UNIT 4

SCADA and DCS

A DCS (Distributed Control System) and SCADA (Supervisory control and Data
Acquisition) are used for industrial automation to control and monitor processes.

They are designed for different applications.

SCADA is used for monitoring and basic control of geographically scattered

operations, whereas DCS is used for exact control of complicated processes.

What is DCS?

DCS is a type of control system used in industrial processes to control and monitor
many process variables.

A DCS is a sophisticated system that controls and optimizes a plant or manufacturing

process by combining several controls, sensors, and actuators.

Control of the process is distributed over numerous controllers in a DCS.

These controllers are connected to a central computer or server through a

communication network.
The central server collects and analyses data from the controllers in order to provide
real-time feedback to the operators.

The DCS system consists of several components, including −

• Controllers − The controllers are distributed throughout the plant and

control numerous process variables, such as temperature, pressure, flow,
and level. Each controller has input/output modules that connect to
sensors and actuators in the field.
• Sensors − Sensors measure numerous process variables and provide the
information to controllers for processing.
• Actuators − Actuators control a variety of process variables, such as
valves, pumps, motors, and switches. The controllers send signals to the
actuators to make necessary adjustments to the process variables.
• Communication network − The communication network connects all of
the DCS system's components, allowing data transfer between controllers,
sensors, and actuators.
• Operator stations − The DCS system is monitored and controlled by
operator stations. The controllers' real-time data is available to the
operators, who can also examine alarms and alerts and change process
variables as needed.

Need for DCS

• DCS functions as a tool to control a loop system where one loop can perform
several control processes.
• Serves as a substitute for manual and automatic control devices that are
separated into a unit so that it is easier to maintain and use
• Data collection and processing facilities to obtain the right process output

DCSs have several advantages over other types of control systems, including:

1. Improved process control:

DCSs use advanced control algorithms, such as PID control, to provide precise
and accurate control of processes.

2. Scalability:

DCSs can be easily expanded to control larger and more complex processes.

3. Remote access:

DCSs can be accessed remotely using a computer or mobile device, which allows
for remote monitoring and control of processes.

4. Redundancy:

DCSs often have redundant components, such as controllers and servers, which
improves the system’s reliability and helps to prevent downtime.

5. Flexibility:

DCSs can be easily configured to control a wide range of processes and can be
used with a variety of input and output devices.

6. Improved data collection and analysis:

DCSs can collect and store large amounts of process data, which can be used for
analysis and process optimization.

7. Improved safety:

DCSs can be used to implement safety interlocks and alarms to improve the safety
of processes.

8. Integration:

DCSs can be easily integrated with other systems, such as SCADA systems and
PLCs systems, to provide a comprehensive control and monitoring solution.

9. Easy Maintenance:
 DCSs often have a modular design, which makes it easy to maintain, upgrade or
replace parts of the system.

Applications of DCS

Some examples of applications of DCS include:

o Power generation:

DCSs are used to control and monitor power generation processes, such as coal-
fired, gas-fired, and nuclear power plants. They are used to control and monitor
the process variables such as temperature, pressure, flow, and level, to ensure the
safe and efficient operation of the power plant.

o Oil and gas:

DCSs are used to control and monitor processes in the oil and gas industry, such
as drilling, refining, and petrochemical production. They are used to control and
monitor the process variables such as pressure, flow, and level, to ensure the safe
and efficient operation of the process.

o Water treatment:

DCSs are used to control and monitor processes in water treatment plants, such
as water purification, desalination, and wastewater treatment. They are used to
control and monitor the process variables such as flow, pH, and temperature, to
ensure the safe and efficient operation of the process.

o Pharmaceuticals and biotech:

DCSs are used to control and monitor processes in the pharmaceutical and biotech
industry, such as fermentation, distillation, and purification.

o Manufacturing:

DCSs are used to control and monitor processes in manufacturing, such as

assembly lines, robotic systems, and packaging systems.
What is SCADA?
SCADA is a control system that is meant to monitor and control entire industrial
processes or systems rather than individual pieces of equipment.

