WHITE PAPER The SCADA Connection: Moving Beyond Auto Dialers ABSTRACT: Auto dialers have long been used to report alarms in SCADA installations. While they are useful for notifying users of alarm states, most models do not provide insight into the status of equipment. This white paper explores how today s technology allows users to augment their SCADA monitoring and control and enjoy benefits never imagined with auto dialers.
OVERVIEW Auto dialers have a long history of providing notifications in remote SCADA (Supervisory Control and Data Acquisition) installations. Most auto dialers detect possible alarm conditions by using discrete digital and analog ports connected to sensors. Once a problem is detected, appropriate users are notified when the device calls one or more pre-defined phone numbers to report the alarm conditions. While in some cases auto dialers are an effective way to remotely monitor pumps, valves, motors and switches, the evolution of SCADA installations has resulted in more complex equipment on site that needs to be monitored and controlled. There is also a greater demand by SCADA users to optimize operations by automating functions that can be done remotely in order to eliminate the costs and time required to send a technician on site to verify the existence of a problem, diagnose the root cause and plan for remediation. In this white paper we will explore how SCADA installations can evolve from the use of auto dialers to a more comprehensive way of managing remote sites that increases visibility while reducing costs. SCADA APPLICATIONS THE BASICS SCADA technology is used in a number of industries including the oil and gas, electricity, and water and waste water industries. It is used to monitor and control equipment of all sizes and complexities. SCADA systems gather information such as pump on/off events, liquid flow, water levels, pressure values, and temperature readings and send them to a central management system. Traditionally, SCADA system operators were looking for confirmation of basic functionality and notification when abnormal events occurred. Examples of events include: Levels above/below predetermined thresholds Pump/generator on/off events or excessive starts Intrusion detection Power loss Temperature readings or pressure values above/below thresholds
These types of events are easily reported by simple auto dialers using conventional phone lines when values have crossed high or low set points. However, as SCADA systems have evolved and operators have increased their demand for information, some data cannot be communicated easily using auto dialers over analog phone landlines. TODAY S SCADA MORE DATA, MORE OPPORTUNITIES Wireless communication has enhanced the possibilities in SCADA monitoring. Operations managers are no longer restricted to relying on auto dialers connected to phone lines for communicating SCADA events. They now have more physical reach by being able to monitor, control and automate equipment located at remote sites spread over large geographical areas. It has also been part of the evolution that allowed customers to move away from closed, analog connections to digital and IP (Internet Protocol) based systems. As technology has evolved, SCADA remote monitoring and control equipment like PLCs (Programmable Logic Controllers) and RTUs (Remote Terminal Units) have also become more feature-rich (and complex). The increase in proliferation and functions of PLCs and RTUs means there is a greater depth of information available locally to operations managers. However, the challenge is to exchange information with the equipment in a timely manner and make it available to the SCADA master station and HMI (Human Machine Interface) for viewing, interpretation and driving business KPIs (Key Performance Indicators).
SCADA SITES POINTS TO CONSIDER WHEN DESIGNING AND RETROFITTING Whether you are building a new remote SCADA site or retrofitting an existing site, there are many points to consider so that you are able to extract more comprehensive information. Building (or upgrading) a successful SCADA network depends not only on understanding today s remote monitoring and control requirements but also on implementing a system that can scale up to tomorrow s needs. Beyond the master station, the architecture of the SCADA network comprises of three main components. These are: 1. Controllers or Data Terminal Equipment (DTE) at the remote sites 2. Data Communication Equipment (DCE) 3. Communication (telemetry) network
CONTROLLERS OR DATA TERMINAL EQUIPMENT (DTE) Today s controllers, whether they are PLCs, RTUs or intelligent communication terminals, come in various sizes and capabilities to meet master station and remote station control needs. Here are 10 factors to consider when selecting this type of equipment: 1. Local Intelligence and Processing: Is the unit programmable? What is the processing throughput? What is the data logging capacity of the unit? 2. Input/Output (I/O) ports: What is the number of I/O ports and what is their accuracy? Do they meet the needs of the application? 3. Communications: What telemetry communication services are supported? Are there provisions for redundant communications for critical applications? Can data be sent and received at the frequency required by the application and the operation manager? 4. Protocols: Does the unit support open standard industry protocols like Modbus and DNP3 on serial and TCP/IP ports? 5. Interfaces: What interfaces are required to connect to DCEs? 6. Power: What are the power requirements of the unit? Can the unit be operated on battery alone? What are the options for backup power? 7. Enhanced Security: Does the equipment support password-protected programming, authentication and IP firewall capabilities? 8. Durability and Ruggedness: Is the unit rated to handle the temperature, humidity, vibration and electrical conditions found at the remote sites? 9. Modularity: Is the unit expandable as demand and needs change? 10. Space and Installation: How much space is required by the controller and how will it be installed at the remote site?
