Five Terms You MUST Be Familiar With SCADA, DCS, PLC, RTU and Smart Instrument EEP

Industrial Automation / SCADA
Five Terms You MUST Be Familiar

With: SCADA, DCS, PLC, RTU and
Smart Instrument
By Edvard April, 25th 2018 Save to PDF ♛
Similar, but not the same

This technical article shed light on terminology
used in the field of SCADA and industrial
automation. The terms SCADA, distributed control
system (DCS), programmable logic controller
(PLC), remote terminal unit (RTU) and smart
instrument are very important when we’re talking
about concept of a industrial telemetry system.
Five Terms You MUST Be Familiar With: SCADA, DCS,

PLC, RTU and Smart Instrument (on photo: PLC panel)
Let’s shed a light on these five terms:
1. SCADA
2. Distributed control system (DCS)
3. Programmable logic controller (PLC)
4. Remote terminal unit (RTU) and
5. Smart instrument
1. SCADA system
A SCADA (or supervisory control and data

acquisition) system means a system consisting of
a number of remote terminal units (or RTUs)
collecting field data connected back to a master
station via a communications system.
The master station displays the acquired data

and also allows the operator to perform remote
control tasks.
The accurate and timely data (normally real-time)

allows for optimization of the operation of the
plant and process. A further benefit is more
efficient, reliable and most importantly, safer
operations. This all results in a lower cost of
operation compared to earlier non-automated
systems.
There is a fair degree of confusion between the

definition of SCADA systems and process control
system. SCADA has the connotation of remote or
distant operation.
The inevitable question is how far

‘remote’ is – typically this means over
a distance such that the distance
between the controlling location and the
controlled location is such that direct-
wire control is impractical (i.e. a
communication link is a critical
component of the system).
A successful SCADA
installation depends on
utilizing proven and reliable
technology, with adequate
and comprehensive training
of all personnel in the
operation of the system.
SCADA Tutorial for Beginners---…
There is a history of unsuccessful SCADA

systems – contributing factors to these systems
includes inadequate integration of the various
components of the system,
unnecessary complexity in the system, unreliable
hardware and unproven software.
Today hardware reliability is less of a

problem, but the increasing software
complexity is producing new
challenges.
It should be noted in passing that many operators

judge a SCADA system not only by the smooth
performance of the RTUs, communication links
and the master station (all falling under the
umbrella of SCADA system) but also the field
devices (both transducers and control devices).
The field devices however fall outside the scope

of SCADA in this manual and will not be
discussed further. A diagram of a typical SCADA
system is given below.
Figure 1 – Diagram of a typical SCADA system
On a more complex SCADA system there are

essentially five levels or hierarchies:
1. Field level instrumentation and control

devices
2. Marshalling terminals and RTUs
3. Communications system
4. The master station(s)
5. The commercial data processing department
computer system
The RTU provides an interface to the field analog

and digital signals situated at each remote site.
The communications system

provides the pathway for
communications between the
master station and the remote
sites. This communication
system can be radio,
telephone line, microwave
and possibly even satellite.
Specific protocols and error
detection philosophies are
used for efficient and
optimum transfer of data.
The master station (and submasters) gather data

from the various RTUs and generally provide an
operator interface for display of information and
control of the remote sites. In large telemetry
systems, submaster sites gather information from
remote sites and act as a relay back to the
control master station.
SCADA technology has existed since

the early sixties and there are now two
other competing approaches possible –
distributed control system (DCS) and
programmable logic controller (PLC).
In addition there has been a growing trend to use

smart instruments as a key component in all
these systems. Of course, in the real world, the
designer will mix and match the four approaches
to produce an effective system matching his/her
application.
Figure 2 – SCADA system
Considerations of SCADA system
Typical considerations when putting a SCADA

system together are:
Overall control requirements

Sequence logic
Analog loop control
Ratio and number of analog to digital points
Speed of control and data acquisition
Master/operator control stations
Type of displays required
Historical archiving requirements
System consideration
Reliability/availability
Speed of communications/update
time/system scan rates
System redundancy
Expansion capability
Application software and modeling
Benefits of a SCADA system
Obviously, a SCADA system’s initial cost has

to be justified. A few typical reasons for
implementing a SCADA system are:
1. Improved operation of the plant or process

resulting in savings due to optimization of
the system
2. Increased productivity of the personnel
3. Improved safety of the system due to better
information and improved control
4. Protection of the plant equipment
5. Safeguarding the environment from a failure
of the system
6. Improved energy savings due to optimization
of the plant
7. Improved and quicker receipt of data so that
clients can be invoiced more quickly and
accurately
8. Government regulations for safety and
metering of gas (for royalties & tax etc)
Go back to contents ↑
2. Distributed control system (DCS)
De!nition – In a DCS, the data acquisition and

control functions are performed by a number of
distributed microprocessor-based units situated
near to the devices being controlled or the
instrument from which data is being gathered.
DCS systems have evolved into

systems providing very sophisticated
analog (e.g. loop) control capability.
A closely integrated set of operator
interfaces (or man machine interfaces)
is provided to allow for easy system
configurations and operator control.
The data highway is normally capable of fairly

high speeds (typically 1 Mbps up to 10 Mbps).
Figure 3 – Distributed control system (DCS)
3. Programmable logic controller (PLC)
Since the late 1970s, PLCs have replaced