SCADA systems are used to manage and control large-scale industrial processes
such as water treatment plants, electricity generation plants, and transportation
systems.

The RTUs or PLCs in a SCADA system are responsible for collecting data from
various sensors and sending it to the central server for processing.

The data is processed by the central server, which delivers real-time feedback to the
operators through operator stations.

The SCADA system consists of several components, including −

• Remote terminal units (RTUs) –

 RTUs are distributed throughout the plant or process and are responsible
for collecting data from multiple sensors and sending it to a central server.
Based on the commands received from the central server, RTUs are also
responsible for controlling other process variables, such as valves and
motors.
• Programmable logic controllers (PLCs) –
PLCs are similar to RTUs, but they control smaller plants or processes.
PLCs are responsible for collecting data from sensors as well as
controlling multiple process variables.
• Sensors –
Sensors are used to measure variables such as temperature, pressure,
flow, and level in processes. Sensors send data to RTUs or PLCs for
processing.
• Communication network –
The communication network connects all of the SCADA system's
components, allowing data to be exchanged between RTUs or PLCs and
the central server.
• Central server –
The data collected from the RTUs or PLCs is processed by the central
server, which then delivers real-time feedback to the operators through
operator stations. In addition, the central server maintains previous data
for analysis and reporting.
• Operator stations –
The SCADA system is monitored and controlled by operator stations. The
operators have real-time data access, can review alerts and notifications,
and can change process variables as needed.
Applications of SCADA

Water/Wastewater systems: SCADA systems monitor and control the water being
pumped at wells and treated at water treatment plants. They are used to control flow
rate sensors, contaminant sensors, etc

Food/Pharma production: This is a major SCADA application. SCADA is used to

monitor and control all phases of production, control the exact mix of ingredients,
monitor the time and temperature required to process/manufacture food & beverages
or pharmaceutical products. SCADA also helps to document data that proves the
production process meets industry standards and governmental regulations.
Manufacturing plants: SCADA controls all plant operations, ensuring all systems run
smoothly and productivity targets are met. It tracks how many units are produced,
measures values like temperature, pressure, humidity, etc. at different production
stages.

Oil & Gas systems: SCADA systems are used to monitor wells and pumping sites,
pumping pressure, pipeline flow and compressor stations. It detects irregularities and
prevents disastrous events from occurring.

Electricity Generation, Transmission and Distribution Systems: SCADA is used

to monitor every phase of generating electricity from fuel input to electrical output.
SCADA also monitors and controls electrical substations and distribution lines.
SCADA is utilized to monitor and control the amount of electrical power being
transmitted over long distances, and to respond instantaneously to fluctuations in
demand.
Need of SCADA

SCADA (supervisory control and data acquisition) is used by manufacturers across

numerous industries and applications to remotely monitor and automate the control
of industrial processes and machines.

➢ Data Acquisition

SCADA systems acquire machine data through networked devices and sensors
connected to a PLC or RTU. These devices and sensors measure parameters
such as temperature, speed, pressure, or weight as raw data. The data is then
sent to a PLC or RTU, where it is translated into information. Finally, the
information is sent to an HMI and displayed to operators to analyze or act on.

➢ Control

Automated process control based on defined set-points is another SCADA

function. SCADA systems can be programmed to perform certain control
decisions based on the parameters received from connected sensors. For
example, if SCADA detects an abnormal condition in the process, such as
power loss to a machine the SCADA system could perform a control function to
automatically turn on a generator to restore power.

➢ Alarms

When abnormal conditions occur within a process, SCADA systems can trigger
alarms to notify operators that something is wrong. Alarm notifications may be
presented to operators in the form of audible sounds, lights, graphical displays,
email/SMS, or phone calls. Additionally, alarms can be programmed with
different levels of priority to help differentiate major system errors from minor
issues.

