How to incorporate digital transformation into SCADA master planning

SCADA master planning insights

• Digital transformation technologies can be harnessed to boost the performance levels of SCADA systems and enable them to meet the demands of modern industrial operations.
• Cost is an important factor for integrating digital transformation technologies, but other factors, like training and scalability are important considerations.

Supervisory control and data acquisition (SCADA) systems have reshaped process automation with the implementation of technology advancements, especially under Industry 4.0 and Industry 5.0. These changes have a farther-reaching impact than sustaining operational continuity, especially in the context of sustainability and accomplishing more with a reduced workforce.

Several important factors must be considered when developing a SCADA master plan (SMP). The tradeoff between budget and implementing emerging technologies is one of the main factors to consider. On the other hand, digital transformation is forcing an exercise of reimagination of products, services and operations to extract value. As Massachusetts Institute of Technology’s Sloan Management Review puts it, “This is an ever-ongoing process about continuously adapting to the never-ending changes of the landscape and building a robust base for fluctuating market and global dynamics.”

Investigating a SCADA master plan, Industry 4.0 and 5.0 and digital transformation

An SMP is a strategic document that defines the vision, objectives and roadmap for developing and implementing SCADA system. The SMP framework includes architectural specifications, standards, interfaces, functionalities, performance, security and governance for SCADA’s technical, operational and organizational setup.

Industry 4.0, known as the Fourth Industrial Revolution, signifies the transition of industrial sectors towards digitization, integrating digital technology into production and physical processes. Industry 4.0 introduces the concept of smart factories, where interconnected machines and systems communicate, enabling automated and optimized production processes.

Industry 5.0 refers to the next industrial development phase, emphasizing human intelligence. Industry 5.0 introduces collaboration between people and machines to solve complex problems. This includes innovation and productivity improvement in efficient and sustainable industrial procedures.

In recent years, the pace of the industry revolution has rapidly increased due to increased connectivity, enhanced collaboration and the swift expansion of computing capabilities. Effective planning for industry revolutions is crucial. It helps anticipate changes to maintain a competitive edge, allocate resources efficiently, ensure smooth transitions to avoid disruptions, stay ahead of regulatory shifts and ensure compliance. This strategic planning gives companies an advantage over their competitors (see Figure 1).

Figure 1. Digitalization evolution time frame. Courtesy: CDM Smith.

Digital transformation refers to the use of technology to create new or restructure current business processes, products, services and customer experiences. Digital transformation in industrial control systems may include new ways of integrating with other information systems, such as manufacturing execution systems (MES), enterprise resource planning (ERP), computerized maintenance management systems (CMMS), business intelligence (BI), geographic information systems (GIS), reporting and data analytic tools.

An SMP provides tools that guide the SCADA system’s design, implementation and management. It ensures the SCADA system considers the latest technological developments in interconnected, automated, data-driven operations. In an Industry 4.0 environment, the SCADA system is not isolated; it is integrated with other digital technologies and systems, such as the Industrial Internet of Things (IIoT), artificial intelligence (AI) and cloud computing. This is where the SMP must look at how it can use these technologies to boost the SCADA system’s performance, efficiency and security. The SMP must identify organizational goals that can be achieved by using technology.

The benefits of digital transformation in SCAD

Digital transformation in SCADA can bring significant benefits to an industrial organization, such as:

• Increased efficiency. Integration with other information systems, such as SCADA, should lead to an optimized production process, minimizing waste while increasing quality. It should increase productivity.
• Data analytics. The organization can leverage big data and AI to derive insights from SCADA data, such as trends, patterns, anomalies and predictions.
• Real-time monitoring. The combination of IIoT, cloud computing and edge computing expands SCADA capabilities for real-time access and monitoring. Edge computing also helps reduce latency and accelerates data analysis, vital to industrial operations where time is critical.
• Predictive maintenance. An organization would implement condition-based monitoring, fault detection and diagnosis into its equipment using IIoT and AI in its strategies.
• IIoT for remote monitoring. IIoT enhances new remote monitoring and control methods for systems that operate at widespread locations.

Digital transformation challenges and considerations

Digital transformation can also bring many benefits to the SCADA system itself, such as efficiency, reliability, security and innovation. However, it also poses some challenges and considerations that must be balanced when developing an SMP (see Table 1).

Table 1. Digital transformation challenges. Courtesy: CDM Smith.

Breakdown of SMP and digital transformation

An SMP explains how different elements in a SCADA project are coupled correctly in terms of system architecture, instrumentation and control (I&C) specification, application standard and interface integration. These are all aligned with functionality and performance requirements and create a robust cybersecurity framework (see Table 2).

Table 2 Traditional outcomes of a SCADA master plan. Courtesy: CDM Smith.

