HIERARCHY OF PROCESS CONTROL

Level 0 after measurement send s the measured data to Level-1 for process control functions. At this
level , functions such as process visualization & control , central operation & monitoring, system
coupling etc. are performed by the computer.

At Level 2, supervisory function is implemented such as data collection, process optimization, etc. At this
level, process oriented mathematical models are implemented to achieve overall process optimization.
At Plant level automation (Level-3) , functions such as plant resource allocation, production planning &
scheduling , production accounting , etc are carried out.

On the basis of inputs such as sales orders, stock level, selling cost, profit margins, operating cost,
scheduled maintenance plans for production units, etc. the production schedule is prepared by Level-3
computer and communicated to the supervisory level (Level-2) computer.

The Level-2 computer calculates the required set points for various parameters to meet the above
production schedule using product recipe and operation sequences already stored in its database.

These set points are then downloaded to process control (Level-1) computer to take control actions to
maintain the set points. Level 3 computer records and monitors all plant/process parameters and
various events, alarm conditions, production and quality details and transfer these to the corporate level
(level -4) for management information (MIS) purposes.
SCADA system usage have became popular from the 1960s with the increase in need
of monitoring and controlling the equipment. Early systems built using mainframe
computers were expensive as they were manually operated and monitored. But the
recent advancements in technology have made-advanced, automated SCADA systems
with maximum efficiency at reduced cost, according to the alarming requirements of the
company.

SCADA Basics

Before discussing about the architecture of SCADA and different types of SCADA
systems, primarily we must know a few SCADA basics. Consider the block diagram of
SCADA system shown in the figure which consists of different blocks, namely Human-
machine Interface (HMI), Supervisory system, Remote terminal units, PLCs,
Communication infrastructure and SCADA Programming.

1. Human-machine Interface (HMI)

It is an input-output device that presents the process data to be controlled by a human

operator. It is used by linking to the SCADA system’s software programs and
databases for providing the management information, including the scheduled
maintenance procedures, detailed schematics, logistic information, trending and
diagnostic data for a specific sensor or machine. HMI systems facilitate the operating
personnel to see the information graphically.
 Human-Machine Interface
2. Supervisory System

Supervisory system is used as server for communicating between the equipment of the
SCADA system such as RTUs, PLCs and sensors, etc., and the HMI software used in
the control room workstations. Master station or supervisory station comprises a single
PC in smaller SCADA systems and, in case of larger SCADA systems, supervisory
system comprises distributed software applications, disaster recovery sites and multiple
servers. These multiple servers are configured in a hot-standby formation or dual-
redundant, which continuously controls and monitors in case of a server failure for
increasing the integrity of the system.

3. Remote Terminal Units

Physical objects in the SCADA systems are interfaced with the microprocessor
controlled electronic devices called as Remote Terminal Units (RTUs). These units are
used to transmit telemetry data to the supervisory system and receive the messages
from the master system for controlling the connected objects. Hence, these are also
called as Remote Telemetry Units.
4. Programmable Logic Controllers

In SCADA systems, PLCs are connected to the sensors for collecting the sensor output
signals in order to convert the sensor signals into digital data. PLCs are used instead of
RTUs because of the advantages of PLCs like flexibility, configuration, versatile and
affordability compared to RTUs.

5. Communication Infrastructure

Generally the combination of radio and direct wired connections is used for SCADA
systems, but in case of large systems like power stations and railways SONET/SDH are
frequently used. Among the very compact SCADA protocols used in SCADA systems –
a few communication protocols, which are standardized and recognized by SCADA
vendors – send information only when the supervisory station polls the RTUs.

6. SCADA Programming

SCADA programming in a master or HMI is used for creating maps and diagrams which
will give an important situational information in case of an event failure or process
failure. Standard interfaces are used for programming most commercial SCADA
systems. SCADA programming can be done using derived programming language or C
language.

Architecture of SCADA

Generally the SCADA system includes the following components: local processors,
operating equipment, PLCs, instruments, remote terminal unit, intelligent electronic
device, master terminal unit or host computers and a PC with human machine interface.