➢ Data Communications
 SCADA systems may use wired or wireless communication technologies, as
well as different communication protocols to transmit data between machines
and operators. Common non-proprietary communication protocols include
distributed network protocol (DNP3), Modbus, and IEC 60870-5.

Advantages of SCADA

• Receiving real-time information to monitor equipment

• Remote industrial control
• Storage of performance data for later analysis
• It allows for proactive maintenance and decreases downtime

COMPARISON OF DCS AND SCADA

Characteristics DCS SCADA

Full Form Distributed Control System Supervisory Control and

(DCS) Data Acquisition (SCADA)

Control Centralized Decentralized

Structure

Process Type Continuous Batch

Number of Larger Small to moderate

Process
Variables

Control High Moderate

Precision

Communication It supports exclusive protocols. It supports open protocols.

Protocols

Processing Processing time of DCS is Processing time for SACDA

Time slow. is fast compared to DCS.
 Industries Oil and gas, chemicals, and Water treatment, power
power generation generation, and
manufacturing

Components Controllers, sensors, actuators, RTUs or PLCs, sensors, a

communication network, and communication network, and
operator stations a central server

SCADA ARCHITECTURE

SCADA system provides supervisory control, monitoring and management of various

industrial automation systems (such as manufacturing and process control
automation systems) by acquiring and analyzing the data from remote devices.

It gathers the real-time data from various remote locations or plants, presents the data
on various HMIs, records and logs the data on SCADA database management.

Architecture of SCADA

A typical architecture of a SCADA system is shown in below figure which describes

the general configuration and major components of the SCADA. In this, control area
or master station house main server which acts as MTU and communication routers.
Also, the control area includes engineering workstations, HMI stations, data servers,
and data historians, which are all connected by local area network (LAN). The master
station is responsible for monitoring and controlling various remote stations.

Remote stations are equipped with one or more RTUs/ PLCs which performs local
monitoring through sensors (such as voltage, current, temperature and pressure) and
local controlling through actuators (such as pumps, relays, and valves). The field site
devices are connected through WAN network to perform remote diagnostics.

The communication or transferring of information between field sites and control

center is carried through proprietary communication protocols over serial
communications using telemetry techniques such as cable, telephone line and RF.

The major components of SCADA include

Master Terminal Unit (MTU)

It is the heart of the SCADA system, which can be a dedicated computer, a

Programmable Logic Controller (PLC), or a network server that communicates with
remote field site RTUs. It initiates all communication, collects the data, stores the data
in database, provides interfaces to operators and sends the information to other
systems.

It allows the users to perform controlling functions on field devices such as breakers,
switches and other actuators depending on the gathered data. It continuously
communicates with other devices in master station so as to facilitate data logging,
alarm processing, trending and reporting, graphical interface and security system.

Remote Terminal Units (RTUs)

RTUs gathers the information from various field sites in which they are employed.
Each RTU is connected with various sensors and actuators that manage local process
or field equipment’s.
It collects the information from various sensors and sends the information to the MTU.
Also, it receives the control commands from MTU and correspondingly controls the
various actuators.

Many RTUs store the data in their database and waits for a request from the MTU to
send or transmit the data. It uses a local area network to communication with various
field devices.

Communication Equipment/Network

It provides the link between RTUs (in the field) to MTU (in the control center). The
communication can be wired or wireless or through internet which provides
bidirectional and uninterrupted communication between RTU and MTU.

SCADA systems can be connected using various communication mediums including

twisted pair cables, coaxial metal cables, fiber optic cables, satellites, high frequency
radio, telephone lines, and microwave radio.

The topology of the SCADA system network depends on the type of system or
application it is intended for. Mostly redundant topology is recommended for critical
control applications.

SCADA SOFTWARE/ EDITORS

Some of the common editors or software that SCADA uses are discussed below:

✓ Siemens - WinCC PCS7

It was developed specifically for process control applications. The PCS7 is a tool
or programming method for using a PLC. A PLC is still used in conjunction with the
process control system and PCS7 is used to build the control software and
interrelations.
 ✓ ABB - Symphony plus

ABB Ability™ Symphony® Plus is an integrated control system (CS) designed to

maximize plant efficiency and reliability through automation, integration, and
optimization of the entire plant.