SkyWave s Data Equipment Terminals for unmonitored SCADA sites In some applications, SkyWave satellite devices are a very cost-effective way to add a controller with communication capability to a remote SCADA site. The IDP 600 series terminals feature four (4) general input/output ports for connecting analog and digital sensors. The terminals also have RS-232 and RS-485 ports for connecting devices that communicate via serial protocols like Modbus. The onboard processor allows customers to program logic into the device to react to events like Send a notification when the water level is above the analog high threshold or Close the valve when pressure reading is below low threshold. This edge analytics capability reduces the amount of data that is sent wirelessly, thereby decreasing reaction time to events as well as monthly airtime costs Learn more about IDP 600 series terminals at www.skywave.com. SkyWave Solutions for SCADA sites with PLCs and RTUs For SCADA sites with PLCs and RTUs, SkyWave offers SCADAconnect - a three-part application which includes an asset gateway that quickly and easily connects to remote PLCs and RTUs to extract data, a communication modem for relaying data from remote sites to enterprise applications, and an enterprise gateway to interpret the data from remote sites and insert it into the SCADA HMI (Human Machine Interface) system. The asset gateway allows customers to not only extract data from the PLC but also to provide the edge analytics portion where only relevant information is sent to the SCADA HMI system. For example, an operations manager can be notified only when the fan speed changes by 5%. Anything below that would not be reported, thereby reducing communication costs and data overload syndrome. Learn more about SCADAconnect at www.skywave.com.
DATA COMMUNICATION EQUIPMENT DCEs are responsible for the exchange of appropriate data between controllers/dtes and the master station by using the communication network. DCEs include auto dialers as well as radio, cellular and satellite modems and terminals. Here are 10 factors to keep in mind when considering DCEs for SCADA sites: 1. Availability: Which communication networks are available at the remote sites? This will drive the selection of the DCE. Options include radio, private leased lines, cellular and satellite. 2. Redundancy: Does the DCE have redundant communication options? 3. Data Requirements: Does the unit support the transmission of analog, digital and/or serial data? 4. Data Communication Rate: How much data needs to be sent to and from the remote site? Will there be a demand to change the data as the site grows or evolves? Can data be sent and received as frequently as required? 5. Transmission Modes: Does the site need half-duplex or full-duplex capability? 6. Response Time and Latency: How much time does it take to relay information between the controllers and the master station? Does it meet the needs of the application? 7. Interfaces: What interfaces are required to connect to the controllers? 8. Standards and Certification: What communication standards need to be complied with in order to operate in that region? 9. Power: How much power is required to operate the DCE? Can the unit revert to backup power in the advent of a failure on the main power line? 10. Durability and Ruggedness: Like the controllers, is the unit rated to handle the temperature, humidity, vibration and electrical conditions found at the remote sites?
SkyWave Products as DCEs An integral part of SkyWave technology is the ability to provide cost effective satellite communications for remote sites requiring the ability to send notification of events and alarms as well as regular telemetry data. Since the system uses the Inmarsat satellite constellation, customers who opt for this solution have the ability to send and receive as much data as they want without being constrained to using time slots at specific times of day. They also receive the information in seconds rather than minutes or hours. The IDP 600 series satellite-only devices are rugged and compact. They are designed to be installed outside and are also available with C1D2 (Class 1, Division 2) certification for use in hazardous locations. TERMINAL IDP-680 C1D2 TERMINAL IDP-690 C1D2 The IDP 700 series satellite-cellular devices are equipped with more than 17 I/O ports and can send information via satellite, cellular or both, depending on need. See satellite and satellite/cellular devices in action at www.skywave.com. COMMUNICATION TELEMETRY NETWORKS The communication network is the essential component for connecting remote sites to master stations. When selecting the primary and secondary communication systems, consider the following 10 factors: 1. Coverage: Is the network available at the remote sites? 2. Uniformity: Looking at the entire SCADA system, is it important to use the same communication networks across all the sites? Choosing different networks depending on local availability will increase the number of DCEs that need to be selected. 3. Infrastructure: Is there a need to install infrastructure like towers and repeaters to support the communication network? What is the required infrastructure investment? Can infrastructure installation and maintenance costs be outsourced to a cellular or satellite communication provider?
