

DCS APPLICATIONS
DISTRIBUTED CONTROL SYSTEM
SCADA (SUPERVISORY CONTROL AND DATA
ACQUISITION)
INTRODUCTION
❖ As the name indicates, it is not a full control system, but rather focuses on the supervisory level. As such, it is a purely
software package that is positioned on top of hardware to which it is interfaced, in general via Programmable Logic
Controllers (PLC's), or other commercial hardware modules.
❖ In reality, the primary purpose of SCADA is to monitor, control and alarm plant or regional operating systems from a
central location. While override control is possible, it is infrequently utilized; however control set points are quite
regularly changed by SCADA.
❖ SCADA systems have made substantial progress over the recent years in terms of functionality, scalability, performance
and openness such that they are an alternative to in house development even for very demanding and complex control
systems.
CONT…
A SCADA application has two elements:
❖ The process/system/machinery you want to monitor a control - this can be a power plant, a water system, a
network, a system of traffic lights, or anything else.
❖ A network of intelligent devices that interfaces with the first system through sensors and control outputs. This
network, which is the SCADA system, gives you the ability to measure and control specific elements of the
first system.
❖ You can build a SCADA system using several different kinds of technologies and protocols. This white paper
will help you evaluate your options and decide what kind of SCADA system is best for your needs.
WHERE IS SCADA USED?
❖ You can use SCADA to manage any kind of equipment. Typically, SCADA systems are used to automate
complex industrial processes where human control is impractical - systems where there are more control
factors, and more fast-moving control factors, than human beings can comfortably manage.
❖ Around the world, SCADA systems control:
• Electric power generation, transmission and distribution:
Electric utilities use SCADA systems to detect current flow and line voltage, to monitor the operation
of circuit breakers, and to take sections of the power grid online or offline.
• Water and sewage:
State and municipal water utilities use SCADA to monitor and regulate water flow, reservoir levels,
pipe pressure and other factors.
• Buildings, facilities and environments:
Facility managers use SCADA to control HVAC, refrigeration units, lighting and entry systems.
CONT…
• Manufacturing:
SCADA systems manage parts inventories for just-in-time manufacturing, regulate industrial automation and
robots, and monitor process and quality control.
• Mass transit:
Transit authorities use SCADA to regulate electricity to subways, trams and trolley buses; to automate traffic
signals for rail systems; to track and locate trains and buses; and to control railroad crossing gates.
• Traffic signals:
SCADA regulates traffic lights, controls traffic flow and detects out-of-order signals.
• As I'm sure you can imagine, this very short list barely hints at all the potential applications for SCADA systems.
SCADA is used in nearly every industry and public infrastructure project - anywhere where automation increases
efficiency.
• What's more, these examples don't show how deep and complex SCADA data can be. In every industry, managers
need to control multiple factors and the interactions between those factors. SCADA systems provide the sensing
capabilities and the computational power to track everything that's relevant to your operations.
CONT..
SCADA systems are used not only in industrial processes: e.g. steel making, power generation (conventional and
nuclear) and distribution, chemistry, but also in some experimental facilities such as nuclear fusion. The size of
such plants range from a few 1000 to several 10 thousands input/output (I/O) channels. However, SCADA
systems evolve rapidly and are now penetrating the market of plants with a number of I/O channels of several
100 thousands I/O’s.
❖ SCADA systems used to run on DOS, VMS and UNIX; in recent years all SCADA vendors have moved to
NT, Windows XP, Windows Server 2003 and some also to Linux.
HARDWARE ARCHITECTURE
 CONT…
Hardware Architecture
One distinguishes two basic layers in a SCADA system: the "client layer" which caters for the
man machine interaction and the "data server layer" which handles most of the process data
control activities. The data servers communicate with devices in the field through process
controllers. Process controllers, e.g. PLC's, are connected to the data servers either directly or
via networks or field buses that are proprietary (e.g. Siemens H1), or nonproprietary (e.g.
Profibus). Data servers are connected to each other and to client stations via an Ethernet LAN.
SOFTWARE ARCHITECTURE
CONT…
❖ The products are multi-tasking and are based upon a real-time database (RTDB) located in one or more
servers. Servers are responsible for data acquisition and handling (e.g. polling controllers, alarm checking,
calculations, logging and archiving) on a set of parameters, typically those they are connected to.
❖ However, it is possible to have dedicated servers for particular tasks, e.g. historian, data logger, alarm
handler. The figure above shows a generic SCADA software architecture.
HOW SCADA SYSTEMS WORK?
A SCADA system performs four functions:
❖ Data acquisition
❖ Networked data communication
❖ Data presentation
❖ Control
These functions are performed by four kinds of SCADA components:
✓ Sensors (either digital or analog) and control relays that directly interface with the managed system.
✓ Remote telemetry units (RTUs). These are small computerized units deployed in the field at specific sites
and locations. RTUs (Remote Telemetry Units) serve as local collection points for gathering reports from
sensors and delivering commands to control relays.
CONT…
❖ SCADA master units. These are larger computer consoles that serve as the central processor for the SCADA
system. Master units provide a human interface to the system and automatically regulate the managed system
in response to sensor inputs.