Here one can choose and compare hardware at a glance, filter according needs
and download pdf-outlines for a product area or export individual data-sheets.

✓ Alan Bradley - Factory Talk

FactoryTalk Services Platform is a suite of services including Live Data, Directory,

Audit, Security, Activation, and Alarm & Events. It is not a product that one
purchase as a standalone software package, but is embedded in most of the
products from Rockwell Software.

✓ Schneider - Foxboro / EcoStruxure

It has state-of-the-art technologies like Dynamic SAMA, Engineer Anywhere and

Control Anywhere capabilities, Visualization and Situation-Awareness
functionalities, and the latest IT technologies in mobility, cloud and analytics.

It is Customizable, embedded real-time model that measure and control the

financial value of every point of the process.

It is Optimized for smart design and flexible engineering using state-of-the-art

technologies.

COMMUNICATION PROTOCOLS FOR SCADA

Some of the common communication protocols used for transmission of data and
information’s in SCADA are:

1.IEC 60870-5

▪ IEC 60870-5 is the collection of standards produced by the IEC(International

Electrotechnical Commission).
 ▪ It was created to provide an open standard for the transmission of SCADA
telemetry control and information.
▪ It provides a detailed functional description for telecontrol equipment and
systems for controlling geographically widespread processes specifically for
SCADA systems.
▪ The standard is made for application in the electrical industries.

2. DNP3 Protocol

▪ The DNP3 or Distributed Network Protocol is a set of communications protocols

used between components in process automation systems.
▪ It is usually used is in utilities such as water and electric companies.
▪ It was specifically developed to allow communications between various types of
data acquisition and control systems. It is used by SCADA Master Stations or
Control Centers, Remote Terminal Units, and Intelligent Electronic Devices. It
is primarily used for communications between a master station and IEDs or
RTU’s.
▪ DNP3 supports multiple-slave, peer-to-peer and multiple-master
communications.

3.Modbus

▪ The point-to-point Modbus protocol has become a virtual standard for RTU and
PLC communications.
▪ During communication on a Modbus network, the protocol determines how each
controller will know device address, recognize a message addressed to it,
determine the action to be taken and extract any information / data attached to
it.

4.MODBUS X

▪ The non-proprietary Modbus X expansion has been adopted by a number of

companies and utilities and by SCADA software suppliers.
 ▪ It fixes the Modbus shortcomings, makes it man readable and able to handle
positive and negative numbers with up to 9 digits of resolution, with an exponent
range from -99 to +99.
▪ It is a Point-to-point protocol, designed to read and write to individual I/O (Input
Output) points in PLCs on a factory floor.
▪ The ModbusX expansion of the protocol is a universal, non-proprietary
expansion, which permits handling large process variables in plain ASCII with
sign and exponent, capabilities that are missing in Modbus.

5.DNP (Distributed Network Protocol)

▪ A member restricted protocol, used in some Electric Power systems. The DNP
protocol has gone through various iterations. Presently it is up to version 3.0.
▪ The DNP association has rules, which tend to restrict the use of the protocol,
and major SCADA software suppliers have been slow in implementing the
protocol.

6.ASCII

▪ The famous computer protocol is ASCII, American Standard Code for

Information Interchange can also be used for SCADA communications.
▪ Virtually all computers, printers, modems and many sensors, actuators and flow
computers now communicate in ASCII.

INTERFACING SCADA SYSTEM WITH PLC

To interface a PLC with SCADA, we need to create a proper communication channel

or bus.

The monitoring PC, in which SCADA software is installed, must be linked with this
communication channel via its communication port.