hardwired relays with a combination of ladder–
logic software and solid state electronic input and
output modules.
They are often used in the

implementation of a SCADA
RTU as they offer a standard
hardware solution, which is
very economically priced.
Figure 4 – Programmable logic controller (PLC) system
How Are Field Devices Wired to PLCs (VIDEO)
Part I
How to Wire Sensors to a PLC -…
Part II
How to Wire Sensors to a PLC -…
4. Remote terminal units
An RTU (sometimes referred to as a remote

telemetry unit) as the title implies, is a
standalone data acquisition and control unit,
generally microprocessor based, which monitors
and controls equipment at some remote location
from the central station.
Its primary task is to control and

acquire data from process
equipment at the remote location
and to transfer this data back to a
central station.
It generally also has the facility for having its

configuration and control programs dynamically
downloaded from some central station. There is
also a facility to be configured locally by some
RTU programming unit.
Although traditionally the RTU

communicates back to some
central station, it is also
possible to communicate
on a peer-to-peer basis with
other RTUs. The RTU can
also act as a relay station
(sometimes referred to as a
store and forward station) to
another RTU, which may not
be accessible from the central
station.
Small sized RTUs generally have less than 10 to

20 analog and digital signals, medium sized
RTUs have 100 digital and 30 to 40 analog
inputs. RTUs, having a capacity greater than this
can be classified as large.
A typical RTU configuration is shown in

Figure 5:
Figure 5 – Typical RTU hardware structure
Typical RTU hardware modules include:
Control processor and associated memory

Analog inputs
Analog outputs
Counter inputs
Digital inputs
Digital outputs
Communication interface(s)
Power supply
RTU rack and enclosure
Typical requirements for an RTU system:
In the writing of a specification, the following

issues should be considered:
Hardware:
Individual RTU expandability (typically up to 200

analog and digital points)
Off the shelf modules

Maximum number of RTU sites in a system
shall be expandable to 255
Modular system – no particular order or
position in installation (of modules in a rack)
Robust operation – failure of one module will
not affect the performance of other modules
Minimization of power consumption (CMOS
can be an advantage)
Heat generation minimized
Rugged and of robust physical construction
Maximization of noise immunity (due to
harsh environment)
Temperature of –10 to 65°C (operational
conditions)
Relative humidity up to 90%
Clear indication of diagnostics
Visible status LEDs
Local fault diagnosis possible
Remote fault diagnostics option
Status of each I/O module and channel
(program running/failed/communications
OK/failed)
Modules all connected to one common bus
Physical interconnection of modules to the
bus shall be robust and suitable for use in
harsh environments
Ease of installation of field wiring
Ease of module replacement
Removable screw terminals for
disconnection and reconnection of wiring
Environmental considerations
The RTU is normally installed in a remote

location with fairly harsh
environmental conditions.
Typically it is specified for the following

conditions:
Ambient temperature range of 0 to +60°C

(but specifications of –30°C to 60°C are not
uncommon)
Storage temperature range of –20°C to
+70°C
Relative humidity of 0 to 95% non
condensing
Surge withstand capability to withstand
power surges typically 2.5 kV, 1 MHz for 2
seconds with 150 ohm source impedance
Static discharge test where 1.5 cm sparks

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Industrial Automation / SCADA

Five Terms You MUST Be Familiar

By Edvard April, 25th 2018 Save to PDF ♛

Similar, but not the same

Five Terms You MUST Be Familiar With: SCADA, DCS,

Let’s shed a light on these five terms:

A SCADA (or supervisory control and data

The master station displays the acquired data

The accurate and timely data (normally real-time)

There is a fair degree of confusion between the

The inevitable question is how far

SCADA Tutorial for Beginners---…

There is a history of unsuccessful SCADA

Today hardware reliability is less of a

It should be noted in passing that many operators

The field devices however fall outside the scope

Figure 1 – Diagram of a typical SCADA system

On a more complex SCADA system there are

1. Field level instrumentation and control

The RTU provides an interface to the field analog

The communications system

The master station (and submasters) gather data

SCADA technology has existed since

In addition there has been a growing trend to use

Figure 2 – SCADA system

Considerations of SCADA system

Typical considerations when putting a SCADA

Overall control requirements

Benefits of a SCADA system

Obviously, a SCADA system’s initial cost has

1. Improved operation of the plant or process

2. Distributed control system (DCS)

De!nition – In a DCS, the data acquisition and

DCS systems have evolved into

The data highway is normally capable of fairly

Figure 3 – Distributed control system (DCS)

3. Programmable logic controller (PLC)

Since the late 1970s, PLCs have replaced

They are often used in the

Figure 4 – Programmable logic controller (PLC) system

How Are Field Devices Wired to PLCs (VIDEO)

How to Wire Sensors to a PLC -…

How to Wire Sensors to a PLC -…

4. Remote terminal units

An RTU (sometimes referred to as a remote

Its primary task is to control and

It generally also has the facility for having its

Although traditionally the RTU

Small sized RTUs generally have less than 10 to

A typical RTU configuration is shown in

Figure 5 – Typical RTU hardware structure

Typical RTU hardware modules include:

Control processor and associated memory

Typical requirements for an RTU system:

In the writing of a specification, the following

Individual RTU expandability (typically up to 200

Off the shelf modules

The RTU is normally installed in a remote