❖ The communications network that connects the SCADA master unit to the RTUs in the field.
THE WORLD'S SIMPLEST SCADA SYSTEM
CONT…
The simplest possible SCADA system would be a single circuit that notifies you of one event.
Imagine a fabrication machine that produces widgets. Every time the machine finishes a widget, it
activates a switch. The switch turns on a light on a panel, which tells a human operator that a widget
has been completed.
❖ Obviously, a real SCADA system does more than this simple model. But the principle is the same.
A full scale SCADA system just monitors more stuff over greater distances.
DATA ACQUISITION
❖ First, the systems you need to monitor are much more complex than
just one machine with one output. So a real-life SCADA system
needs to monitor hundreds or thousands of sensors. Some sensors
measure inputs into the system (for example, water flowing into a
reservoir), and some sensors measure outputs (like valve pressure
as water is released from the reservoir). Some of those sensors
measure simple events that can be detected by a straightforward
on/off switch, called a discrete input (or digital input). For example,
in our simple model of the widget fabricator, the switch that turns
on the light would be a discrete input. In real life, discrete inputs
are used to measure simple states, like whether equipment is on or
off, or tripwire alarms, like a power failure at a critical facility.
❖ Some sensors measure more complex situations where exact
measurement is important. These are analog sensors, which can
detect continuous changes in a voltage or current input. Analog
sensors are used to track fluid levels in tanks, voltage levels in
batteries, temperature and other factors that can be measured in a
continuous range of input.
CONT…
For most analog factors, there is a normal range defined
by a bottom and top level. For example, you may want the
temperature in a server room to stay between 60 and 85
degrees Fahrenheit. If the temperature goes above or
below this range, it will trigger a threshold alarm. In more
advanced systems, there are four threshold alarms for
analog sensors, defining Major Under, Minor Under,
Minor Over and Major Over alarms.
DATA COMMUNICATION
❖ In our simple model of the widget fabricator, the "network" is just the wire leading from the switch to the
panel light. In real life, you want to be able to monitor multiple systems from a central location, so you need
a communications network to transport all the data collected from your sensors.
❖ Early SCADA networks communicated over radio, modem or dedicated serial lines. Today the trend is to put
SCADA data on Ethernet and IP over SONET. For security reasons, SCADA data should be kept on closed
LAN/WANs without exposing sensitive data to the open Internet.
❖ Real SCADA systems don't communicate with just simple electrical signals, either. SCADA data is encoded
in protocol format. Older SCADA systems depended on closed proprietary protocols, but today the trend is to
open, standard protocols and protocol mediation.
CONT…
Sensors and control relays are very simple electric devices that can't generate or interpret protocol
communication on their own. Therefore the remote telemetry unit (RTU) is needed to provide an interface
between the sensors and the SCADA network. The RTU (Remote Telemetry Unit) encodes sensor inputs into
protocol format and forwards them to the SCADA master; in turn, the RTU (Remote Telemetry Unit) receives
control commands in protocol format from the master and transmits electrical signals to the appropriate control
relays.
DATA PRESENTATION
❖ The only display element in our model SCADA system is the light that comes on when the switch is
activated. This obviously won't do on a large scale - you can't track a light board of a thousand separate
lights, and you don't want to pay someone simply to watch a light board, either.
❖ A real SCADA system reports to human operators over a specialized computer that is variously called a
master station, an HMI (Human-Machine Interface) or an HCI (Human-Computer Interface).
❖ The SCADA master station has several different functions. The master continuously monitors all sensors and
alerts the operator when there is an "alarm" - that is, when a control factor is operating outside what is
defined as its normal operation. The master presents a comprehensive view of the entire managed system and
presents more detail in response to user requests. The master also performs data processing on information
gathered from sensors - it maintains report logs and summarizes historical trends.
❖ An advanced SCADA master can add a great deal of intelligence and automation to your systems
management, making your job much easier.
 Unfortunately, our miniature SCADA system monitoring the widget
fabricator doesn't include any control elements. So let's add one. Let's
say the human operator also has a button on his control panel. When
he presses the button, it activates a switch on the widget fabricator
that brings more widget parts into the fabricator.
 Now let's add the full computerized control of a SCADA master unit
that controls the entire factory. You now have a control system that
responds to inputs elsewhere in the system. If the machines that make
widget parts break down, you can slow down or stop the widget
fabricator. If the part fabricators are running efficiently, you can speed
up the widget fabricator.
 If you have a sufficiently sophisticated master unit, these controls can
run completely automatically, without the need for human
intervention. Of course, you can still manually override the automatic
controls from the master station.
 In real life, SCADA systems automatically regulate all kinds of
industrial processes. For example, if too much pressure is building up
in a gas pipeline, the SCADA system can automatically open a release
valve. Electricity production can be adjusted to meet demands on the
power grid. Even these real-world examples are simplified; a full-
scale SCADA system can adjust the managed system in response to
multiple inputs.

