SCADA Supervisory Control And Data Acquisition

SCADA systems are actively used for industrial and power control

Purpose and objectives of SCADA systems

SCADA systems are designed for monitoring and dispatch control of a large number of remote facilities (from 1 to 10,000, sometimes at a distance of thousands of kilometers from each other) or one geographically distributed facility. Such facilities include oil pipelines, gas pipelines, water pipelines, electrical distribution substations, water intakes, diesel generator stations, etc.

The main task of SCADA systems is to collect information about many remote objects coming from control points and display this information in a single control center. Also, the SCADA system shall provide long-term archiving of the obtained data. The dispatcher often has the ability not only to passively observe the object, but also to control it, responding to various situations.

Tasks of SCADA systems:

• data exchange with RTU (communication devices with the object, that is, with industrial controllers and I/O boards) in real time through drivers;
• Real-time information processing
• displaying information on the monitor screen in a form that is understandable to the person;
• maintaining a real-time database with process information;
• Alarm and alarm management
• preparation and generation of process progress reports;
• communication with external applications (DBMS, spreadsheets, word processors, etc.).

SCADA System Structure

SCADA System Structure

Any SCADA system includes three components: a Remote Terminal Unit (RTU), a Master Terminal Unit (MTU) and a Communication System (CS).

The remote terminal connects directly to the monitored object and performs real-time control. Such a terminal can be both a primitive sensor that takes information from an object, and a specialized multiprocessor fault-tolerant computing complex that performs information processing and control in real time.

The control room performs data processing and high-level control, usually in quasi-real time mode. It provides a man-machine interface. The MTU can be either a single computer with additional communication connection devices, or a large computer system or a local network of workstations and servers.

The communication system is required to transfer data from the RTU to the MTU and back. The following data transmission channels can be used as a communication system: dedicated lines, radio networks, analog telephone lines, ISDN networks, GSM cellular networks (GPRS). Often, devices connect to several networks to ensure reliable data transmission.

Control Process Features in SCADA Systems

• In systems SCADA , the presence of a person (operator, dispatcher) is mandatory.
• Any incorrect impact can lead to a failure of the control object or even catastrophic consequences.
• The dispatcher is generally generally responsible for managing a system that, under normal conditions, only occasionally requires adjustment of parameters to achieve optimal operation.
• Most of the time, the manager passively observes the displayed information. Active participation of the dispatcher in the control process occurs infrequently, usually in the event of critical events - failures, emergency and emergency situations, etc.
• Operator actions in critical situations can be severely limited in time (several minutes or even seconds).

Protection of SCADA systems

There is an opinion among some users of SCADA systems - if the system is not connected to the Internet, thereby it is insured against cyber attacks. Experts disagree.

Physical isolation is useless against attacks on SCADA systems, said Faizel Lakhani, an expert on protecting information resources. In his opinion, physical isolation of systems is tantamount to fighting windmills^[1]

Most SCADA systems are theoretically isolated, but they are still not completely disconnected from the network. In addition, there are ways to bypass isolation due to incorrect system configuration, the presence of test links, or because someone has configured a Wi-Fi bridge. Management systems used at enterprises of the electric power sector were created without taking into account safety. They were designed to control the current voltage - and that's all they do to this day. SCADA technology was based on protocols that are outdated by today's standards, and systems were originally created with the ability to connect to each other, but not to the Internet. However, the ubiquitous TCP/IP protocol has reached SCADA systems over the past 15 years. In the world of the Internet, almost everything is connected, which means it cannot be considered safe. Faizel Lakhani, president of the company SS8

The opinions of Russian experts regarding the security of the APCS and SCADA systems are consonant. Since I&C security issues have come to the attention of the public, some manufacturers of security solutions have begun to develop products focused on countering threats to industrial information complexes (such products, in particular, may include a secure operating system - an environment for the functioning of only trusted applications)^[2].

Individual companies began to prepare analytical materials on these issues, making attempts to assess the state of the APCS from the point of view of security. The response to these initiatives from specialists working with industrial systems is mixed and not always approving. An outside observer can conclude: there is a misunderstanding between the I&C operators and the developers of information security tools - manufacturers are trying to create something specifically for the needs of owners and users of industrial information systems, but this does not work out very well.