Architecture of SCADA
The block diagram of SCADA system shown in the figure represents the basic SCADA
architecture. The SCADA (supervisory control and data acquisition) systems are
different from distributed control systems that are commonly found in plant sites. When
distributed control systems cover the plant site, SCADA system cover much larger
geographic areas.

Above figure depicts an integrated SCADA architecture which supports TCP/IP, UDP
and other IP based communication protocols as well as industrial protocols like Modbus
TCP, Modbus over TCP or Modbus over UDP. These all work over cellular, private radio
or satellite networks.

In complex SCADA architectures, there are a variety of wired and wireless media &
protocols involved in getting data back to the monitoring site. This allows
implementation of powerful IP based SCADA networks over landline, mixed cellular and
satellite systems. SCADA communications can utilize a diverse range of wired and
wireless media.

The choice of the existing communication depends on the characterization of a number

of factors. The factors are remoteness, available communications at the remote sites,
existing communications infrastructure, polling frequency and data rates. These factors
impact the final decision for SCADA architecture. Therefore, a review of SCADA
systems evolution allows us to better understand many security concerns.

4 Types of SCADA systems

There are different types of SCADA systems that can be considered as SCADA
architectures of four different generations:

1. First Generation: Monolithic or Early SCADA systems,

2. Second Generation: Distributed SCADA systems,
3. Third Generation: Networked SCADA systems and
4. Fourth Generation: Internet of things technology, SCADA systems

1. Monolithic or Early SCADA Systems

Minicomputers are used earlier for computing the SCADA systems. In earlier times,
during the time of first generation, monolithic SCADA systems were developed wherein
the common network services were not available. Hence, these are independent
systems without having any connectivity to other systems.
 Monolithic or Early SCADA Systems

All the remote terminal unit sites would connect to a back-up mainframe system for
achieving the first generation SCADA system redundancy, which was used in case of
failure of the primary mainframe system. The functions of the monolithic SCADA
systems in the early first generation were limited to monitoring sensors in the system
and flagging any operations in case of surpassing programmed alarm levels.

2. Distributed SCADA Systems

In the second generation, the sharing of control functions is distributed across the
multiple systems connected to each other using Local Area Network (LAN). Hence,
these were termed as distributed SCADA systems. These individual stations were used
to share real-time information and command processing for performing control tasks to
trip the alarm levels of possible problems.

Distributed SCADA Systems

The cost and size of the station were reduced compared to the first generation system, as each
system of the second generation was responsible for performing a particular task with reduced
size and cost. But even in the second generation systems also the network protocols were not
standardized. The security of the SCADA installation was determined by a very few people
beyond the developers, as the protocols were proprietary. But generally the security of the
SCADA installation was ignored.

3. Networked SCADA Systems

The current SCADA systems are generally networked and communicate using Wide
Area Network (WAN) Systems over data lines or phone. These systems use Ethernet or
Fiber Optic Connections for transmitting data between the nodes frequently. These third
generation SCADA systems use Programmable Logic Controllers (PLC) for monitoring
and adjusting the routine flagging operators only in case of major decisions
requirement.

The first and second generation SCADA systems are limited to single site networks or
single building called as sealed systems. In these systems, we can not have any risk
compared to the third generation SCADA system which are connected to the internet
causing the security risks. There will be several parallel working distributed SCADA
systems under a single supervisor in network architecture.

4. Internet of Things

In fourth generation, the infrastructure cost of the SCADA systems is reduced by

adopting the internet of things technology with the commercially available cloud
computing. The maintenance and integration is also very easy for the fourth generation
compared to the earlier SCADA systems.
These SCADA systems are able to report state in real time by using the horizontal scale
from the cloud computing facility; thus, more complex control algorithms can be
implemented which are practically sufficient to implement on traditional PLCs.

The security risks in case of decentralized SCADA implementations such as a

heterogonous mix of proprietary network protocols can be surpassed using the open
network protocols such as TLS inherent in the internet of things which will provide
comprehendible and manageable security boundary.

