SCADA ACADEMIC SEMINAR

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ABSTRACT

SCADA – (Supervisory Control and Data Acquisition) plays an important role in most of
the Industries like petrochemical, cement, sugar & process industries. And is mainly used
to monitor or to control a chemical, physical or transport process, integrated with power
system Management application functions. The basic of SCADA lies in automation
majorly done by PLCs (Programmable logic Controller). Using this, a project can be
done with effective increase of speed, and meaningful processing. Any channel failures
can be detected automatically by the use of SCADA without any human interaction. It
will control a complete site. The bulk of the site control is actually done by a remote
terminal unit (RTU). Data acquisition begins at the RTU or PLC level. This paper will
explain the working of SCADA in control process and applications. Any SCADA system
uses advanced linear electronic components for its working. A state of embedded
controller technology will be much suitable to achieve SCADA function in all
instrumentation environments

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INTRODUCTION

SCADA basically originated in 1993. Since there was need of monitor the campus
electrical supply and distribution systems. Many researchers took place on SCADA and
finally resulted in automation of status without man power.1994 installation took place
and presently finds multiple opportunities in different departments. when comes to
working, the signal is trapped in between source and destination (termed as set points)
and error is detected if any. SCADA automatically generates alarms in case of any
disturbances or any occurrence of errors. Its remote system for power management
promises to reduce fault restoration time by over 60%.SCADA is a giant leap in
automating the total process of electricity management. It integrates geographical
information system (GIS), distribution management system (DMS) and SAP operations.

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WHAT IS SCADA?

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 (RTU) or by programmable logic controllers (PLC). 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.

BENEFITS OF SCADA
Benefits of SCADA system include monitoring and control from one place. The various
trends and reports can be generated from the SCADA system

 Single view of entire network.

 Remote monitoring.
 Reduced outage down time.
 Better voltage quality.
 Pinpointing and isolation of faults.

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FUNCTIONING OF SCADA

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MAIN PARTS

 Human-Machine Interface:

HMI is the apparatus which presents process data to a human operator, and through
which the human operator controls the process. 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.

 Remote terminal Unit:

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
set points. Important to know that quality SCADA RTUs must have three important
characteristics: Data Networking, Data Reliability and 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,

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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 stand by formation providing continuous
control and monitoring in the event of a server failure.

WHAT DOES SCADA DO?

A SCADA system is used to monitor or control a chemical, physical, or transport process.

Integrated power system management application function, it provides an integrated
distributed management systems to improve the reliability of power supply, manage load
effectively, reduce restoration time and increase the utilization efficiency of the network
equipment.

There are many functions of SCADA. Few of them are

 Data exchange
 Data processing
 Supervisory control
 Switching order
 Load shedding and restoration

Any abnormality in the system is immediately flagged and corrective action is taken. The
term SCADA usually refers to the central system that monitors and controls a complete
site. The bulk of the site control is actually performed automatically by a remote terminal
unit (RTU).Host control functions are almost always restricted to basic site over ride or
supervisory level capability. Data acquisition begins at the RTU or programmable logic
control (PLC) level and equipment status that are communicated to the SCADA are
required. Data is then compiled and formatted such that a control room operator using the
human machine interface (HMI) can make appropriate supervisory decisions that may be
required to over ride normal RTU or PLC controls. SCADA system includes all the PCs,
HMI, controllers, in put output devices, network, software etc

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SCADA PRACTICAL APPROCH

The SCADA is subdivided in to five modules. These are

Data Acquiring:

Data acquiring is acquiring the variable status like temp pressure flow, level etc. And
main data acquisition components are from simple thermocouple to complex gas
analyzers transducers are classified in to two types there is active transducer, passive
transducer

Data Processing:

Data processing is much essential in field instrumentation techniques for save and
secured operations of process industries. It plays a major role and data acquisition
systems. Data processing circuits accept input from the transmitter or transducer directly
and convert as per the ADC standards.

Data conversion:

Data conversion means, converting analog data in to computing data, computing data
means, and the old data must be like BCD, data bus or logic level signals. Data
converters are used to convert the unknown field variables in to known data’s, which can
be manipulated with a computer by using computing languages.

Data Manipulation:

Data manipulation is a simple calculation between real value and ADC value. The real
value must be sent to record files, graph file, controller setting a transmission file.
Manipulation value must be compared with set points and controller action

Data Transmission:

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Data transmission is to form a bridge between master control room and sub system area.
The distance between master control room and sub system area may dependent on the
transmission medium.

SCADA ARCHITECTURES

SCADA systems have evolved through 3 generations as follows;

First generation: "Monolithic"

In the first generation, computing was done by mainframe computers. Networks did not
exist at the time SCADA was developed. Thus SCADA systems were independent
systems with no connectivity to other systems. Wide Area Networks were later designed
by RTU vendors to communicate with the RTU. The communication protocols used were
often proprietary at that time. The first-generation SCADA system was redundant since a
back-up mainframe system was connected at the bus level and was used in the event of
failure of the primary mainframe system.

Second generation: "Distributed"

The processing was distributed across multiple stations which were connected through a
LAN and they shared information in real time. Each station was responsible for a
particular task thus making the size and cost of each station less than the one used in First
Generation. The network protocols used were still mostly proprietary, which led to
significant security problems for any SCADA system that received attention from a
hacker. Since the protocols were proprietary, very few people beyond the developers and
hackers knew enough to determine how secure a SCADA installation was. Since both
parties had vested interests in keeping security issues quiet, the security of a SCADA
installation was often badly overestimated, if it was considered at all.