Operational technology (OT) technical experts developed a survey to explore critical aspects of modern SCADA systems, including the significance of cloud computing and IoT integration, the challenges encountered during digital technology integration and the top skill development needs for digital transformation. Additionally, it seeks to uncover perspectives on the future roles of AI and machine learning (ML) in SCADA systems and the criticality of data analytics in enhancing system performance and decision-making processes. Here’s a glimpse into the key findings:

• Cloud computing and IoT integration. Opinions varied among respondents, with many emphasizing their value for noncritical SCADA assets. However, consensus on their necessity was not unanimous.
• Challenges in digital technology integration. Cybersecurity emerged as a paramount concern when integrating digital technologies into existing SCADA architectures. Respondents emphasized the urgency of cybersecurity measures to safeguard critical infrastructure and assets, highlighting the need for effective cybersecurity strategies amidst the convergence of digital technologies. Many respondents also emphasized the importance of compatibility and addressed skill gaps within SCADA systems.
• Skill development priorities. The survey highlighted the growing importance of data analytics and AI expertise in digital transformation for SCADA systems. Professionals and organizations were urged to prioritize developing these skills to leverage digital technologies effectively.
• Prospects of AI and ML. Envisioning AI and ML’s future role in SCADA systems revealed diverse opinions. Respondents anticipated a supporting or central role, emphasizing the need for continued exploration to advance SCADA capabilities.
• Criticality of data analytics. Data analytics is almost unanimously recognized as critical for enhancing SCADA system performance and decision-making, as well as essential for optimizing performance, ensuring reliability, and enabling informed decision-making (see Figure 3).

Figure 3. Summary of survey results. Courtesy: CDM Smith.

Preparing for digital transformation

Digital transformation is essential to avoid organizational obsolescence. But adopting this transformation may be cumbersome, especially in sectors whose operation is highly dependent on SCADA systems. These systems are complex, sensitive and typically outdated with obsolete or unmaintained instrumentation. They are considered soft targets due to devices not made with security in mind, adding an extra layer of challenge to the digital transformation process.

This complexity is heightened because SCADA systems, often embedded with legacy technology, have not effectively been updated to withstand current cybersecurity threats. The convergence of needing to modernize these critical systems while ensuring they are secure and capable of integrating with newer, more digitally agile frameworks underscores the multifaceted challenges facing sectors reliant on SCADA for their operations.

Understanding the current SCADA systems landscape

From this perspective, understanding the current technology framework is critical to embarking on digital transformation for the OT organization. This evaluation helps identify potential enhancements and areas for innovation, laying the groundwork for the strategic integration of these technologies. Still, it is also essential to determine what is currently being collected and historized. You cannot develop a digital strategy without gathering the necessary information. This foundational step ensures the digital transformation journey is informed by a comprehensive understanding of existing data practices, enabling targeted improvements and more effective integration of new technologies (see Figure 4).

Figure 4. Key factors for a SCADA master plan technology assessment Courtesy: CDM Smith.

Identifying areas for improvement –– incorporating digital technologies

This stage entails leveraging advances to improve operational efficiency, better use of data and fortifying cybersecurity. It is the process of identifying how these technologies can automate processes, optimize the performance of systems, and provide strategic insights for decision-making (see Figure 5).

Figure 5. Key aspects when incorporating digital technology in a SCADA master plan. Courtesy: CDM Smith.

Setting realistic SCADA goals and objectives

In this phase, the increased focus is to align the digital transformation goals with the latest capabilities that technologies offer. This would include clear strategic goals on enhancing operational efficiency, security, and other functional requirements aligned with broader business strategies (see Figure 6).

Figure 6. Aligning technology to business objectives with measurable goals. Courtesy: CDM Smith.

Key components of digital transformation in SCADA

The SMP identifies and delivers the standard specifications necessary to configure, support, maintain and operate the system.

A standard specification for IIoT in SCADA should cover some of the following minimum elements based on the given design criteria.

• Connectivity. The specification should indicate which communication protocol, standard and IIoT sensor interface the device can support to ensure the device can share data with other devices more uninterrupted and dependable over the internet or other IP-based networks.
• Interoperability. Specify data format, model and protocols to be used by IIoT sensors and avoid vendor lock-in so multiple systems and platforms can interoperate or integrate.
• Embedded intelligence. The specification should include algorithms, functions and processing capabilities that dictate what IIoT sensors, embedded intelligence and edge computing should offer to allow the possibility of local decision-making, event detection or anomaly identification.
• Remote management and diagnostic. The specification should indicate which management capabilities, protocols and tools must be part of the IIoT sensors for remote management and configuration.
• Enhanced security features. The specification should define advanced security features other than traditional sensors, such as encrypted communication, secure boot, trusted hardware, VPN, etc.
• Energy efficiency. The specification should cover the power efficiency of the IIoT sensors; therefore, energy management for IIoT sensors is also necessary.

Using data analytics for improved decision-making

There are several key factors to consider when evaluating data analytics for improved decision-making in SCADA systems. These factors encompass the choice between software as a service (SaaS) and on-premises tools, vendor support, low-code versus no-code solutions selection and other considerations.

SCADA’s predictive capabilities extend to proactive maintenance, allowing for the early identification of potential issues to minimize downtime and associated costs. This proactive approach ensures timely equipment servicing, preventing costly breakdowns and prolonging the lifespan of critical infrastructure. Ultimately, SCADA data analytics offers more than just efficiency; it holistically enhances operational resilience and promotes financial prudence.