CONTROL
A BRIEF NOTE ON SENSORS
AND NETWORKS
❖ Sensors and control relays are essentially commodity
items. Yes, some sensors are better than others, but a
glance at a spec sheet will tell you everything you
need to know to choose between them.
❖ An IP LAN/WAN is the easiest kind of network to
work with, and if you don't yet have LAN capability
throughout all your facilities, transitioning to LAN is
probably one of your long-term goals. But you don't
have to move to LAN immediately or all at once to
get the benefits of SCADA. The right SCADA
system will support both your legacy network and
LAN, enabling you to make a graceful, gradual
transition.
WHAT TO LOOK FOR IN A SCADA RTU (REMOTE TELEMETRY UNIT)?

❖ Your SCADA RTUs need to communicate with all your on-site equipment and survive under the harsh
conditions of an industrial environment.
Here's a checklist of things you should expect from a quality RTU:
❖ Sufficient capacity to support the equipment at your site … but not more capacity than you actually will use.
At every site, you want an RTU (Remote Telemetry Unit) that can support your expected growth over a
reasonable period of time, but it's simply wasteful to spend your budget on excess capacity that you won't use.
❖ Rugged construction and ability to withstand extremes of temperature and humidity. You know how
punishing on equipment your sites can be. Keep in mind that your SCADA system needs to be the most
reliable element in your facility.
❖ Secure, redundant power supply. You need your SCADA system up and working 24/7, no excuses. Your
RTU (Remote Telemetry Unit) should support battery power and, ideally, two power inputs.
CONT…

❖ Redundant communication ports. Network connectivity is as important to SCADA operations as a power

supply. A secondary serial port or internal modem will keep your RTU (Remote Telemetry Unit) online even
if the LAN fails. Plus, RTUs with multiple communication ports easily support a LAN migration strategy.
❖ Nonvolatile memory (NVRAM) for storing software and/or firmware. NVRAM retains data even when
power is lost. New firmware can be easily downloaded to NVRAM storage, often over LAN - so you can
keep your RTUs' capabilities up to date without excessive site visits.
❖ Intelligent control. As I noted above, sophisticated SCADA remotes can control local systems by
themselves according to programmed responses to sensor inputs. This isn't necessary for every application,
but it does come in handy for some users.
❖ Real-time clock for accurate date/time stamping of reports.
❖ Watchdog timer to ensure that the RTU (Remote Telemetry Unit) restarts after a power failure.
WHAT TO LOOK FOR IN A SCADA MASTER?

