Introduction

SCADA is an acronym and stands for "Supervisory Control and Data Acquisition".
SCADA refers to a system that collects data from various sensors at a factory, plant or in
other remote locations and then sends this data to a central computer which manages and
controls the data. SCADA is used in power plants as well as in oil and gas refining,
telecommunications, transportation, and water and waste control. SCADA systems include
hardware and software components. The hardware gathers and feeds data into a computer that
has SCADA software installed. The computer then processes this data and presents it in a
timely manner. SCADA also records and logs all events into a file stored on a hard disk or
sends them to a printer. SCADA warns when conditions become hazardous by sounding
alarms. Contemporary SCADA system exhibits open loop control characteristics and utilizes
long distance communications. Systems similar to SCADA system are routinely seen in
factories and treatment plants. They are also referred to as Distributed Control Systems
(DCS). They have similar functions to SCADA systems, but the field data gathering or
control units are usually located within a more confined area. Communication may be via a
Local Area Network, and will normally be reliable and high speed. A DCS system usually
employs significant amount of closed loop control. SCADA system on the other hand covers
large geographical areas, and relies on a variety of communication systems. A closed loop
control in such a situation is less desirable. The control may be automatic or initiated by
operator commands. The data acquisition is first accomplished first by RTU scanning the
field inputs connected to the PLC. This data is processed to determine alarm conditions, and
if an alarm is present, it will be displayed on special alarm list. Data can be of three main
types:
a) Analogue Data - The real numbers will be placed in graphs
b) Digital Data - This may have alarms attached to one state or the other.
c) Pulse Data - This type of data is generally accumulated or counted.

The primary interface to the operator is a graphical display which shows a representation of
the plant or equipment in graphical form. Live data is shown as graphical shapes over a static
background. As the data changes in the field, the foreground is updated. Analog data can be
shown either as a number, or graphically. The system may have many such displays, and the
operator can select from the relevant ones at any time.
Basic Components

A SCADA System usually consists of the following subsystems:

a. A Human Machine Interface (HMI) - This presents process data to a human operator
which helps to monitor and control the processes.
b. A Supervisory System - It gathers data and sends commands to process.
c. Remote Terminal Units (RTU) - It converts sensor signals to digital data and sends
these digital data to supervisory systems.
d. Programmable Logic Controller (PLC) - It is used as field devices and configurable.
e. Communication Infrastructure - It connects supervisory system to RTU.

The brains of a SCADA system are performed by the Remote Terminal Units. The Remote
Terminal Units consists of a programmable logic converter. The RTU are usually set to
specific requirements and can also allow human intervention. In addition, any changes or
errors are usually automatically logged for and displayed. Most often, a SCADA system will
monitor and make slight changes to function optimally; SCADA systems are considered
closed loop systems and run with relatively little human intervention. One of key processes of
SCADA is the ability to monitor an entire system in real time. This is facilitated by data
acquisitions including meter reading, checking statuses of sensors, etc at regular intervals
depending on the system. The HMI of a SCADA system is where data is processed and
presented to be viewed and monitored by a human operator. This interface usually includes
controls where the individual can interface with the SCADA system. HMI's facilitate
monitoring of multiple RTU's or PLC's. Usually RTU's or PLC's will run a pre-programmed
process. The SCADA system communicates with PLC's throughout the system network and
processes information that is easily disseminated by the HMI. HMI's can also be linked to a
database, which can use data gathered from PLC’s or RTU's. Data acquisition begins at the
RTU or PLC level which is communicated to SCADA as required. Data is then compiled and
formatted in such a way that a control room operator using HMI can make supervisory
decisions to adjust or override normal RTU controls.
PROJECT OR CASE
VFDs for draft and FGD fan
flow control
Upgrade sensors & actuators
Balanced draft conversion
VFDs for boiler, circulating and
condensate pump flow control
Motors & drive-trains upgrade
DCS replacement for 20+ years
old system
Coordinated boiler-turbine
control, sliding pressure
operation
Boiler startup optimization
Advanced controls for steam
temperature control
Stabilizing firing rate
Reduction of excess air
Improved Feed water Pressure
& Level Control
SCOPE DESCRIPTION & BENEFITS
Eliminate flow restricting control methods.
May be part of a balanced draft conversion.
May also include benefit of peak loading,
previously limited by fan capacity on hot
days
Retrofit electro-hydraulic(turbine) , smart
positioners for
dampers, louvers
Proper furnace draft control using ID fans
instead of FD
fans and speed control instead of dampers
Eliminate flow restricting control methods;
may be part of a feed water heater upgrade
Replace existing motor and drive-trains with
right-sized, higher efficiency equipment
Improved automatic and operator control
response
Coordinated boiler turbine control, use of
feed forward techniques for rapid response.
Improved efficiency at low
loads
Less fuel, shorter time during start-up
Increase main steam temperature, reheat
steam temperature, and ramp rate
Improved heat rate, reduced need for
attemperation. 1-2 % improvement in heat
rate
Decrease the average flue gas O2 of the
boilers through improved airflow control.
General loop tuning
Electrical power system
upgrade
Plant availability improvement
Cooling tower retrofit
Environmental upgrade
Coal variability enhancements
Feed water heater upgrade
Plant Information Management System
Manual and adaptive tuning techniques
Power quality improvements, transformer
right-sizing and efficiency upgrade
Diagnostics, condition monitoring, asset
management
Improve drive power & controls related to
condenser systems
Improve drive power & controls for FGD,
precipitators, catalytic conversion
Coal blending, improved soot blower/water
canon systems, mill replacements, fan
modifications/rebuilds to accommodate more
variability in coal quality with multiple coal
sources without loss of efficiency or
reliability
Improved efficiency with compact heat
exchangers + condition monitoring
PIMS can enable energy efficiency
performance of up to improvements of 1.5%
through continuous monitoring and warning
of plant degradation.