Data Modeling – The Future of SCADA?

SCADA systems have undergone numerous evolutions since their inception many decades ago. Innovations in technology and control systems have led software developers to develop new SCADA software to keep up with the changing industrial workplace. Data Modeling is one of the many new features some of the pioneering SCADA developers are introducing. The idea is that the complexity of large systems with numerous assets can be reduced, making the entire systems more understandable and manageable using a data model.

Anyone involved in process automation has had the misfortune of trying to make sense out of many different types of data from many different sources. When HMI screens are bound directly to data coming from PLCs, there are several problems that can emerge:

• First of all, creating the screens and data bindings requires an intimate knowledge of the many memory addresses in each logic controller – this means there is usually only one individual or a small group capable of creating or modifying the screens.
• This also means that the PLCs have to be running and returning live data while the HMI screens are being set up – this can lead to unnecessary downtime and more complicated deployments.
• Any change in the process or processes requires a time significant investment in modifying the HMI displays to coordinate with the new data.

With a little imagination, I’m sure most people can think of several other drawbacks to binding HMI graphics directly to PLC memory addresses.

How Does Data Modeling Help?

In the world of SCADA, a data model is a logical representation of a real world system. A data model contains instances of all assets that are to be measured, along with properties of those assets (i.e. temperature, velocity, volume, etc.). When using a data model, HMI graphics are bound to properties of these assets rather than the actual data. The actual data is read to the model and the HMI updates accordingly.

Data modeling provides a number of advantages:

• Creating HMI screens and data bindings does not require knowledge of the specific memory addresses since the graphics are bound to the model – screens can be created quickly and easily
• HMI screens can be created independently of the PLCs – this means the entire SCADA system can be set up without having to take the process down.
• If assets are lost or changed – or new ones are added – simply update the data model and every instance of the asset can be modified simultaneously – this means HMI screens can be reused instead of recreated, saving countless hours of development and training time.
• A well-designed data model can give a unique overall perspective on a process that makes it easier to make plans and decisions about how the data can be used to make improvements.

Data modeling also allows new types of data to be monitored and controlled. Your data model can include work orders, purchase requests, human resources, supply chain data – in short your entire enterprise can now fall under the watchful eye of your SCADA system. This creates whole new possibilities for management and strategic planning.

Case in Point

Consider a recently developed SCADA application from B-Scada: Status Enterprise Edition. Status Enterprise allows users to create a logical model of their enterprise, including everything from equipment to users. Each type of equipment can be created with all associated properties, alarms and historical records. If there are 1000 instances of a particular asset, just create the type once and automatically generate 1000 instances of it. Assets can be grouped into collections, or one asset can be subordinated as a component of another (i.e a motor that has a cooling fan as a component). Work orders, maintenance records and troubleshooting guides can be created and associated with particular assets.

Aside from making data more manageable, modeling can also make creating HMI screens much easier. Imagine you have 1000 motors that each have a unique temperature value, a unique RPM value, a unique asset tag, etc. Since each of these motors is an instance of the same type, one screen template can be created for that type. That template can then be used to create 1000 unique screens for each instance of that type. This can save a tremendous amount of time (and money) in developing or updating a SCADA system.

Data modeling is not a new idea, but it is fairly new to the world of SCADA software, and it seems a safe bet to assume that it is not going anywhere. In fact, it’s likely that it will eventually be the way that all SCADA software operates. 

What’s Wrong with My Antique HMI? It’s a Classic!

You would think that if you plan to pay someone to sit in front of a screen (or a bunch of screens) all day every day, you would want those screens to be as effective and performance-oriented as possible. You would think that every possible effort would be employed to ensure that this employee was given all of tools available to assist him/her in performing his/her assigned duties. That’s what you would think.

Unfortunately, for many process control operators and technicians, this is not the case at all. They are relegated to using screens designed 20 years ago or more, using outdated graphics and without any concept of the HMI design best practices that have been developed over the last couple of decades.