❖ Your SCADA master should display information in the most useful ways to human operators and intelligently
regulated your managed systems. Here's a checklist of SCADA master must-haves:
❖ Flexible, programmable response to sensor inputs. Look for a system that provides easy tools for
programming soft alarms (reports of complex events that track combinations of sensor inputs and date/time
statements) and soft controls (programmed control responses to sensor inputs).
❖ 24/7, automatic pager and email notification. There's no need to pay personnel to watch a board 24 hours a
day. If equipment needs human attention, the SCADA master can automatically page or email directly to
repair technicians.
❖ Detailed information display. You want a system that displays reports in plain English, with a complete
description of what activity is happening and how you can manage it.
❖ Nuisance alarm filtering. Nuisance alarms desensitize your staff to alarm reports, and they start to believe
that all alarms are nonessential alarms. Eventually they stop responding even to critical alarms. Look for a
SCADA master that includes tools to filter out nuisance alarms.
CONT…
❖ Expansion capability. A SCADA system is a long-term investment that will last for as long as 10 to 15
years. So you need to make sure it will support your future growth for up to 15 years.
❖ Redundant, geo diverse backup. The best SCADA systems support multiple backup masters, in separate
locations.. If the primary SCADA master fails, a second master on the network automatically takes over, with
no interruption of monitoring and control functions.
❖ Support for multiple protocols and equipment types. Early SCADA systems were built on closed,
proprietary protocols. Single-vendor solutions aren't a great idea - vendors sometimes drop support for their
products or even just go out of business. Support for multiple open protocols safeguards your SCADA system
against unplanned obsolescence.
WHY IS SCADA SO POPULAR?
❖ The major attraction of SCADA to a municipality is the ability to significantly reduce operating labor costs,
while at the same time actually improve plant or regional system performance and reliability. Information
gathering within a plant no longer requires personnel to spend time wandering all over the site, and
correspondingly the frequency of field site inspections required in a regional system can be minimized.
❖ Costly after-hours alarm call-outs can often be avoided since a SCADA system will indicate the nature and
degree of a problem, while the ability to remotely control site equipment may permit an operator at home to
postpone a site visit till working hours. SCADA based alarming is also very reliable since it is inhouse and
tied directly to process control.
❖ A significant feature of a SCADA system, often not fully appreciated, is the trending of data and nothing
comes close for speed and ease of operation. When graphically displayed, accumulated operating data often
will indicate a developing problem, or an area for process improvement. Reports can easily be generated
from this data utilizing other common software programs.
❖ It should be appreciated that while a SCADA system is often complex to configure - it is extremely easy to
operate!
WHAT IS INVOLVED?

❖ There are five phases to creating a functional SCADA system:

❖ Phase 1
The DESIGN of the system architecture. This includes all important communication system, and with a
regional system utilizing radio communication often involves a radio path survey. Also involved will be any
site instrumentation that is not presently in existence but will be required to monitor desired parameters.

❖ Phase 2
The SUPPLY of RTU, communication and HMI equipment, the latter consisting of a PC system and the
necessary powerful graphic and alarm software programs.
CONT…

❖ Phase 3
The PROGRAMMING of the communication equipment and the powerful HMI graphic and alarm software
programs.

❖ Phase 4
The INSTALLATION of the communication equipment and the PC system. The former task is typically
much more involved.

❖ Phase 5
The COMMISSIONING of the system, during which communication and HMI programming problems are
solved, the system is proven to the client, operator training and system documentation is provided.
WHY YOU NEED HELP WITH YOUR SCADA IMPLEMENTATION?

❖ Implementing an SCADA system can seem deceptively easy - you just look on the Web, find a few vendors,
compare a few features, add some configuration and you're done, right?
✓ The truth is, developing a SCADA system on your own is one of the riskiest things you can do. Here are
some of the typical problems you might face if you don't get expert advice when you're designing your
system:
✓ Implementation time is drawn out:
It's going to take longer than you think. Network monitoring is a highly technical subject, and you have a
lot to learn if you want a successful implementation. And anytime you are trying to do something you've
never done before, you are bound to make mistakes - mistakes that extend your time and your budget
beyond their limits.
CONT…

✓ Resources are misused:

If you're not fully informed about your options for systems integration, you may replace equipment that
could have been integrated into your new system. Rushing into a system wide replacement when you could
have integrated can cost you hundreds of thousands of dollars.
✓ Opportunities are missed:
If you install a new SCADA system today, you're committing your company to that system for as long as
10 to 15 years. Many companies design what they think is a state-of-the-art SCADA system - and then find
that their technology is actually a generation behind.
DCS VS. SCADA IN MODERN ENVIRONMENTS

❖ There is considerable confusion today about the difference between DCS ("Distributed Control Systems")
and SCADA ("Site Control And Data Acquisition") systems. As you can tell from expanded acronyms above,
SCADA includes "Data Acquisition" in addition to "Control". DCS, on the other hand, contains only
"Control".
❖ Understanding why this difference exists requires a 15-second history lesson. Historically, when computer
networks either did not yet exist or had very low bandwidth, a SCADA system was the top-level controller
for many lower-level intelligent agents. It was simply impractical to have a single system controlling every
minute aspect of a system. In this technical environment, DCS devices did most of the detail work and simply
reported to (and took high-level orders from) the SCADA system.
 CONT…
Today, computer networks have become so fast that there's no
practical reason for SCADA and DCS to be separate. That's why
they have blurred together into a single monitoring and control
system. The choice of name - SCADA vs. DCS - largely depends on
the region where you work. Some areas favor SCADA, others favor
DCS. Occasionally, some people who worked with the systems
before they effectively merged or who have moved from another
region will use a term different than their coworkers. This again
leads to confusion when new employees must learn to manage
SCADA/DCS.
Thank you