4. Monthly Costs: What are the monthly usage costs? 5. Total Cost of Ownership: How do initial infrastructure and monthly costs fit into company s financial policies? 6. Reliability: What is the reliability of the communication network at each remote site? Does it meet the mandated or desired service level agreement? 7. Data Communication Requirements: How much data needs to be sent to and from the remote site? Will the data demand change as the site grows or evolves? 8. Transmission Modes: Does the site need half-duplex or full-duplex capability? 9. Responsiveness and Latency: How much time does it take to connect to the network and relay information between the controllers and the master station? Does it meet the needs of the application? How frequently can data be polled or accessed from remote sites? 10. Emergency Management: Does the communication network stand up to extreme weather like hurricanes, tornadoes and tsunamis? SkyWave Products and Communication Telemetry Networks Think satellite is expensive? Think again. SkyWave devices are ideal for applications that require cost-effective connectivity in remote areas where other communication services are unavailable or cost-prohibitive to implement. In some cases, customers who have chosen SkyWave solutions pay less than they would for cellular solutions. In addition to costs savings, since SkyWave uses the Inmarsat satellite constellation, data from SCADA sites is received within seconds, allowing operation managers to react immediately to events. The system is also resilient to local weather events like tornadoes and hurricanes since it does not rely on terrestrial towers. Learn more about satellite solutions for your SCADA applications at www.skywave.com.
BENEFITS OF INCREASED VISIBILITY AT REMOTE SCADA SITES Increased visibility of the status of equipment at remote SCADA sites and the ability to collect more data than was provided solely by alarms (as offered by auto dialers) has translated into significant cost and operational savings for managers. The benefits include: Reduced field visits, thereby decreasing labor and fuel costs. Ability to schedule maintenance on equipment based on need rather than time passed. Decreased MTTR (Mean Time to Repair) by receiving real-time alerts of issues. Plus, being able to poll more data from the sites means being able to diagnose the problem before dispatching a technician. Minimized downtime by being alerted of degradation in performance of equipment To achieve these results it is important to spend time considering the architecture of your SCADA site including the Controllers or Data Terminal Equipment (DTE), the Data Communication Equipment (DCE), the Communication (telemetry) network and how the solution can meet today s remote monitoring and control requirements but scale to tomorrow s needs. For more information about how SkyWave products can address your DTE, DCE and communication telemetry network, visit us at www.skywave.com.
ABOUT SKYWAVE MOBILE COMMUNICATIONS SkyWave Mobile Communications is a global provider of satellite, cellular and satellitecellular devices and services and operates the only 3rd generation satcom network in the world for the Machine-to-Machine (M2M) market. SkyWave s products provide dependable communication, tracking, monitoring and remote management of fixed and mobile assets. Over the past 17 years, SkyWave has designed, manufactured and shipped more than 750,000 Inmarsat-based satellite terminals to customers globally in the transportation, maritime, oil and gas, utilities and government sectors. For more information, please visit www.skywave.com. ABOUT INMARSAT Inmarsat plc is the leading provider of global mobile satellite communications services. Since 1979, Inmarsat has been providing reliable voice and high-speed data communications to governments, enterprises and other organizations, with a range of services that can be used on land, at sea or in the air. Inmarsat employs around 1,600 staff in more than 40 locations around the world, with a presence in the major ports and centres of commerce on every continent. For the year ended 31st December 2013, Inmarsat had total revenue of US$1.261 million and an EBITDA of US$648 million. Inmarsat is listed on the London Stock Exchange (LSE:ISAT.L). For more information, please visit www.inmarsat.com.