What is SCADA?
When you work in such fields as the oil and gas industry or the utilities industry, there’s a significant chance that you will encounter a SCADA system while on the job. These systems are essential for the monitoring and control of various pieces of equipment that are designed to handle time-sensitive and critical events. While there are many different types of SCADA software, each type comes with similar features. Whether you own an industrial company or are a key manager at one, you’ll likely want to know more about SCADA systems and how they work. While this software is designed to run in the background, there are times when a problem could develop with the software, which is why it’s important to understand what SCADA is and how it works.
What Does a SCADA System Refer To?
SCADA stands for supervisory control and data acquisition, which is a type of computer system that is meant to gather and quickly analyze real-time data. These systems are commonly used within production facilities and industrial plants. When put in use, a SCADA system is designed to help with the control and monitoring of an entire plant or equipment that deals specifically with time-sensitive and critical events. For instance, when a leak occurs in a pipeline, the SCADA system that’s in place will help to detect the leak and transfer the information pertaining to the leak back to a central location.
While it’s possible for this software to be simplistic, there are also many scenarios that require a complex SCADA system. An example of a simple SCADA system is when it’s being used to monitor the general conditions inside of a small office building. On the other hand, more complex systems are required for real-time monitoring of a municipal water system or nuclear power plant. While this type of software was initially used in the 1960’s, it has since become an essential component in nearly all production facilities and industrial plants.
There are many things that can be done with SCADA depending on the exact needs of the company using the system. This system provides organizations with the ability to control various processes locally or in a remote location. Real-time data can be gathered, monitored, and processed in an instant when using this software. The HMI (human-machine interface) software also allows employees or managers within the organization to directly interact with a wide variety of devices, which include valves, sensors, motors, and pumps. Any event that occurs can be recording by the system into a log file, which can be addressed immediately.
Primary Applications of SCADA Systems
SCADA is used in many different applications, most of which are specific to the type of business that’s using the system. When it comes to the oil and gas industry, the main applications that they use SCADA for include the monitoring and control of pipelines, the remote monitoring and control of pumping, storage, and production locations, the monitoring of offshore platforms, and the control of refineries. When looking specifically at utilities, the businesses in this industry typically use SCADA to control the distribution of electrical power from coal, nuclear, and gas-fired sources. These systems can also be used for the transmission of electrical power.
For water and wastewater plants, SCADA is typically utilized for the monitoring and control of water treatment centers and wastewater collection and treatment facilities. Some of the other industries that this software is commonly used in include agriculture and irrigation, transportation, pharmaceutical, telecommunications, and manufacturing. While these systems are able to maintain equipment efficiency and process data for quicker and smarter decisions, a key benefit of this software is that the real-time communication of system issues helps to significantly reduce downtime.
How SCADA Works
The standard architecture for a SCADA system starts with PLCs or RTUs, which stand for programmable logic controllers and remote terminal units respectively. These are both considered to be microcomputers that are designed to interact and communicate with many different objects, which extend to sensors, HMIs, factory machines, and end devices. These communications and pieces of information are then routed from the objects in question to the computers that have been outfitted with SCADA software.
Once the SCADA software receives the information, the data is then processed, distributed, and displayed, which allows employees and operators to analyze this data and make decisions from it. One example of how SCADA works involves an oil pipeline that has a leak. Once the leaks occurs, SCADA will detect the exact location of the leak and then transfer this data back to a central location, which helps to alert employees about the leak. This data will also be analyzed by the system. For instance, SCADA will be able to determine if the leak is critical, which could require additional measures to be taken by any nearby staff. The information will then be displayed in a manner that’s organized and logical, which allows employees to read and interpret the information immediately. Being able to read this information quickly is essential for operators to make rapid decisions.
Another example of how SCADA works involves the manufacture of a certain product. An operator may be notified by the SCADA system that a specific batch of the product is displaying a high number of errors, which could lead to significant problems if the product is placed on the market before the errors have been corrected. With this notification, the operator can pause the operation momentarily while they take a look at the data received by the SCADA system through an HMI. This data allows the operator to determine what’s causing the problem. Once the problem has been identified, a correction can be made and future losses can be prevented. A standard SCADA system includes sensors or manual inputs that feed data to the PLC or RTU in the system. This data can then be sent to an operational terminal via an HMI or a workstation.
Costs Associated With SCADA Systems
The costs for a SCADA system depend mainly on how complex the system is. If the SCADA software that you need to purchase is designed for a small office setting, the costs will be low. However, if the SCADA software is going to be installed for the monitoring of a municipal water plant, the costs will be much higher. SCADA pricing also depends on the company that you purchase from, the bundle that you select, and the features that you want your software to have. Some companies offer custom solutions that are available for as low as $1,500-$2,000. Basic packages tend to cost upwards of $8,000-$10,000 and come with such features as alarm notification, the ability to store tag histories, and unlimited SQL access.