You would think that the research on industrial accidents that has pointed unequivocally to poor HMI screen design as a primary contributing factor in process failures that have cost millions of dollars – even killed several people – would lead our captains of industry to recognize the hidden cost in employing outdated screens. You would think all kinds of things that are apparently not true if thinking is something that you’re into.

So, why is nobody upgrading their HMI displays? Money. The cost is too much when people are of the belief that what they have works just fine. The problem is that it is not easy to quantify the cost of what could be, and so people are left with just the cost of what is. And, frankly, what is isn’t good enough.
What makes a good HMI screen? There are different schools of thought on that, but there are some factors that most agree are necessary in a high performance display:

• Clarity - Graphics are easy to read and clearly show the process state and conditions. Graphics will display relevant information and not just data. Alarms and indicators of abnormal conditions are clear and prominent.
• Consistency - Graphics are standardized and consistently formatted. Interaction requires a minimum of keystrokes or pointer manipulations. Navigation is arranged in a logical, heirarchical manner.
• Feedback - Controls will function consistently in all situations. Important actions have confirmation mechanisms to prevent inadvertent activation. Design principles are employed to reduce user fatigue.

Of course, much more can be said on the subject, and much more has been written. There are numerous best practices and techniques that can be used to ensure your HMI screens are efficient and performance-oriented. Too few of them are.

It is a researched and verified fact that an improved HMI means fewer accidents, less downtime, less human error, greater efficiency, and greater anticipation and control of abnormal conditions.


The next time you consider how much it would cost to upgrade your HMI displays, do yourself a favor and consider how much not doing it is already costing you.

How SCADA Shapes the World (Part 1 – Water)

There was a time when hearing someone use terms like scum, sludge, or grit chamber would have made me think I was listening in on the creation of a new comic series or primetime TV drama. Now, when I hear these terms (which, incidentally, is not often) I know that I am actually listening in on a discussion about something much more significant. These are terms used in the waste water treatment industry. I know “waste water” is not really a hot buzzword with the kids today, but it is very important aspect of today’s efforts to conserve and sustain our precious resources. And does a resource get any more precious than water? I think not.

So, what does this blogger think he’s up to writing about waste water treatment on a blog that has been clearly dedicated to SCADA? Well, that’s about as good of a transition as I can muster.

The waste water treatment industry has become one of the largest consumers of SCADA software. It just so happens that the treatment process is one that lends itself quite nicely to the features of a SCADA deployment, and the success of such deployments has only accelerated the trend.

A powerful SCADA system has optimal tools for enhancing operational efficiency, from detecting leaks to controlling distribution. One immediate benefit facilities receive after implementing a visualization solution is that small leaks can be detected before they become larger and a major (more expensive) problem. By carefully monitoring the conditions through each stage of the treatment process, the slightest abnormality becomes immediately noticeable. Detecting small problems before they become larger can save facility operators and maintenance technicians a tremendous amount of time – and the facility itself will save money.

Before SCADA, technicians would have to go out in the field to manually inspect gauges on each individual tank. Pump stations would be visited daily. Now, all of these conditions can be monitored remotely, allowing technicians to focus on improving plant operations and increasing efficiency. All of this has led to an increase in the output of accountable water.

So, SCADA is helping water treatment facilities save time, money, hardware and – most importantly – water. No wonder more and more facilities are implementing SCADA systems. Water treatment is just another one of the many ways that SCADA is helping shape the world in which we live.
(For more information on SCADA in water treatment, or to view a case study, visit our website.)

SCADA Saves the World – One kWh at a Time

Let me start by saying I am not trying to promote any particular theories or ideologies. When it comes to global climate change, I don’t have a dog in the fight. I’m not a climatologist. I’m not a producer of industrial waste. I’m just a casual observer taking note of what I see, and what I see is a new trend in SCADA usage: energy management.

As more and more of the objects in our world are gaining intelligence, and as we continue to find new ways of monitoring our environments, one immediate advantage is called to mind. SCADA systems allow us to pay attention to things that we just didn’t have time to pay attention to before. It has suddenly become a simple matter to track our energy consumption – recognizing periods of high demand and other patterns that lead to higher consumption. Now, I’m not about to suggest you should be concerned about your energy consumption because you’re killing the planet and bankrupting our children’s future – I’ll let someone else point that finger. There are plenty of good reasons to reduce your energy consumption that have nothing to do with melting icebergs.

