Professional Documents
Culture Documents
By Paul Miller
Today’s state-of-the-art SCADA is not your granddad’s supervisory control and data
acquisition system. It’s not even the one you may have cut your teeth on as a new
process engineer back in the day. The monolithic master station running proprietary
supervisory applications is long gone. So is communication via inflexible, single-purpose,
analog remote terminal units (RTUs) over often-tenuous, low-bandwidth radio or
telephone system-based links.
Over time, commercial-grade personal computers (PCs) or servers running more open
and interoperable, standards-based HMI and supervisory applications replaced that
proprietary master station. Broadband wireless networks or Internet protocol (IP)
technology lifted directly from the commercial world have replaced the telephone and
old-fashioned radio links. Those dumb, analog RTUs have evolved into today’s much
smarter and more functional digital RTUs. And, increasingly, industrial programmable
logic controllers (PLCs) or programmable automation controllers (PACs) are taking the
place of dedicated RTUs in many SCADA applications. We also now have a new class of
intelligent electronic devices (IEDs) that communicate with either the RTUs or directly
with the SCADA via standard protocols.
“SCADA used to be a proprietary station that reached out to RTUs with a limited number
of points and some minor control algorithms going back and forth,” says Jack Peterson,
senior project manager, energy supply and management, at Southern California Edison,
Rosemead, Calif. “Today, SCADA is more closely aligned to a DCS or specialized hybrid
control system that uses open architecture platforms and today’s high-speed networking
technology. These are combined with secure protocols and secure stations following new
guidelines, such as those issued by NERC (North American Electric Reliability Corporation)
and FERC (Federal Energy Regulatory Commission) in the electric industry. Now SCADAs
are sitting on top of PCs or laptops doing everything they used to do – only faster,
smarter and more connected.”
This evolution offers many advantages to end users.
“Over the last 25 years, SCADA has evolved by orders of magnitude, pushing more
intelligence from the central control room into the field and embracing standard protocols
over proprietary protocols,” says Mike Chmilewski, vice president/general manager of the
controls business at Invensys Process Systems. “This provides new degrees of freedom
for field device selection and for integrating real-time operational data with advanced
applications and business systems to enable real-time business control.”
“While SCADA was previously used as a monitoring and control system for RTUs, it now
has a broader concept,” says Prasad Pai, Proficy HMI/SCADA iFIX Product Manager at GE
Fanuc Intelligent Solutions. “PLCs have taken over much of the control, and SCADA’s
scope has expanded into new applications. Because of the flexibility of SCADA, everything
that happens in a facility can now be in a single application. What we used to think of as
DCS has now become a PLC. It all used to be in one box – both hardware and software.
Now a PLC is controlling the plant, and the software, the SCADA, is PC-based. What we
used to think of as DCS has shrunk in size, but not in functionality.”
Phil Aponte, HMI/SCADA product marketing manager at Siemens Energy and Automation,
says, “SCADA is evolving from a centralized architecture to a more distributed
architecture, and the trend is to push production data up the chain to the business. In
brownfield facilities, where DCSs, PLCs or other automation platforms from different
vendors are already in place, SCADA is also often the path of least resistance for
migration purposes.”
Cybersecurity has developed into a healthy specialty within the already healthy IT
consulting industry.
Increasingly, elements of SCADA technology are also being used for in-plant process
control applications. Since today’s SCADA, HMI, MES and DCS systems all share many of
the same open technologies (Microsoft-based HMI, data analysis, and historian
applications; Ethernet IP; Web services; etc.) and can be used to address overlapping
applications, it’s becoming increasingly difficult to differentiate between the different
systems.
This all begs questions such as, “What does a modern SCADA system look like,” “What
kind of technology does it use?” and even, “What is a SCADA application?” The answer to
all three questions pretty much appears to be, “anything goes.”
For example, the way modern SCADA technology is being applied in today’s municipal
and utility operations bears little resemblance to the traditional SCADA with which many
old-school automation professionals grew up.
“The EWSU CSO project provides an excellent example of how SCADA technology is
evolving and can be used in a creative manner to ease regulatory compliance,” says
Michael Halbig, InGen’s president.
This broadband wireless umbrella now provides an efficient communications backbone for
the entire EWSU system.
“The ISCO flowmeters indicate how much, if any, combined wastewater is being diverted
to the Ohio River, and the T-BOXes automatically upload this information in real time via
the wireless umbrella to a secure server in the utility’s central data center. If for any
reason, the wireless link is lost, the individual T-BOXes retain the data until it can be
uploaded. A web server in each of the T-BOXes also provides a basic human interface and
simplifies troubleshooting, if needed, via a technician’s laptop.”
InGen also developed a custom Web application for the CSO system that allows
Evansville residents to subscribe for automatic overflow notification via email or to access
current CSO status via the utility’s website. Real-time data from the flowmeters are
automatically uploaded into this web application, thus meeting the EPA’s CSO notification
mandate. Anyone can visit this website at http://cso.evansvillegov.org/.
The SCADA configuration for the district’s water system gathers information from nearly
30,000 different widely dispersed data points via PLCs and RTUs. The Windows XP-based
SCADA system uses Wonderware’s InTouch HMI software for real-time visualization for
monitoring and control of the different sites. LBWD engineers programmed a PLC to poll
the 40 remote sites throughout the water system an average of once a minute.
Operators can remotely operate pumps and valves via this HMI. This is important to the
water department, since it enables the district to adjust water pressure in emergency
situations. Data inputs from the remote PLCs and RTUs are centrally stored in a
Wonderware IndustrialSQL Server historian, where the information is readily available to
operators. Wonderware trending and analysis software helps the operators predict and
avoid operational or maintenance issues and also to generate reports.
