Advanced SCADA applications, Part 4: Upcoming SCADA technology advances

SCADA insights

• In an October 12, 2023 webcast, “SCADA series: Advanced SCADA applications,” Andreina Lugo, software automation manager at Northwind Technical Services, and Mike Lennon, vice president at Applied Control Engineering, discussed the SCADA software selection process and SCADA implementation best practices.
• In Part 1, Lugo discusses the SCADA software selection process and vendor research.
• Read part 2 for more information on the role and value of system integrators, part 3 for SCADA best practices and part 4 for upcoming advances in SCADA technology.

For an industrial company, selecting a supervisory control and data acquisition (SCADA) system is vital decision that involves taking a variety of different factors into consideration. End-users most find a platform that is compatible with their pre-existing software and hardware; capable of accommodating the needs of their unique applications; allows for future scalability via easy expansion and upgrades; and provides appropriate report configuration and data sharing capabilities. Moreover, once a platform is selected, adhering to best practices is critical to ensuring that end-users get the most out of their chosen software.

In an October 12 Control Engineering webcast, “SCADA series: Advanced SCADA applications,” Andreina Lugo, software automation manager at Northwind Technical Services, and Mike Lennon, vice president at Applied Control Engineering, discussed the SCADA software selection process and SCADA implementation best practices.

Below, the transcript of their presentation has been provided with minor edits and adaptations.

The importance of proper control and alarming in SCADA systems

Mike Lennon: In a SCADA system, it’s crucial to have a control system that clearly identifies issues, guiding the operator on where to focus and what actions to take. This leads us to the topic of alarming. Modern HMI and SCADA packages offer features like the ability to shelve an alarm temporarily. This function is particularly useful when an operator or supervisor needs to prioritize certain alarms over others.

Defining alarms and information in SCADA systems

According to the ISA definition, an alarm necessitates an operator response. If no response is required, it is merely information, which, while useful, should not be categorized as an alarm. A key process in developing effective SCADA systems is alarm rationalization, where you analyze each alarm to determine the urgency of response, the potential causes, consequences of inaction, and the corrective actions required.

Alarm rationalization and data integration

Alarm rationalization is a comprehensive process that involves capturing extensive data about each alarm. This data should be integrated into the SCADA system in real-time to inform operators’ actions. An example of this process is presented with the scrubber application, showing how operators are guided through potential alarms and the necessary steps to address them.

Application of SCADA in various industrial processes

SCADA systems vary in their application, from continuous processes to batching and packaging lines. The design of the system, whether it’s a traditional display or a dashboard, depends on the specific needs of the process. For instance, in the pharmaceutical industry, where processes like fluid bed drying are crucial, having real-time trends displayed on the main process screen can be invaluable for operators to monitor critical parameters like outlet air temperature.

Dashboards for contextual information

Dashboards in SCADA systems provide a tailored view of the process, catering to different user needs. For example, a supervisor might be interested in the current stage of a process, alarm history, key performance indicators (KPIs), Overall Equipment Effectiveness (OEE), and line performance. Modern SCADA software facilitates this by presenting data in user-friendly formats accessible on various devices, including smartphones and tablets.

SCADA applications in diverse environments

Today’s SCADA software is versatile, allowing data access in the format and location needed by the user. An interesting application of SCADA is in unique environments like wave-to-energy converters. For instance, the Triton-C wave-to-energy converter off the coast of Hawaii, developed by Oscilla Power, required a specialized SCADA system. This project underscores the broad applicability and adaptability of SCADA systems in various industries and innovative technological endeavors.

Customizing SCADA systems for specific needs

Initially, the request was for a graphic resembling a living Process & Instrumentation Diagram (P&ID), which is particularly useful for Input/Output (IO) checkouts. The graphic displayed in the lower left showcases current values and serves as a foundational tool. However, further discussions with the client focused on their specific needs and goals, leading to questions about the purpose of the graphic and the type of data being collected. Given the nature of the project as a research device, numerous sensors were involved. Consequently, we developed a dashboard that provides comprehensive insights into the operation of their wave-to-energy converter. This dashboard not only displays current operations but also historizes data, facilitating analysis and design adjustments based on varying wave conditions. The principles applied here can be similarly implemented in plant settings for enhanced operational efficiency.

The importance of continuous improvement in SCADA systems

In the realm of SCADA applications, selecting the right software and assembling the best team for implementation is just the beginning. Post-implementation, it is crucial not to let the system become static. Many HMIs and SCADA systems remain unchanged over extended periods, sometimes up to a decade. Emphasizing a continuous improvement cycle is vital. Listening to operator feedback, akin to Teddy’s insights at the hydroelectric plant, is essential for making the system more effective and efficient. Operators are often a rich source of practical knowledge and ideas for system enhancements.

Future directions in SCADA system development

Looking toward the future of SCADA systems, there are several areas of potential development. The pandemic has highlighted the need for robust remote capabilities in SCADA systems, ensuring data accessibility and operation continuity. Additionally, augmented reality is becoming a significant feature in SCADA systems, offering opportunities for enhanced operator training and remote support. This technology allows staff to guide someone remotely, enhancing the overall efficiency and safety of operations.

Do you have experience and expertise with the topics mentioned in this content? You should consider contributing to our WTWH Media editorial team and getting the recognition you and your company deserve. Click here to start this process.