SCADA Systems
SCADA (Supervisory Control and Data Acquisition) systems are essential tools for monitoring various parameters in industrial environments. The collection of this data is done through sensors and transmitters, which are connected to a communications network that can be either wired or wireless.
Over the last 15 years, SCADA software has evolved significantly. Initially, their implementation was at the local level, but over time they have become distributed systems on multiple computers, with access to them via the internet and even mobile devices. Over the years, at Avanzate, we have worked with a variety of SCADA systems, including Wonderware Intouch, Wonderware Archestra, Siemens WinCC, Rockwell Factory Talk, and Omnon CX-Supervisor.
What is a SCADA system?
A SCADA system is an industrial automation and control tool used in various industries to supervise and manage production processes. These systems allow operators to monitor equipment and devices from a centralized location, providing real-time information and facilitating remote control.
The main function of a SCADA system is the acquisition and analysis of data, gathering information from sensors and industrial instruments. This information is presented clearly through a graphical interface, showing graphs, alarms and trends. In addition, SCADA systems store historical data for further analysis and reporting, helping to improve efficiency and optimize industrial processes.
Types of SCADA systems
There are several types of SCADA systems, each designed to meet different needs and scales of operation. The main types of SCADA systems are:
Monolithic
Also known as first generation systems, they were the first to be developed and are based on mainframe computers. These systems are autonomous and isolated from other systems, without connections to external networks, which makes them very secure against external attacks but limited in terms of integration and communication.
Distributed
Distributed, or second-generation, SCADA systems have improved on the monolithic architecture by introducing local area networks (LANs) that allow communication between multiple control stations and remote units. In these systems, data are collected and processed in a distributed manner, which improves system efficiency and redundancy. In addition, user interfaces can be located at different points within the network, which facilitates decentralized monitoring and control.
In Network
These systems use wide area networks (WAN) to connect geographically distributed SCADA systems, enabling monitoring and control of remote facilities from a centralized location, which is ideal for companies with dispersed operations, such as power grids, oil and gas pipelines. Integration with wider networks allows for better information exchange and coordination between different parts of the system.
Web-based
Web-based SCADA systems are a more recent evolution that leverages internet technologies to provide remote and flexible access to SCADA system data and controls. These systems allow operators to access the SCADA interface from anywhere via web browsers, mobile devices or dedicated applications. This significantly improves system accessibility and responsiveness , enabling real-time monitoring and control from any location.
In the Cloud
These cloud systems take the idea of accessibility even further by hosting the SCADA infrastructure on cloud computing platforms. This reduces the need for local hardware and allows for almost unlimited scalability, as well as the ability to easily integrate additional cloud-based services such as advanced analytics and data storage. Security and redundancy are handled by cloud service providers, which can simplify system management.
Hybrid
Hybrid SCADA systems combine elements of the above types to create a customized solution that leverages the advantages of each approach. For example, a hybrid SCADA system can use cloud infrastructure for data storage and analysis, while maintaining local controllers and distributed networks for critical real-time operations. This allows for optimal flexibility and adaptability to suit the specific needs of each organization.
What is a SCADA system for?
SCADA systems offer a variety of essential functions for the monitoring and control of industrial processes. This type of system allows companies to:
- Industrial process control: Manage your industrial processes locally or remotely.
- Real-time monitoring: Collects and transmits data in real time, facilitating constant monitoring by operators.
- Device interaction: Facilitates direct interaction with sensors, valves, motors and HMI (Human Machine Interface).
- Event logging: Sequentially records events in a file or database for later analysis.
- Alarm generation: Detects problems and generates alarms to notify operators of machine malfunctions.
- Maintenance management: Uses the magnitudes obtained to manage preventive and corrective maintenance.
- Quality control: Helps in quality control by means of data collected during the production process.
- Data analysis: Analyzes the data obtained to generate reports and make informed decisions.
- Equipment control: It can directly control process equipment and plants, activating or deactivating motors, and opening or closing valves as required.
How does a SCADA system work?
The basic structure of a SCADA system consists of programmable logic controllers, also known as PLCs or remote terminal units(RTUs), which communicate with a variety of instruments, such as manufacturing machinery, HMIs, sensors and end devices. These devices are responsible for collecting essential data on the operation of the production process, which are transmitted to computers running the software.