According to LBWD’s Gonzalez, “Now that real-time data is accessible from all the remote
sites and our treatment plant, we no longer have to employ additional operators and
maintenance staff to control various equipment and pumping stations throughout the
city. The remote stations have local intelligence, which means they run as stand-alone
stations. The operators have the ability to change remote station operations by
downloading setpoints to increase or decrease flows.”
The old plant was run using fixed-time logic, where the sewage water was retained in the
various vessels for a predetermined time period. To improve plant processing and energy
efficiency, the new system controls the transit times of the sewage in the tanks and
machine operation based on real-time sensor data, such as oxygen, ammonia, suspended
solids and nitrates measurements.
The new control system also provides both a local operator interface in the plant as well
as relaying data via a direct Modbus/TCP link to a central off-site control room that Hera
Imola-Faenza, the company that operates the Formellino plant, mans around the clock to
be able to monitor their different plants when they are unmanned.
Novanet, a system integration and engineering firm based in Imola, Italy, designed
implemented the new SCADA and process control systems at the Formellino plant. The
redundant GE Fanuc PACs provide the local intelligence and control and interface with the
field instruments on a Profibus network using a combination of fiber optic and copper
wire. There are approximately 600 controlled tags in all. A local computer running the GE
Fanuc HMI/SCADA software collects, monitors and displays information and data for the
local daytime operators. Data from the Formellino plant is stored in Hera’s SQL database
and displayed so that a remote operator can be alerted to faults and respond if
necessary.
In the short time since the new system has been in operation, process operations have
improved and energy consumption has been reduced by 30%.
Increasingly, new SCADA software applications provide critical real-time decision support
information to help companies meet new, increasingly more complex business challenges.
For example, generation management systems (GMS) extend SCADA technology to
enable electric utility companies to operate successfully in the newly competitive,
deregulated environment.
In one example, Invensys’ Foxboro SCADA group and a large, U.S. investor-owned
electric utility designed a new GMS that enabled the utility to accurately determine its net
energy position. This is critical for effective power supply scheduling and purchasing. The
GMS provides:
According to LBWD’s Gonzalez, “SCADA technology is getting to the point where the
software can be programmed to take care of everything from controlling pumps and
valves to bypassing problematic processors to automatically restarting a halted PLC or
frozen PC. Already, my computers run around the clock and pretty much take care of
themselves, though my technical staff check them weekly to verify communications.”
SCE’s Peterson says, “The open architecture has allowed SCADA to morph from the old
hard-wired days to what it is today, and I only see the SCADA architecture getting more
open and non-proprietary. This includes both hardware and software platforms. I also
think that we’ll see multiple applications running on one SCADA platform. For example,
instead of just doing a little supervisory control and data acquisition, I think you’ll
probably see some high-level batch applications doing things across blends, or detailed
control applications working across different RTUs, while the high-level batch is running.
In a large process plant, the DCS will still be your workhorse, but outside the plant, you’ll
have SCADA applications that can keep running even if the communications are lost.”
Clearly, the distinctions between SCADA, DCS, PLC, PAC, HMI, MES and other technology
categories and application spaces will become even less defined and less important as
these technologies and applications continue to merge via the adoption of common
industry standards and commercial IT technologies and approaches.
While the line between SCADA and DCS appears to be blurring a bit, some important
distinctions remain.
“Distributed Control Systems are very deterministic in nature. SCADA operates in a less
deterministic, ‘select before operate,’ environment, where the control will periodically
time out or deactivate for safety or security reasons. You’d almost never see that happen
in a deterministic DCS,” says Invensys’ Chmilewski. “Another distinction is that, with
SCADA, the hardware and software can be separate platforms. With a DCS, the hardware
and software are bound together into one platform. Most SCADA today still deals with
out-of-plant activities, often across widely distributed assets. However, it’s not
uncommon for a SCADA system to sit over and provide supervisory functions for multiple
different in-plant systems, such as process control, HVAC and laboratory systems,” says
Chmilewski.
Wonderare’s Ballina adds, “Distributed control systems are very process-centric and focus
on controlling the process. SCADA systems are more data-centric and focus on gathering
data while performing supervisory control only. DCSs are permanently connected to their
associated hardware, which is typically in one location. SCADA systems connect to widely
distributed equipment and are better designed to deal with low bandwidth intermittent
communications.”
ABB’s Quesada explains the differences between DCS and SCADA as follows:
While a DCS will typically have a relatively small number of I/O concentrated at a single
site, a SCADA system will typically have a large number of I/O spread over multiple sites.
A DCS is controller-centric, and those controllers will typically be made by the DCS
vendor; SCADA is system-centric and can communicate with many different brands of
RTUs and PLCs. A DCS is designed to communicate with controllers over a high-speed
network; SCADA is designed to communicate over many different communications media
and often at low speeds. DCSs are designed for very fast data acquisition (measured in
milliseconds); SCADA data acquisition operates at moderate speeds (measured in
seconds). The respective approaches to fault-tolerance and recovery also differ. DCSs
have redundant hot servers, preventing disruption in the event of switchover. With
SCADA systems, the redundant server will be in standby mode, requiring seconds to
switchover. Unlike most DCSs, SCADA systems also have the ability to buffer data locally
when communications are interrupted, enabling the upper level SCADA station catch up
with no data loss once communications are restored. This is known as “store and forth of
data.”