Some companies will offer additional packages and bundles that can range from $15,000-$40,000. The mid-tier package might include an extra layer of business analytics and data management, while the top-tier package could be outfitted with SMS functionality, voice notification, and sequential function charts. The package that’s right for you and your business largely depends on the needs of your company. Many businesses will also offer individual modules with their SCADA software that allows you to only purchase the features that you require. For instance, you might be able to obtain unlimited HMI visualization clients for around $5,000-$7,000 or a reporting module for a few thousand. The best SCADA providers will offer packages that bundle software features as well as individual modules, which means that even smaller companies would be able to afford the software.
Problems You Might Encounter With SCADA
Even the best SCADA systems can malfunction from time to time. The system may even appear to be working correctly during diagnostics only to malfunction at a later date, which can be problematic when you need to make sure that your office building or industrial plant is operating smoothly. One of the more common problems that you might encounter with SCADA involves a direct connection from external enterprise systems to SCADA. These systems are designed first and foremost to be data collection and visualization tools, which means that additional functionalities aren’t always readily supported.
While most SCADA software comes with quality storage systems, most are incapable of supporting hundreds or even thousands of external connections to the system from third parties. The performance of your SCADA system can quickly deteriorate if substantial amounts of data are being taken from SCADA storage systems. The better method for warehousing this data is to store the data directly in a process historian, which is isolated from the rest of the SCADA system and allows for a more controlled data stream. Other problems with the SCADA system might involve an application redundancy when you purchase individual modules, poor engineering, and an incorrect application or protocol stack, the latter of which primarily occurs when the SCADA software you own supports the “Sequence of Events” feature.
How to Secure SCADA Systems
Like all types of software, the security of your SCADA system can be breached if it’s not strong enough to account for various cyber threats. Most of this software has been designed to bolster efficiency, which means that the security of the software is usually weak. In the event that your security isn’t strong enough, your system will be open to such vulnerabilities as process redirection, disruption of service, or the manipulation of data. No matter the size of your SCADA network, it’s important that you increase the security of the system in question.
You should begin by identifying every connection to your SCADA network. Once you’ve identified these connections, a risk analysis should be performed to determine how necessary each connection is. Any connections that aren’t deemed necessary should be disconnected. The connections that you should check include dial-up connections, internet connections, wide area or local networks, connections to vendors and business partners, and wireless network devices. You can also evaluate how secure each connection is by conducting a vulnerability analysis for all remaining networks. For the less secure networks, it’s recommended that you implement intrusion detection systems and firewalls at each point of entry.
There are some older systems that don’t have any actual security features, which is dangerous if you want to keep your network secure. Even if you have an older system, you must request to your SCADA vendor that they provide you with security features via upgrades and patches. Even in modern systems, it’s common for the factory default security settings to be set for maximum usability, which means that security is low. You should change these settings to provide you with the maximum amount of security instead.
Some additional steps you should take to bolster security include establishing a team that can identify and evaluate potential attacks and system vulnerabilities, performing regular technical audits to highlight security concerns, and establishing incident monitoring that’s up and running 24/7. Your system administrators, managers, and other users of the SCADA system should all understand their roles and responsibilities for keeping the system secure. If ever a cyber attack occurs, system backups and recovery plans should be in place to allow for rapid recovery. By enhancing the strength of your system security and building a strong cyber security team, you should be able to mitigate the inherent risks that come with using a SCADA system.
Features of Modern SCADA Systems
SCADA systems have gone through many technological advancements in recent years, which has allowed for the introduction of some highly beneficial features and components. For instance, modern systems allow for real-time data to be accessed from any remote location in the world, which makes for better decision-making. Most of these systems are also equipped with rapid application development capabilities, which provides users with the ability to design applications with relative ease. The usage of modern IT standards has bolstered the security, reliability, efficiency, and productivity of most SCADA systems. The availability of wireless equipment for these systems has also helped to reduce costs and enhance reliability.
How SCADA Can Help Businesses
In essence, SCADA systems help with efficiency of various operations through the use of automation. With one of these systems installed, your business would be able to study the results of measured conditions and create an optimal response to these conditions, which could then be executed automatically whenever these conditions occur in the future. For example, if ever a critical leak is detected, the system could immediately close a nearby valve to get rid of the hazardous conditions.