SCADA software has multiple communication protocols, such as

• MPI/DP (Multi-point interface)

 • Profibus
• Ethernet
• OPC, etc.
Now, we need to confirm the PLC protocols.
Generally, PLC has protocols such as MPI/DP, Ethernet, Serial Port, etc.
This is the primary step to check the communication protocols which both the PLC
and SCADA have.

Let’s create a new project in the TIA (Telecommunications Industry Association)

portal first.

First, we are going to add an HMI application.

For that go to
Add new device >> HMI >> Simatic HMI application.
You will find various WinCC versions in there, just take it as per your requirement.
Here, we have selected the WinCC RT Advanced.
Now in the next step, we are providing a communication channel in SCADA.

For that, we are adding an ethernet.

To add ethernet just drag and drop IE General in that.
To interface WinCC RT Advanced with PLC, we have to add a PLC controller to our
project.

Now go to
Add new device >> Controllers
and then add your PLC here.
We are adding here an S7 1200 series CPU 1212 DC/DC/DC.

After adding a PLC controller, the next step is to configure its ethernet protocol,
because we are going to connect PLC with SCADA through ethernet protocol.

For that Go to

PLC CPU Properties >> General >> Ethernet addresses.

The subnet in the ethernet properties in both PLC and SCADA must be common to
connect PLC with SCADA.

In other words, we can say that the PLC and SCADA must be on the same ethernet
network for proper communication.
We are just adding a simple logic to start and stop the motor.

Create a simple logic and then download it into PLC.

After downloading our logic in the PLC, we need to prepare and graphic to control
and display the status of the motor.

And also, we need to create a connection between PLC and SCADA.

Go to the
HMI Application >> Connection and configure it.
Select communication driver as Simatic S7 1200 because our PLC controller is of S7
1200 series.

Now, we are all set to start and stop the motor from the SCADA, and also, we can
check the online status in PLC as well.

Here, in the below image, we can see those two buttons, start and stop, and the motor
indication as well.
When the operator will press the start button, it will activate the output Q0.0 bit and
will start the motor.

We can see that the motor’s image is showing in green color, which indicates that the
motor is running now.
 OBJECT LINKING AND EMBEDDING FOR PROCESS CONTROL
(OPC) ARCHITECTURE

OPC is a software interface standard that allows Windows programs to communicate

with industrial hardware devices.

The purpose of the standard is to provide a common means for data access
applications from any source, from field devices or from other files or applications.

The great motivation to create the OPC ™ OLE for the Process Control standard is
the need to establish a standard mechanism for communication between different
data sources, either from field devices or even from other data files.

Information architecture in an Industrial Process involves three levels:

1. Field Management:

With the advent of intelligent field equipment, a wide variety of data equipment,
such as configuration and control data, may be used or even other applications.

2. Process Management:

The use of SCADA and SDCD (Strategy for distributed controller defence)
control systems allow the decentralized control of industrial processes. The data
provided can be considered together to allow effective and integrated of the
entire Industrial Process.

3. Business Management:

It is the integration of factory floor information and individual management data

from each controlled process with the company’s corporate data, administrative
and financial data. The data and information can be used by client applications
to optimize the management and integration of the entire process of
manufacturing.
Architecture of OPC applications:

OPC ™ - OLE for Process Control, implements two large modules:

a) OPC Server and

b) OPC Client.

While the OPC Server specifies standard interfaces for direct access to equipment or
applications, the OPC Client specifies the default interface for applications to access
the collected data.

There are three types of OPC data servers:

a) Data Access Server: direct access to equipment data;

b) Alarm & Event Server: notification mechanism for OPC clients for specific
events and alarm conditions;
c) Historical Data Server: reading, processing and editing historical data.

OPC applications are written in several languages, such as Visual Basic, Delphi,
Power Builder, etc.
The OPC servers are written in C or C ++, taking advantage of the encapsulation
characteristics of these languages, providing “objects” that can be accessed through
any application

All specifications have been made to facilitate the development of OPC servers and
can also be written in another language.