One way or another, the general opinion of the expert community is that the state of security of the APCS is very weak. On the one hand, there are powerful control subsystems that provide the operator with full control over production processes, including in strategic sectors of the economy, where any failures are dangerous, and on the other hand, with due skill and a share of carelessness on the part of the company, this operator can become a very, very extraneous person. There are few practices for ensuring information security at industrial enterprises, management is inclined to overestimate the security of APCS, and companies working in the field of information protection often do not understand the real needs of this sector and the principles of functioning of industrial information systems. Integrators and consultants can attract far from the widest range of security solutions to build their security system, which, to a large extent, is facilitated by an inflexible certification policy and not very active production of these products in Russia.

How today's HMI/SCADA solutions can accelerate the transition to Industry 4.0

Most of the data used by IoT industrial solutions comes from HMI/SCADA automation software. How to accelerate the transformation of production with this in mind? Automation technologies such as HMI/SCADA software have been around for many years. They provided the impetus for what many call the "third industrial revolution." In 2020, when the next phase known as "Industry 4.0" is reached, many companies are rethinking their futures and trying to understand how they can realize the benefits brought by digital transformation. Automation solutions are an integral and key part of the process, opening an era in which operational data is immediately analyzed with algorithms artificial intelligence /.machine learning AI automatically optimizes operations through a "closed loop" or warns a person about further actions. HMI/SCADA allows for more informed decisions for rapid response. Converting operational data into analytics, which can then be used to streamline processes, brings true business value, turning automation into a layer on which users can build their digital transformations. In fact, automation becomes the basis of the company's digitization strategy^[3].

Digital conversion helps reduce costs

Risk assessment

Since the launch of the operating technology^[4]. manufacturers face three main challenges: how to simultaneously increase availability, manage risk, and reduce costs. The ultimate goal is to ensure optimal asset performance to maximize desired outcomes. Manufacturers can use HMI/SCADA to improve visibility, optimize operations, and improve quality and performance. Quick look - operators know what is important and what actions will be right to improve efficiency and reduce costs. Initially, you need to go through the stage of risk assessment. It includes the process of assessing the criticality of all assets within the business and assessing: high, medium and low. Analytical solutions then provide an optimized plan to reduce costs while reducing the risk of failure accordingly, taking into account probabilities and consequences. The recommendations issued by the analytics are returned to the process through the automation level, HMI/SCADA, in which case the operator will be able to check the recommended parameters before sending them to the real process or directly to the PLC. This data transformation is used to make better decisions, proactivity, and process optimization.

Why modern automation software matters

Eighty-five percent of the data used by analytical tools such as asset performance management (APM) software or operations management (OPM) software comes "from the field" (OT data). Thus, proper adjustment of the automation level is necessary to enable decision-making in Industry 4.0.

The main purpose of automation software is to provide the operator with a window in the application with mnemonic diagrams, trend views, signal views, alarms, etc. However, new technologies make HMI/SCADA more powerful, easier to use and more "connected."

Mobility is increasingly important. Now operators want to view operational data where they are, "in the field," and not only in the place of the operator. The COVID-19 crisis has shown how important it is to work remotely to keep our critical infrastructure enterprises running.

People want to access our personal information from anywhere and anytime with their smartphone; The same applies to process or production data. A plant manager who is en route or must be separated from a business should be able to monitor the enterprise while away from the office.

Digital conversion does not always mean that everything must be in the cloud.

Many tools can be deployed locally as part of the company's automation or workflow management solutions, which essentially become the edge node for the industrial internet.

Digital workflow management software has huge results and can be deployed on top of the existing level of automation, providing (almost) paperless installation.

Typical applications range from standard operating procedures to maintenance procedures or operator rounds.

Key factors

Digital conversion does not happen overnight; this is a long way. Like any journey, it must include a clear and achievable goal, whether financial, operating or any other. For the journey to be successful, you need to take the right steps. It is recommended to take one step back, return to the aspects of IT and OT to identify the main problems.

It will not be harmful to include a pair of external, fresh eyes in the team to ask questions. For example, how can you save on production losses to be more competitive? How can maintenance strategies be optimized and downtime reduced? How do I reduce risk and improve productivity?