The most obvious and most compelling reason is simple: money. I think it’s fair to say that most of us would like to have more and spend less. If you can reduce your monthly electric bill by 20%, why not do it? Imagine a small company that spends $1000 a month on electricity. That’s $12000 a year. A 20% reduction would lower that expense to $9600 a year. If you can do that without taking anything away from your productivity then there is really no good reason not to.

You try to get the most value for your investment in everything you do – whether it’s buying office supplies or advertising. If your production monitoring system will allow you to save money by simply monitoring your energy consumption as well, then do it. And don’t worry about people thinking you're some tree-hugging communist (not that there’s anything wrong with that). To hell with the rainforests and whales – I’m saving money!

And while we’re using SCADA to reduce our consumption, utility companies are using it to create a smarter, more efficient power grid, eventually reducing the overall cost of generating and distributing electricity. So SCADA is making power cheaper and helping us use less of it. Now, that’s some helpful software.

Thank you SCADA! 

SCADA and Security: Are Our Systems Safe?

In the last 30 years, major advances have been made in both SCADA technology and security. Yet, somehow, the security of SCADA systems has changed very little. Even though SCADA systems are deployed all over the world – with the number of current deployments trending consistently upward, security has not been a primary concern of the software engineers. There are a number of reasons that could be cited, but the primary one relates to the ways that the software is being used. Frequently the same SCADA software can be used to automate various types of processes, from water treatment and power distribution to building automation and energy management. Furthermore, SCADA customers who have invested numerous hours into designing and implementing their systems however many years ago are not especially excited about the idea of making the sweeping changes that would be required to make the systems more secure. Basically: “If it ain’t broke, don’t fix it”.

The problem with this philosophy is that – when it comes to security – many times the system is “broke”. Just because a system has not fallen victim to an attack doesn’t imply that it’s not vulnerable. And once an attack has occurred it will likely be too late to “fix it”.

The Legacy of Stuxnet

When the Stuxnet worm was discovered in 2010, it called attention to the scope of the potential danger inherent in attacks on SCADA systems. Though Stuxnet is a very sophisticated worm created by sophisticated minds with virtually unlimited resources at their disposal, it is a plain fact that if a group or organization is sufficiently motivated there are very few (if any) barriers that cannot be overcome.

The fact that some very sensitive and necessary processes are currently controlled by some sort of SCADA software – from electrical grids to mass transit systems – an effective attack could be absolutely devastating. For this reason there are some very legitimate concerns.

I.T. departments are frequently tasked with designing and implementing the security parameters of SCADA systems – not an easy task since a functional SCADA system relies on easy accessibility. If it is not easy for multiple people to access multiple data points at any given time, the SCADA system is not going to be effective, and it could in fact be dangerous. So, it is often a delicate balancing act to make a system simultaneously accessible and secure, and it would be naïve to not think that some security is compromised for the sake of accessibility.

SCADA in the Cloud

The latest conversation as it relates to SCADA and security centers around cloud-based deployment of SCADA systems. The inherent dangers of cloud-based deployment are well-known and well-documented, so I will leave it to the reader to ascertain the details. Suffice it to say that terrestrial SCADA systems have not be thoroughly secured against all attacks, so I think it’s safe to assume there are some valid security concerns associated with publishing operational data to the cloud. That’s not to say it won’t be happening; it almost certainly will. When cloud-based SCADA becomes the norm, you can be fairly certain that a whole new array of security concerns will surface. The good news is changes in technology will eventually force users of older SCADA and HMI systems to strongly consider upgrading. And when that happens, let’s just hope they make security a top priority.

New Ideas In Security

Scada developers at B-Scada have integrated some new security features into their latest software product, Status Enterprise Edition. Status will allow users to be assigned to specific roles with access limited according to the permissions of the role - something like user groups in Windows. Additionally, specific aspects of the SCADA system wil be organized into Workgroups. Users will be limited to accessing the assets and information that have been made available to the workgroup(s) to which their role has access. 