Access to OPC servers is done through the OLE / COM ™ (Component Object Model
)and OLE / DCOM ™ (Distributed Component Object Model) components provided
by the Microsoft ™ Windows ™ operating system.

(OLE) - Object Linking Embedding:

An object is an information unit that can be created and manipulated by users. It has
intrinsic behavior specified by its type, with its own commands and facilities. In other
words, objects are data/software modules that can be included in software packages.
They can be LINKED or EMBEDDED.

Linked Objects: Stored separately and can be “partitioned” by multiple applications;

Embedded Objects: are stored together with the applications. In this case, they are
for the exclusive use of the same ones.

Benefits of using OPC:

• Simple to develop;
• Flexibility to “accommodate” the features of multiple manufacturers;
• High level of functionality;
• Enables efficient operation.
• Hardware manufacturers must only develop a set of components to access
their equipment;
• Software developers do not have to rewrite drivers because of changes in
equipment;
• Users have more options to develop international and integrated systems;
HOW TO CONFIGURE A SIMPLE SCADA SYSTEM

In order to configure a simple SCADA system using only a laptop / PC one needs to
target the following basic SCADA components:

• Tag (IO)
• Trending / Report
• Alarm
• Screen / Mimic

Tools / Dependencies:

• Ecava IGX
• Inkscape SAGE
• Modbus Simulator

Step 1: Create New Project

Go to

Start Menu > Ecava IGX, and launch IntegraXor Editor.

Create a new project as shown below.

Step 2: Create New I/O Port

On the left menu, click on element “IO Driver” to display the content in main window.
Next, add a new I/O port in the existing table content and enable it, as shown in
following.

Ethernet port will be used to connect the device to SCADA via Modbus TCP/IP
protocol.
Address 127.0.0.1 indicates the localhost address.

Step 3: Create New Device

Click on the newly created I/O Port on the left menu.

Create a new device in the table as shown below, choose Modbus from the dropdown
Driver list.
Step 4: Create Tags

Tags are one of the main components in a SCADA system, they are variables created
in both SCADA and PLC/RTU in order to pass parameters between instruments and
SCADA. Here, 2 tags will be created to indicate an instrument’s measurement value
and status.
Note that the “Log” attribute for tag ‘meter_value’ is configured in order to log the tag
value into database for data monitoring purpose.

Step 5: Trending

Trending is another basic feature in SCADA for data monitoring purpose.

Let’s include one of the tags created to understand how it works.

On the left menu, go to

‘Screen’ > ‘Trend’ > ‘Single Layer’ and reveal the pre-created html code page. Append
the following scripts into the html file as shown.

Step 6: Report

Other than trending, reports are very useful for data monitoring in SCADA system.

Click on

‘Report’ > ‘Archive’ to create a report to record the measurement values of our
instrument.
In the new report (.htm) file, create a simple table to record ‘meter_value’ tag as shown
below.

Next, in order to view the report in front-end, it is required to add it as one of the
display screens.

Click on ‘Screen’ and add a new Sub-Menu under ‘Report’, then browse and select
the report file created just now.
Step 7: Alarm

Process alarms are important in a production to avoid any unwanted loss. Thus, let’s
add an alarm to monitor our instrument’s measurement value.
Click on ‘Alarm’ > ‘Group’ > ‘Process’ and add a new alarm as shown below.

The alarm will be activated when instrument reading reaches high limit, and similarly
for low limit.

Step 8: Screen / Mimic

A mimic screen is necessary to represent a front-end HMI to interact with the SCADA
system.

Let’s create a fairly simple one by using Inkscape SAGE.

From Start menu, launch Inkscape SAGE. We will only target on mapping the drawing
objects with SCADA tags to understand their inter-relations.

Create a text object to indicate values and a shape object that will target to change
color according to different status, example as follows.
Save the SVG file in the project folder.

Right click on the text and select “Object Properties”. On the “Get” tab, select the tag
‘meter_value’ created in Step 4 as shown below. Hit on button “Apply” and “OK” and
save the file.
Next, right click on the circle shape and select “Object Properties”. On the “Color” tab,
select tag ‘meter_status” and define the color based on the tag value as shown below.
After done, apply the changes save the file.

