Learning Outcome Content Suggested
Assessment
Methods
1. Industrial Industrial communication networks Written
networking Identify control mechanisms used in assessment
industrial automation Project assessment
Oral questions
Transmission media
Portfolio
Wireless: radio waves assessment
Wired: twisted pair, coaxial cable or
fiber optics
Hierarchical levels in an organization
Operational management
Control level
Field level
Functional classification of industrial
communication networks
Device level
Control level
Information level
2. Backup SCADA Establish SCADA system Written
program Extract SCADA program assessments
Operation of SCADA software Observation
Recovery of SCADA program
Troubleshooting and restoring SCADA
program
3. Deploy SCADA Operation of SCADA system Oral assessment
systems Mounting of SCADA system Observation.
Installation of SCADA program on Written
assessment
SCADA system
Network troubleshooting
Documentation of SCADA system
positions
4. Diagnose Correct interconnections of SCADA Observation
SCADA faults system Written
Online diagnostics of SCADA system assessment
Portfolio
Identification of faults in remote
assessment
terminal units
Identification of network faults
5. Replace faulty Preparation of requisition forms as per Oral assessment
SCADA parts operational regulation Observation.
Removal of faulty parts from system Supervisory
Learning Outcome Content Suggested
Assessment
Methods
Replacement of faulty parts with new assessment
parts
Test replaced parts as per maintenance
manual
6. Perform routine Faults diagnostics on SCADA system Oral assessment
maintenance Inspection of remote terminal unit Supervisor report
condition Written
assessment
Inspection of network utilities condition
Servicing of sensors
SCADA system updating
7. Document Filling work orders as per workplace Written
maintenance standards assessment
records Filling maintenance check sheets Trainee
presentation
Generating maintenance reports
Supervisor’s report
SCADA – Supervisory Control and Data Acquisition
Definition:
SCADA is an industrial control system (ICS) used to monitor, control, and analyze industrial
processes from a central location. It combines hardware (sensors, PLCs, RTUs,
communication systems) and software (SCADA servers, HMI applications, databases) to
give operators real-time visibility and control of plant operations.
Core Functions of SCADA
1. Supervisory Control
o Operators can start/stop equipment, adjust setpoints (e.g., motor speed, valve
position), and issue commands remotely.
o Example: Start a water pump at a pumping station from a central control room.
2. Data Acquisition
o Collects real-time data from sensors, meters, and field devices (flow, temperature,
voltage, pressure, etc.).
o Example: A flow transmitter sending readings of liters/second to the SCADA
system.
3. Data Communication
o Uses industrial communication protocols (e.g., Modbus, Profibus, DNP3, OPC-
UA, Ethernet/IP) to link field devices with SCADA servers.
4. Human-Machine Interface (HMI)
o Provides graphical screens where operators view system status (tanks, pipelines,
machines).
o Example: A control room screen showing live water levels, alarms, and pump
status.
5. Historical Data & Reporting
o Stores data in historians (databases) for trend analysis, compliance, and
performance optimization.
o Example: Generating a daily energy consumption report in a factory.
6. Alarm Management
o Generates alerts when process variables exceed limits.
o Example: High-pressure alarm in a boiler system.
SCADA System Architecture
A typical SCADA system has four main layers:
1. Field Devices – Sensors, actuators, transmitters, PLCs, RTUs.
2. Communication Network – Wired/wireless connections, industrial protocols.
3. SCADA Server & Historian – Collects, processes, and stores data.
4. HMI/Operator Station – Visual interface for operators and engineers.
Applications of SCADA in Industry
Power & Energy: Grid monitoring, substation automation, renewable energy integration.
Water & Wastewater: Pump station control, leak detection, water quality monitoring.
Manufacturing & Process Industries: Batch process control, machine monitoring,
quality assurance.
Oil & Gas: Pipeline monitoring, offshore platform supervision, storage tank control.
Transport & Infrastructure: Railway signaling, traffic management, building
automation.
Why SCADA is Important
✅ Centralized monitoring of distributed assets
✅ Increases efficiency and productivity
✅ Enhances safety with alarms and predictive maintenance
✅ Reduces downtime through real-time diagnostics
✅ Provides compliance and audit trails
SCADA vs PLC vs DCS
1. PLC (Programmable Logic Controller)
Role: The “brain” at the machine or process level.
Function: Executes logic (ON/OFF, sequencing, timing, PID control).
Location: Close to machines/equipment (local panels or control cabinets).
Strengths:
o Rugged, fast, real-time control.
o Reliable in harsh industrial environments.
o Can run independently (even without SCADA).
Example: A PLC controlling the filling sequence of a bottling machine.
2. SCADA (Supervisory Control and Data Acquisition)
Role: The “supervisor” and “dashboard” for monitoring.
Function: Collects data from PLCs/RTUs, provides visualization, alarms, historical
logging, and remote control.
Location: Centralized, usually in a control room (but can also be web-based or cloud).
Strengths:
o Wide-area monitoring (factories, pipelines, substations, plants).
o Powerful HMIs for operators.
o Historical trending, reports, alarms.
Example: SCADA showing real-time water levels across 10 pumping stations, with
operators able to start/stop pumps remotely.
3. DCS (Distributed Control System)
Role: The “conductor” for continuous process industries.
Function: Provides both control (like PLC) and supervision (like SCADA), but tightly
integrated.
Location: Plant-wide, usually in oil refineries, chemical plants, power stations.
Strengths:
o Best for continuous, complex processes.
o Hierarchical structure: controllers distributed in plant sections.
o Very reliable, redundancy built-in.
Example: A DCS running an oil refinery’s distillation column, with thousands of I/O
points.
Quick Comparison Table
Feature PLC SCADA DCS
Main Role Machine/field-level Monitoring + supervision Integrated process
control control & supervision
Scope Local equipment Wide area / multiple sites Entire plant, continuous
processes
Control Direct (logic Supervisory (issues Distributed (controllers
execution) commands to embedded in system)
PLCs/RTUs)
User None (unless local Central HMI, alarms, Central HMI with full
Interface HMI panel) reports integration
Industries Manufacturing, Utilities, water, power, Oil & gas, power
packaging, robotics transport generation, chemical,
pharma
Scale Small to medium Medium to very large Large continuous plants
Dependency Independent, can work Needs PLCs/RTUs to Comes as a complete
alone function solution