Once the data is received, the SCADA software processes, distributes and displays it in real time through user interfaces(HMI). Operators and maintenance technicians use these interfaces to analyze the SCADA data and make informed decisions about the industrial process.
For example, if a high incidence of errors is detected in a batch of product, the operator can stop production and analyze the cause of the problem using the HMI. Maintenance technicians can review the data to identify the cause of the problem, such as a faulty machine.
How does a scada system obtain data?
SCADA systems obtain data from various components that work together to monitor and control industrial processes. Sensors are responsible for measuring physical variables such as temperature, pressure and flow, which generate electrical signals that are sent to PLCs (Programmable Logic Controllers) or RTUs (Remote Thermal Units). These devices process the signals and transmit the relevant information.
Once processed, the data is sent to servers, which centralize, store and process large volumes of information. These servers also host data historians, which store historical data for analysis and reporting. This historical data is essential for detecting trends, identifying anomalies and optimizing processes.
The visualization and control of data is done through Human Machine Interfaces(HMI), which present data in real time and allow operators to monitor system status and make informed decisions, facilitating manual control of processes.
Finally, data is stored in databases and application servers, allowing fast and efficient access to information. Gateways and communication modules guarantee interoperability between different networks and protocols, ensuring that data can flow freely between all SCADA system components.
Applications
SCADA systems have a wide range of applications in various industrial sectors. At Avanzate, we have software for the metallurgy sector. Here, they are used to control the running and shutdown of equipment and lines, as well as to monitor product yield and quality.
Alarm activation
SCADA systems constantly monitor process variables and compare measured values to predefined limits . When a variable exceeds these limits, such as excessive temperature, the SCADA system triggers an alarm notifying operators of the conditions, allowing a quick response to correct potential problems before they become major failures, improving process safety and efficiency.
Historize Values
The data collected by the sensors and processed by the PLCs or RTUs are stored in a data historian. This historian continuously and systematically records process variables, creating a historical database that can be queried at any time. Data historization is essential for performing long-term trend analysis, evaluating system performance, and meeting reporting and auditing requirements. In addition, this functionality allows you to identify patterns that could indicate recurring problems, facilitating preventive maintenance and system optimization.
Graphing Values
Value graphing provides operators with a clear and understandable display of real-time and historical data . SCADA system HMIs can generate graphs and trends that show how process variables change over time. These graphs can be customized to show specific data and particular time periods, helping operators quickly identify deviations or anomalies in the process making it easier to make informed decisions, diagnose problems and communicate complex information in a visual and accessible way.
Advantages of using a SCADA system
- Increased efficiency and productivity through process automation.
- Reduced operating costs and downtime.
- Customization of products and services to meet customer needs.
- Improved product quality.
- Greater flexibility and capacity to adapt to market demands.
- Improved strategic decision making with real-time data.
Components
- HMI (Human Machine Interface): This interface facilitates interaction between the operator and the machinery, presenting process data in an understandable way and allowing control through an intuitive touch screen.
- Supervisory System or MTU: Responsible for collecting process data and sending the necessary instructions for its control and management. This component centralizes the operation of the system, managing the communication with the different devices and acting as the brain of the SCADA.
- Remote Terminal Units (RTU): These microprocessors capture signals independent of the environment and transmit them for remote processing. They are essential for real-time data acquisition and monitoring of critical variables in the industrial process.
- PLC (Programmable Logic Controller): PLCs are versatile and configurable devices that control equipment and processes in the field. They offer an economical and flexible solution for task automation, enabling efficient and safe operation.
Frequently Asked Questions
What is a SCADA system?
A SCADA system is a control and supervision tool for acquiring and controlling plant data. It is connected to the plant PLCs to monitor and control the production process.
What SCADA systems do we work with?
Over the past 15 years, we have worked with SCADA systems such as Wonderware Intouch, Wonderware Archestra, Siemens WinCC, Rockwell Factory Talk and Omnon CX-Supervisor.
What are the benefits of implementing a SCADA system in a factory?
Benefits include improvingproduction process control, optimizing operational efficiency, reducing downtime and facilitating data-driven decision making.
How can a SCADA system help improve factory safety?
A SCADA system can provide early warnings of potential safety problems, enabling a rapid response to avoid accidents and minimize risks to workers.
What support and maintenance services do you offer for SCADA systems?
We offer ongoing technical support services, software upgrades, preventive and corrective maintenance, as well as personnel training to ensure optimal operation of the SCADA system.