Other than reading data from devices, most of the time a SCADA system requires
setting command to a process.

For example, create a button as shown below to start a process when clicked. Right
click on the button and select “Object Properties”. On “Set” tab, choose your tag to
trigger the process. In this case, tag “start_button” is Boolean type, where its value
will be set to “True” when clicked on the button. You can also add a prompt message
for double confirm upon clicking on front-end.

Similarly with meter status above, create a process status light with color animation
to indicate the status after the start button is clicked. (i.e. process started = green,
otherwise = red)

Apply the changes and save the file when done.

Lastly, add the SVG file as one of the screens in Project Editor in order to view them
on front-end display. (Refer to Step 6)

SCADA application for Traffic Control Monitoring

The simplest and most direct application of the SCADA concept to municipal traffic
control is system monitoring or precisely a system of effective equipment monitoring.

Traffic lights have equipment cabinets, usually located at their feet or corners of
intersections. If the equipment in the cabinet is working, so is the traffic light.

By monitoring equipment cabinets, municipalities can:

• See when a traffic light goes down.

• Detect a traffic light failure before it happens.
• Repair a traffic light before it fails, heading off collisions in an uncontrolled
intersection.
• Make sure networks are up and running for first responders in the event of an
emergency.

This is done by adding a gear that will act as a traffic control device to each equipment
cabinet. This is known as an RTU (remote terminal unit). RTUs can track
environmental conditions inside equipment cabinets, warning municipal managers if
temperature or humidity threatens the operation of traffic lights.

RTUs can be used to detect other issues, such as flooding, unauthorized physical
entry, or voltage deviations. If an issue is detected, RTUs transmit the information to
the appropriate responder. This represents the "Data Acquisition" portion of SCADA.

For small traffic grids - with a dozen lights or less - RTUs can directly inform the
maintenance crew leads of problems.

Once grids become larger and more complex than this, it becomes more efficient to
route alarms to a master station.

A central master station sorts, prioritizes, and informs dispatchers and managers of
problems by order of importance.

Large cities may further subdivide their traffic grids into multiple regions - each
watched over by an individual master station.

This allows regions to deal with problems locally. By transmitting information to a

central master station - which displays it in a browser.

Applications of SCADA for Water Systems

SCADA has a broad range of applications. Their monitoring functions allow real-time
insights across filtration plants, pump stations, and entire distribution networks.

Each piece of equipment that requires monitoring, from valves to tanks, can be
equipped with sensors. Control relays can be installed on equipment like pumps,
valves, UV emitters, or booms.

Sensors and process controller devices (control relays) are attached to remote
terminal units (RTU). Multiple remote terminal units at different sites transmit the data
collected to a single master station which displays the information in a browser. For
especially large water management systems, several master stations can be
controlled by a single top-level master.

Each aspect of a large water system derives unique benefits from a SCADA system:

Filtration Plants
SCADA systems can monitor tank levels, chemical levels, ultraviolet (UV) intensity,
and environmental conditions, as well as pumps, valves, and filters.

• Remote monitoring of filtration plants allows managers to detect conditions

requiring maintenance immediately without needing to send staff out on rounds.

• Control relays enable operational adjustments with the click of a mouse.

Pump Stations
Pump stations in urban and rural areas alike are widespread and numerous. Rather
than staffing each pump station full-time, or relying on periodic inspections, water
systems can monitor each pump from a single location. This:

• Delivers fine control over the entire network

• Improves routine operations and emergency response

• Provides accurate, timely maintenance information

Distribution and Sewer Networks
Water distribution networks are comprised of hundreds of miles of pipe. Sewer and
stormwater systems sprawl and maze similarly. Monitoring an entire network requires
continuous pressure and volume readings from numerous sites.