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Third generation: "Networked"

Due to the usage of standard protocols and the fact that many networked SCADA systems
are accessible from the Internet; the systems are potentially vulnerable to remote cyber-
attacks. On the other hand, the usage of standard protocols and security techniques means
that standard security improvements are applicable to the SCADA systems, assuming
they receive timely maintenance and updates.

SECURITY ISSUES

The move from proprietary technologies to more standardized and open solutions
together with the increased number of connections between SCADA systems and office
networks and the Internet has made them more vulnerable to attacks—see references.
Consequently, the security of some SCADA-based systems has come into question as
they are seen as potentially vulnerable to cyber attacks.

In particular, security researchers are concerned about

 The lack of concern about security and authentication in the design, deployment and
operation of some existing SCADA networks
 The belief that SCADA systems have the benefit of security through
obscurity through the use of specialized protocols and proprietary interfaces

 The belief that SCADA networks are secure because they are physically secured

The belief that SCADA networks are secure because they are disconnected from the
Internet.

SCADA systems are used to control and monitor physical processes, examples of which
are transmission of electricity, transportation of gas and oil in pipelines, water
distribution, traffic lights, and other systems used as the basis of modern society.

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The security of these SCADA systems is important because compromise or

destruction of these systems would impact multiple areas of society far removed from the
original compromise. For example, a blackout caused by a compromised electrical
SCADA system would cause financial losses to all the customers that received electricity
from that source. How security will affect legacy SCADA and new deployments remains
to be seen.

There are two distinct threats to a modern SCADA system. First is the threat of
unauthorized access to the control software, whether it be human access or changes
induced intentionally or accidentally by virus infections and other software threats
residing on the control host machine. Second is the threat of packet access to the network
segments hosting SCADA devices? In many cases, there is rudimentary or no security on
the actual packet control protocol, so anyone who can send packets to the SCADA device
can control it. In many cases SCADA users assume that a VPN is sufficient protection
and are unaware that physical access to SCADA-related network jacks and switches
provides the ability to totally bypass all security on the control software and fully control
those SCADA networks.

These kinds of physical access attacks bypass firewall and VPN security and are best
addressed by endpoint-to-endpoint authentication and authorization such as are
commonly provided in the non-SCADA world by in-device SSL or other cryptographic
techniques.

The reliable function of SCADA systems in our modern infrastructure may be crucial to
public health and safety. As such, attacks on these systems may directly or indirectly
threaten public health and safety. Such an attack has already occurred, carried out on
Maroochy Shire Council's sewage control system in Queensland, Australia . Shortly after a
contractor installed a SCADA system there in January 2000 system components began to
function erratically. Pumps did not run when needed and alarms were not reported. More
critically, sewage flooded a nearby park and contaminated an open surface-water
drainage ditch and flowed 500 meters to a tidal canal.

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Automation has been helping industry operation in many aspects. Production process
control or any industrial operation obviously had become easier with the aid of
automation system and devices.

1. As SCADA system is the main role of supervision and controlling the automation system,
it brings the following advantages:
2. Reduce time consumption
3. Reduce human resource consumption
4. Increase product/project revenue
5. Greater accessibility (remotely)
6. More security (implementation of user access levels)
7. Instantaneous alert on alarms or events
8. Organized data records and report generation automatically
9. Data analysis (real-time and historical data plotting of graphs, charts, trends, etc.)
10. Ensure system availability (implementation of system redundancy)
11. Easy user interfaces for interaction (graphical HMI interface with animation for easy
understanding)

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APPLICATIONS
SCADA systems are often used by:

Power companies: SCADA systems can be used to maximize the efficiency of power
generation and distribution processes. More specifically, SCADA systems can monitor
the power flow, power line voltage, circuit breaker status, and other electrical
processes.SCADA systems can even be used to control individual sections of the power
grid.

Major Utility Companies: Both government and private utility companies use SCADA
for water sewage services. This includes collecting water use and distribution
information, gauging supply levels, monitoring pressure readings, and other similar
applications.

Physical sites: SCADA systems can be used to control environmental factors at an

organization’s physical sites. SCADA data collections functions can be used at facilities
and buildings to monitor variables such as temperature lighting, and entry systems.

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Manufacturing companies: Production managers can use SCADA to monitor their

inventory. They can use their SCADA systems to regulate production machinery and
implement quality control tests.

Cellular technology: The cellular technology can be also used with SCADA applications
to improve productivity, increase plant’s uptime and prevent damages. The device that
makes the difference is the cellular modem.

CONCLUSION

SCADA systems monitor a variety of plant data including temperatures, water levels,
voltages and pressure levels. Alarms at central or remote monitoring sites are triggered by
any abnormal conditions.

The primary benefit of SCADA is to identify and correct problems quickly. By enabling
constant monitoring of the condition of the network, it cans often pin-point problems for
troubleshooting and maintenance technicians. It also helps reduce maintenance costs.

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FUTURE SCADA

In many cases the applications that run at that level are becoming more important than
the user interface stuff. The user interface is an area where there is lots of competition. A
spreadsheet can even provide a decent user interface for some situations. However
applications like batch tracking and leak detection are a SCADA vendor's advantage.
Those applications are becoming modularized and contain many man-years of
experience. And they usually run only on a SCADA system. In a world of "economic
rationalism" SCADA vendors become a pool of experience from all of their customers.
Not those trade secrets are being passed around, it's just that no one wants to, or should,
fund a new application 100%. A large SCADA vendor can play a role in reducing the cost
of an application that in turn provides cost saving benefits to the customer. Meanwhile
many utilities are looking more to their marketing side to get the advantage over the
competition than the operations side so sharing resources (informally) isn't perceived as a
problem.

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REFERENCES

1. www.wikipedia.com

2. www.howstuffworks.com

3. www.tycho.usno.org

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