This allows for easy enforcement of essential security principles such as the Principle of Least Privilege, and restrict users accounts to the least amount of information rewuired to do their jobs.

It will be possible for organizations to divide access to key data among multiple personnel, so that no one person can access everything at once; this will make it very difficult for unauthorized parties to make any potentially dangerous changes to the SCADA system without the support of multiple people on the inside. 

Is There a Place for Independent SCADA Developers?

An undeniable growing trend in the SCADA (Supervisory Control and Data Acquisition) industry is the consolidation of SCADA developers under larger corporate brands. It seems that when a small company develops a SCADA product that has any success at all, it’s not long before a larger company with more resources acquires the smaller company and their software.

Now, I’m not about to judge whether this is good or bad – and there are valid arguments for both sides. I am simply calling attention to an obvious fact. The trend is illustrated on the timeline below:

As time goes by, the mergers and acquisitions become increasingly frequent, and this trend shows no signs of changing any time soon.

So, the question is: Is there a place for independent SCADA developer’s in today’s market?

The short answer is yes. There is a place and a real need for independent developers who create quality software and are able to sell the software at a more accessible price. There are several reasons why this is the case:

• Many industries in developing nations have a need for process automation and monitoring software, but the offerings of the larger companies are cost prohibitive.
• Systems Integrators all over the world have projects with very specific needs, and the larger SCADA products and their excessive cost are not entirely necessary.
• Some customers place a greater value on service and support, and the more personalized attention they can receive from a smaller company outweighs the perceived value of a well-known brand.

There are several other reasons why smaller, independent SCADA developers have a place in today’s market. The important point, though, is that SCADA customers need to have options. There are so many different industrial processes and so many types of data to monitor, that it is bordering on preposterous to think that one SCADA solution – or even a small set of similar solutions – can accommodate all of the varied needs of today’s consumers.

(For more on SCADA, visit: www.scada.com)

The Evolution of SCADA

Like the first legless mammals that flopped ashore from a primordial bog to eventually walk, talk, fly airplanes and eat hamburgers, SCADA too has come a long way since its origins. And much like our swimming forebears, the early iterations of SCADA were hardly recognizable as the SCADA we know today.

The acronym SCADA (Supervisory Control And Data Acquisition) originated in the 1960’s with the advent of mainframe computers, but the concept is actually much older – dating back to the 1930’s, when telephone companies began using magnetic stepping switches for switching telephone circuits. Electric utilities quickly adopted the technology, and the notion of remote supervisory control was born.

Proto-SCADA

The earliest efforts to remotely monitor electrical systems were not as automated as today’s. For security, a human operator was involved in the process. Communication between the master station and the remote terminal would be checked and verified by a human operator before changes were made.  This select/check/operate scheme is still used today in some cases.

Tone/Pulse SCADA

Ok – technically, we’re still not talking about actual SCADA, but it’s getting closer. 

Around 1950 companies began using a telephone type pulse counting system to relay information from one terminal to another. Information was conveyed by both the length of pulses as well as their frequency. This quickly proved to be a very reliable system, and was adopted by electric utilities, gas companies, oil pipelines – even airport control towers.

It was around this time that manufacturers began competing over this technology. Major players included Westinghouse, Visicode and General Electric. This competition led to more rapid advancement as we approached the 1960’s and the development of solid state supervisory control technology.

Manufacturers adopted the new solid state technology almost immediately.

Solid State SCADA

Westinghouse introduced REDAC; GE had GETAC, and Control Corporation introduced a system called Supertrol. These first solid state systems were really just solid state versions of the systems already in place.

The term SCADA came into use around 1965, when computer based master stations became common. By this time, computers were capable of real-time functions, which now included scanning and monitoring data, alarming for changes, and displaying the data on digital displays.

By the end of the decade, CRT displays allowed for more advanced HMIs (Human Machine Interfaces) and periodic data logging was introduced. Better computer technology led to more complex monitoring and more advanced displays, and the introduction of network technology paved the way for today’s world of industrial automation and process control.