With a SCADA system, information on the entire network can be collected and
displayed at once, drastically improving managerial overview. This:

• Reduces the manual labor needed to check meters

• Cuts costs while improving service

Water safety can be monitored by the same system, protecting residents.

Site Security
Water infrastructure is vulnerable to vandalism, theft, sabotage, or terrorism.
Preventing unauthorized access to important sites including filtration plants, pump
stations, and storage facilities helps protect the valuable assets stored within.

SCADA can be a monitor and control system like door alarms, motion sensors, and
video cameras, alerting security personnel to intruders.

Control relays can close doors, and activate sirens and lights to deter trespassers.

In addition to its direct effects, SCADA systems simplify another important task:

Record Keeping
With asset, equipment, and operational information all flowing through the same
central system, there's no need to tediously transfer information from one media to
another for analysis or storage. This:

• Reduces the amount of time spent on routine labor

• Frees employees for more pressing tasks

The records kept can be used to demonstrate regulatory compliance or to generate
insights into operations

Electricity Generation, Transmission, and Distribution Systems:

• SCADA systems are used in electric power generation plants, transmission

areas, and distribution systems.
• SCADA systems monitor each and every phase of the generation of electricity
from fuel input to electrical output.
• SCADA systems can also be used to monitor and control electrical
switchboards, Grids, and transmission lines.
• SCADA monitors and controls the actual electrical power being transmitted over
long distances.
• This system responds to load fluctuations instantaneously.
SCADA in Power transmitting Systems

• Re-routing services for station maintenance

• Service Restoration
• Protective relay interface/interaction
• Voltage regulation management
• Load tap changer control
 • Transformer management
• Real-time modeling.
• Automatic control of circuit isolation.
• Collective switch control display
• Interface real-time single-line displays
• On-line operation and maintenance logs
• Automatic system diagnostics through system alarm management.
The general features of a SCADA substation system are

• Substation parameter monitoring

• Controlling electrical network components remotely
• Safety tagging
• High-resolution time stamping
• The sequence of event reporting for post-event analysis
• Demand side management
• Volt/VAR control
• Preventive maintenance
• Fault detection isolation and restoration.
SCADA for Power Utility Network

• Power Utility Network (PUN) software provides an electrical utility with tools to
enhance system operation at a very low cost.
• The PNU software consumes real-time SCADA data.
• PNU logic is a combination of both mathematical and logical techniques.
• The present scenario is to produce and distribute quality power at the minimum
investment.
• Proper operation of the electrical network & having real-time data about the
network helps to achieve the required goal.
• PNU provides the user with a host of applications to distribute automation.
Features of Power Network Utilities

• Component Modeling
 • State Estimation
• Bad Data Suppression
• Contingency Analysis
• Fault Isolation/Islanding
• Load Shedding
• Volt/VAR Scheduling
• Dispatcher Power Flow
• Short Circuit Analysis
• Network Topology Processor

PLC Maintenance Procedures

Steps in performing preventive PLC maintenance:

1. Check environmental factors / operating conditions. Humidity, temperature and

other factors play an important role in the longevity and proper operation of your
components. Be sure that these factors are consistently within the range of your
PLCs optimal operating conditions.
2. Clear debris, dust, and buildup from your units. A clean working environment for
your PLC is a great way to prevent downtime. Also, dust getting to the circuit
boards could cause a catastrophic short circuit.
3. Clean or replace all filters installed in enclosures. This allows your PLC to get
the maximum airflow and ensures consistency.
4. Check all your connections for a tight fit, especially I/O modules. This is a very
simple way to make sure everything is working smoothly. Also, a loose
connection may cause lasting damage to your components.
5. Inspect I/O devices for proper adjustments.
6. Check LED battery indicators on the RAM memory module in the CPU. If the
OK LED is on or flashing, replace the battery ASAP.
7. Calibrate circuit cards with process control analogs every 6 months.
8. Service devices such as sensors every month.
9. Never place other pieces of equipment that produce lots of noise or heat close
to your PLC.