Applications of SCADA

SCADA systems are used for monitoring a variety of data like flows, currents, voltages,
pressures, temperatures, water levels, and etc., in various industries. If the system
detects any abnormal conditions from any monitoring data, then the alarms at the
central or remote sites will be triggered for alerting the operators through HMI.

There are numerous applications of SCADA systems, but a few most frequently used
SCADA applications include:

1. Manufacturing Industries
2. Waste Water Treatment and Distribution Plants
3. SCADA in Power System
1. SCADA In Manufacturing Industries

In manufacturing industries the regular processes like running the production systems to
meet the productivity targets, checking the number of units produced and counting the
completed stages of operations along with temperatures at various stages of the
manufacturing process, and so on, are taken care by using the SCADA application.

2. SCADA Application in Waste Water Treatment and Distribution Plants

Wastewater treatment plants are of different types such as surface-water treatment and
a well water treatment system in which many control systems and automation
processes are involved in water treatment and distribution systems. SCADA systems
are used for controlling the automatic operations of the equipment used like
backwashing the filters based on the hours of working or amount of water flow through
the filters.

In distribution plants the water tank levels, pressure of system, temperature of plant,
sedimentation, filtration, chemical treatment and other parameters or processes are
controlled using the SCADA applications such as PLCs, PC based workstations which
are connected each other using Local Area Network (LAN) such as Ethernet.

3. SCADA in Power System

Power system can be defined as constituent of power generation, transmission and

distribution. All these sectors are needed to be monitored regularly for improving the
system efficiency. Thus, the application of SCADA in power system improves the overall
efficiency of the system by providing the supervision and control over the generation,
transmission and distribution systems. SCADA in the power system network increases
the system’s reliability and stability for integrated grid operation.
Wireless SCADA

In large scale industries like power plants, steel plants and so on, many processes and
operations such as movement of conveyer belts for coal or product transport, boiler heat
temperature, etc. are to be monitored continuously and there is need to control the
factors affecting these parameters. So, application of wireless SCADA will provide
better control over the required control systems and operations.
In this project 2.4 GHz wireless transmitter and USB receiver are used for sending and
receiving the data collected from the temperature sensors which interface with 8051
microcontroller. If the temperature goes beyond the set limit whether the low limit or
high limit, then the microcontroller sends commands to the relays to turn on or off based
on the command signal.

Monitoring and controlling of multiple operations in maximum number of industries are

being automatically controlled by most advanced SCADA technology implementations.
Already we are observing that many industrial operations are automatically controlled
using the application of SCADA system technology, but still many researchers are
working to develop more efficient SCADA systems for adopting full automatic control of
all types of industrial operations. Having any queries and ideas? Post your comments in
the comment section below for any technical help for implementing your ideas to
develop real time projects.
 RS-232 INTERFACE
Introduction:

The RS-232 interface is the Electronic Industries Association (EIA) standard for the
interchange of serial binary data between two devices. It was initially developed by
the EIA to standardize the connection of computers with telephone line modems. The
standard allows as many as 20 signals to be defined, but gives complete freedom to
the user. Three wires are sufficient: send data, receive data, and signal ground. The
remaining lines can be hardwired on or off permanently. The signal transmission is
bipolar, requiring two voltages, from 5 to 25 volts, of opposite polarity.

Communication Standards:

The industry custom is to use an asynchronous word consisting of: a start bit, seven or
eight data bits, an optional parity bit and one or two stop bits. The baud rate at which
the word sent is device-dependent. The baud rate is usually 150 times an integer
power of 2, ranging from 0 to 7 (150, 300, 600 ,...., 19,200 ). Below 150 baud, many
system-unique rates are used. The standard RS-232-C connector has 25 pins, 21 pins
which are used in the complete standard. Many of the modem signals are not needed
when a computer terminal is connected directly to a computer, and Figure 1 illustrates
how some of the "spare" pins should be linked if not needed. Figure 1 also illustrates
the pin numbering used in the original DB-25 connector and that commonly used with
a DB-9 connector normally used in modern computers.

Refer ppts for RS232/RS422/RS485