Once the goals are established, the next task is to draw up an implementation plan. Many industrial facilities have already begun the journey without realizing it themselves. But travel can also have challenges. One of the key issues identified within Industry 4.0 and the Industrial Internet Consortium is interoperability. With the advent of standards like OPC UA, this is becoming less of a problem. When the OPC UA is applied to the automation layer, it not only provides connectivity, but also provides structured data security. It is not possible to manage, analyze or optimize what is not visible. For existing installations or infrastructures, it is important to ensure that there is no disruption to production and operating technology during the digitization process. In contrast to implementing ERP systems, it is recommended to start small and deploy the new system in its own rhythm.

Start with the automation layer

The first step is to modernize what exists, assess the gaps and start building on this assessment. Automation technologies can help reduce the risk of failures and become a very valuable deployment border point. These are mature and proven technologies that can deliver new capabilities, ensuring that the app remains secure, accessible and compatible.

Thus, the digital conversion process must take into account the needs of the user and ensure that the changes affect the operator positively. The goal is to make life easier for operators, engineers, production management, etc.

Modern HMI/SCADA can deliver content to any connected device - PC, smartphone, tablet - providing tools that meet the user's needs. Mobile devices have demonstrated the ability to improve efficiency, and recent studies have shown that operators with mobile AWS are 30% more efficient than operators using stationary devices.

Thus, if we consider the path of digital transformation, it begins with a layer of automation.

The flexibility of the automation layer helps to combine all the necessary data and can reduce the gap between heterogeneous systems at low costs with the speed and accuracy necessary to gain a holistic understanding of the application.

By using automation as the main part of digital conversion, it is possible to take advantage of many of its advantages.

SCADA Systems and Projects Catalog

Main Directory Partition: SCADA

Chronicle

2024: Global Data Acquisition and Dispatch Systems Market Size Reached $41.75 Billion for the Year

In 2024, Global Data Acquisition and Dispatch Systems Market Expenditures control (SCADA) amounted to $41.75 billion. More than a third of the specified amount fell on the North American region. This is stated in the study Fortune Business Insights, the results of which TAdviser reviewed in early October 2025.

SCADA is specialized software that is used by for real-time dispatch control and data collection. Such systems allow timely detection and prevention of emergency situations, reducing equipment downtime. The information received can used to optimize processes, which helps reduce operating costs, as well as more efficient use of resources and materials. SCADA tools enable process management remotely, including from mobile devices. At the same time, certain actions and reactions can be programmed based on given conditions that promotes automation.

Industry analysts call the development of the concept of "Industry 4.0" (fourth industrial revolution) and the ongoing digital transformation enterprises in various fields. Companies are increasingly implementing SCADA systems for Intelligent Operations Management and Enhancement autonomy, as well as to improve the quality of products, general performance, flexibility, and efficiency. SCADA integration with cloud platforms, cyberphysical systems and artificial intelligence.

The COVID-19 pandemic has had a significant impact on the industry. From one side, it led to disruption of enterprises and supply chains, as well as provoked delays in the implementation of projects in the field of digitalization. But, with on the other hand, against the background of the spread of coronavirus, the need for automation of work processes and reduction of the number of employees. It stimulated additional demand for SCADA solutions.

The authors of the study cite significant as the main deterrent initial investments related to the deployment of SCADA systems, including Hardware Procurement, Software Integration and customization for specific company requirements. To maintain operation SCADA platforms require highly qualified specialists, resulting in increased operating costs.

Study Authors Segment Market into Hardware, Software provision and services. In 2024, the largest share in total revenue provided services, while software accounted for about a third of all expenses - 32,9%. In terms of application, industrial production is distinguished, electric power enterprises, oil and gas industry, telecommunications, automotive and transport, etc. A significant contribution to market growth is made by the first of the listed directions. From a geographical point of view North America dominates, accounting for 37.7% of spending, or $15.74 billion Major players on a global scale are:

• ABB;
• Schneider Electric;
• Rockwell Automation;
• Emerson Electric;
• Honeywell International;
• Siemens;
• Omron;
• Toshiba Infrastructure Systems and Solutions;
• Yokogawa Electric;
• Mitsubishi Electric.

By the end of 2025, the global SCADA market size, as predicted, will reach $44.59 billion. Fortune Business Insights analysts believe in further compound percentage CAGR will be 8.4%. Thus, by 2032, costs may increase to ^[5]

Notes