 SaaS versus on-premises tools

SaaS solutions frequently come with the benefit of a scalable and flexible nature with low, upfront costs. On the other side, an on-premises solution best supports increased control in the context of data security up to a greater level of customization and better compliance for regulatory needs.

It is essential to evaluate the level of support that will be given through vendors, both for SaaS and on-premises software. Specifically, the quality of technical support, reaction rate to problems and reputation in the industry should be measured.

Solution providers must have a profound knowledge of SCADA systems and existing infrastructure.

Selection of low-code versus no-code solutions

Low- and no-code solutions refer to platforms or tools allowing users to develop software applications or solutions with minimal programming knowledge or involvement. Low-code and no-code development further accelerate app development cycles of analytics and their deployment within the SCADA system. For example, direct stakeholders like users on the ground with varied levels of technical experience taking part in these processes.

Considering the complexity of the analytics task and the level of technical proficiencies that may be required in data analytics problems, low-code could enable much more room for provision toward customizability and flexibility on solution types that might impose higher technical demands.

Consciously, the no-code solutions are more likely to have a friendlier face but give up some of this flexibility.

The benefits of edge computing

When considering real-time decisions, especially for process optimization and advanced control, the SMP must evaluate typical plant controllers’ current and prospective technical capabilities, such as programmable logic controllers (PLCs) and distributed controller systems (DCS). Edge computing is becoming the proposed tool either as a data collector for IIoT sensors or as an interface to execute advanced ML models in integration with PLC, DCS and SCADA systems. Vendor selection is a crucial component of this analysis.

The benefits and methods of using cloud services for SCADA

Evaluating the core interrelations of SCADA integration with cloud computing services must be critical. This evaluation could be provided as a technical memo.

• Objectives and scope of evaluation. Provide clear definitions of the evaluation’s purpose and identify the problem statement looking to pursue but lack the capacity to confront the scope, criteria and stakeholders to enable knowledge of appropriate mechanisms for realigning user expectations.
• Evaluation of cloud computing services and providers. Explain the categories of services to be provided by cloud-based services in terms of features, costs and availability and computing power. Indicate other points such as service level agreements (SLA) and compliance certification, location of data centers, etc.
• Integration and migration strategies. Understand the provider integration strategies, associated risks and steps to ensure a smooth transition and a minimum disruption of the existing operations, including disaster recovery plans and data gaps during transition.
• Pros and cons of cloud computing services for SCADA systems. The probable benefits, such as scalability, elasticity, cost-efficiency, reliability and security, generally include integration capabilities and return on investment (ROI). Among probable risks, one should underline risks for data security, along with regulatory compliance problems, system reliability challenges, network latency problems and integration complexity.

Incorporating digital transformation on a SCADA master plan

For most organizations, and more so for industries, digital transformation has become a strategic investment. Four basic steps are relevant in the context of SMP:

1.     Evaluate stakeholder’s needs. Understanding stakeholder’s needs, including stakeholders inside and outside the OT domain is critical to integrating emerging technologies that align with all needs and capabilities (see Figure 7).

Figure 7. SMP mechanism to understand stakeholder’s needs. Courtesy: CDM Smith.

2.     Planning and strategy development. This includes a comprehensive strategy for the technologies that will be integrated, the processes affected and the expectations on benefits, including a timeline for implementation and a plan for managing risks or challenges.

Cybersecurity has become a paramount concern, so prioritizing cyberspace security to protect infrastructure and assets is necessary (see Figure 8).

Figure 8. Realistic schedule is a crucial part of an SMP. Courtesy: CDM Smith.

3.     Selecting the right technologies and partners. Selecting technologies and partners is important for success. Choosing partners with expertise, a strong track record and support capabilities is an ongoing and intensive exercise that should not be overlooked (see Figure 9).

Figure 9. The selection of technology and partners on SMP in a digital transformation project helps reduce uncertainty. Courtesy: CDM Smith.

4.     Training and skill development plan. Digital transformation is more about people than technology. Success relies on your staff’s ability to use and manage the new technologies effectively. This can involve formal training programs, training or hiring people with the requisite skills.

Approaches to tackling digital transformation with SCADA systems

Organizations embarking on digital transformation within SCADA systems should:

Embrace a strategic approach. Develop a comprehensive SMP that integrates digital technologies seamlessly while addressing operational needs and cybersecurity concerns.

Prioritize cybersecurity. Given the integration of digital technologies, cybersecurity must be at the forefront of the digital transformation strategy to protect critical infrastructure.

Invest in skill development. Equip teams with the necessary skills in AI, data analytics and cloud technologies to leverage the full potential of digital transformation.

Foster a culture of innovation. Encourage a culture that embraces change, innovation and continuous learning to adapt to the evolving digital landscape.

Select the right partners. Choose technology partners with proven expertise in digital transformation and SCADA systems to ensure a smooth transition and successful implementation.

CDM Smith is a Control Engineering content partner.

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