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SCADA SYSTEMS: DESIGNING FOR RELIABILITY JONATHAN WHITE, PE FEBRUARY 16, 2016 WEAT FEBRUARY SEMINAR
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SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

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Page 1: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

SCADASYSTEMS:DESIGNING FORRELIABILITY

JONATHAN WHITE, PEFEBRUARY 16, 2016

WEATFEBRUARY SEMINAR

Page 2: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

A reliable SCADA system isachieved by…

1

2

3

Providing redundancy at single points of failure

Enhancing reliability of communications systems

Mitigating adverse environmental conditions

Page 3: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

IntegratedControl Systems

Instrumentation

Reliable SCADA systems require acomprehensive design approach

SCADA System

Page 4: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Reliable SCADA systems require acomprehensive design approach

SCADA System

Process Design

Electrical Design

Programming Design

CommunicationsSystems Design

HVAC Design

Page 5: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

A reliable SCADA system isachieved by…

1

2

3

Providing redundancy at single points of failure

Enhancing reliability of communications systems

Mitigating adverse environmental conditions

Page 6: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Redundant methods can eliminatesingle points of failure

Controller VFDRemoteTelemetry

Wetwell

ControlPanel

Page 7: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Redundant methods can eliminatesingle points of failure

Wetwell

ControlPanel

Controller VFDRemoteTelemetry VFD

Page 8: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Redundant methods can eliminatesingle points of failure

Wetwell

ControlPanel

Controller VFDRemoteTelemetry VFD

Page 9: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Redundant methods can eliminatesingle points of failure

BackupRelay

Control

Wetwell

ControlPanel

Controller VFDRemoteTelemetry VFD

Page 10: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Redundant methods can eliminatesingle points of failure

Cellular

BackupRelay

Control

Wetwell

ControlPanel

Controller VFDRemoteTelemetry VFD

Page 11: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Redundant controllers protect againstfailures with a centralized approach

PrimaryPLC

Remote I/O PanelHeadworks

Remote I/O PanelAeration Basins

Remote I/O PanelRAS/WAS

Main Control Building

Primary Server

Page 12: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Redundant controllers protect againstfailures with a centralized approach

PrimaryPLC

SecondaryPLC

Redundant crossload

Remote I/O PanelHeadworks

Remote I/O PanelAeration Basins

Remote I/O PanelRAS/WAS

Main Control Building

Primary Server

Sec. Server

Page 13: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Distributed control approacheliminates single point of failure

Standalone PLC PanelHeadworks

Main Control Building

Standalone PLC PanelAeration Basins

Standalone PLC PanelRAS/WAS

SCADA Server

Page 14: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Typical configurations only allowone path of communication

PrimaryPLC

SecondaryPLC

Redundant crossload

Remote I/O PanelHeadworks

Remote I/O PanelAeration Basins

Remote I/O PanelRAS/WAS

Main Control Building

RAS/WASSPOF

Page 15: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Ring configurations allow datato travel multiple ways

PrimaryPLC

SecondaryPLC

Redundant crossload

Remote I/O PanelHeadworks

Remote I/O PanelAeration Basins

Remote I/O PanelRAS/WAS

Main Control Building

Self Healing Ring

Page 16: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Backup power is necessary tomaintain system control

STANDBYGENERATOR

UPS

1hour

10 seconds –24 hours

OUTAGE LENGTH

Critical timewithout power as

generator kicks on

Page 17: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Redundant control executedat WWTP

Redundant PLCs &SCADA Servers

17 MGDWWTP

Local PLCs and RIOPanels

Ring NetworkConfiguration

11

2

3

2

2

2

2

2

3

Page 18: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

A robust SCADA system isachieved by…

1

2

3

Providing redundancy at single points of failure

Enhancing reliability of communications systems

Mitigating adverse environmental conditions

Page 19: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Remote communication networksprovide variable reliability

Dedicated fiber optic

Radio telemetry

Broadband

Cellular

MOSTRELIABLE

LEASTRELIABLE

MOST CRITICALSCADA OPERATIONS

LEAST CRITICALSCADA OPERATIONS

Page 20: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Radio telemetry reliabilitydepends on:

• Grounding is very important• Surge protection at multiple

levels

LightningProtection

• Signal buffer at receiving end• 20dB recommended• Atmospheric conditions• Keep coax lengths short

FadeMargin

• Only transmit what is needed• Slower rate = fewer errorsData Rate

Page 21: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Remote communicationprovides secondary control

REMOTESECONDARY

SCADAWork station

RADIO RADIO

LOCALPRIMARY

PLC

Page 22: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

A robust SCADA system isachieved by…

1

2

3

Providing redundancy at single points of failure

Enhancing reliability of communications systems

Mitigating adverse environmental conditions

Page 23: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Environmental conditionsaffect control reliability

Ideal Adverse

Relia

bilit

y

Environmental Conditions

High

Low

Page 24: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Proper cooling increasesexpected life

0

30,000

60,000

90,000

104 122 140 158 176

Life

in H

ours

Temperature in °F

10 Years

Variable Frequency DriveLife Expectancy

5 Years

Page 25: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Panel protection extends lifeexpectancy

Type 1 Type 12 Type 3R Type 4X Type 7

Ingressof dirt

Dirt, lightsplashing

water

Rain, snow,and sleet

Rain, snow,sleet,

hosedownwater,

corrosiveagents

ExplosionProof

Hazardouslocations

Cost

Page 26: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

Comprehensive design approachcreates SCADA system reliability

Provides redundancy at single points of failure

Enhances reliability of communications systems

Mitigates adverse environmental conditions

1

2

3

Page 27: SCADA Systems: Designing for Reliability · 2016-02-16 · scada systems: designing for reliability jonathan white, pe february 16, 2016 weat february seminar. a reliable scada system

QUESTIONS?JONATHAN WHITE, PE

[email protected]

WEATFEBRUARY SEMINAR