When a business leaves their employees or managers to monitor equipment and the processes that occur with this equipment, human error is always a possibility. Using SCADA eliminates these human errors. This software also automates the routine and commonplace tasks that would otherwise take up far too much time when performed by an employee, which increases productivity. The presence of these systems allows for better management of critical failures with machines in real-time, which means that the successful recovery from a critical failure is more likely.
When an employee or operator is left to handle a case of equipment failure on their own, the stresses that come with making split-second decisions could lead to one or more mistakes being made, which could prove to be very costly. These systems are practically essential for any large business or industrial plants. Because of how large oil refineries and wastewater collection facilities are, using a SCADA system to monitor and control the equipment may be the only way to reduce costs and maintain profitability. Larger work sites require more manpower to handle such tasks, which is why it’s better to automate these tasks.
Further Readings:
The Ultimate Guide to SCADA Systems
IndustLabs SCADA Systems
Here at IndustLabs we make a quality reliable SCADA System. We can provide a specifically designed for your operation’s specifications. If you would like to learn more about our SCADA System Solution, be sure to contact us today.
UL 508A Standard for Industrial Control Panels
UL 508A is a standard set by Underwriters Laboratories (UL) for the safety of industrial control panels. This standard is an important aspect of ensuring that industrial control panels are safe and reliable, and can protect against hazards such as electrical shock and fire. UL 508A is a supplement to the UL 508 standard, which covers the general requirements for the construction of industrial control panels.
What does a UL Listed Industrial Control Panel label signify?
The UL 508A standard is specifically designed for the construction of industrial control panels that are used in air-conditioning and refrigeration equipment. This standard includes additional requirements for the use of air conditioning and other types of equipment in control panels, as well as for the use of specific types of wiring methods and terminal blocks.
One of the key requirements of UL 508A is that industrial control panels must be tested and certified by UL before they can be used in industrial settings. This ensures that the panels are safe and reliable, and can protect against hazards such as electrical shock and fire. UL 508A certification also ensures that the control panels are designed and constructed with specific materials and components, and that they meet certain minimum requirements for things like short circuit current rating, overcurrent protection, and marking requirements.
The UL 508A standard includes specific requirements for the use of power circuit components, such as circuit breakers and overload relays, as well as for the use of related control circuit devices, such as pilot lights and interconnecting wiring. This ensures that the control panels are designed and constructed in a way that ensures safe and reliable operation, even under extreme conditions such as high ambient temperatures or in hazardous locations.
In addition to the UL 508A standard, many industrial control panels also follow the National Electric Code (NEC), which is a nationally recognized safety standard for electrical equipment and wiring methods. The NEC requires that industrial control panels be designed and constructed in a specific way, and that they meet certain minimum requirements for things like short circuit current rating, overcurrent protection, and marking requirements.
Industrial control panel builders should consider the importance of meeting UL 508A standard to ensure safety and reliability of their control panels, it's important to consider the long-term value of a panel that meets all the necessary safety standards. While it may cost more upfront to build a panel that meets UL 508A standards, it can save money in the long run by avoiding costly safety issues and ensuring the panel can be used for a longer period of time.
In addition to designing and building industrial control panels that meet UL 508A standards, many companies also offer third-party certification services. This means that they can test and certify their own control panels, as well as those built by other companies, to ensure they meet UL 508A standards. This service is important as it guarantees that the control panel is built to the highest safety standards and that it is suitable for use in a wide range of industrial settings.
In conclusion, UL 508A is an important standard to ensure safety in industrial control panels that are used in air-conditioning and refrigeration equipment. This standard includes additional requirements for the use of air conditioning and other types of equipment in control panels, as well as for the use of specific types of wiring methods and terminal blocks. It's important for panel builders to consider the importance of meeting UL 508A standard to ensure safety and reliability of their control panels.
What if an Inspector rejects my equipment ?
UL 508A is a standard set by Underwriters Laboratories (UL) for the safety of industrial control panels. This standard is an important aspect of ensuring that industrial control panels are safe and reliable, and can protect against hazards such as electrical shock and fire. The UL 508A standard is specifically designed for the construction of industrial control panels that are used in air-conditioning and refrigeration equipment. It includes additional requirements for the use of air conditioning and other types of equipment in control panels, as well as for the use of specific types of wiring methods and terminal blocks.
One of the key requirements of UL 508A is that industrial control panels must be tested and certified by UL before they can be used in industrial settings. This ensures that the panels are safe and reliable, and can protect against hazards such as electrical shock and fire. UL 508A certification also ensures that the control panels are designed and constructed with specific materials and components, such as power circuit components, circuit breakers, and overload relays, and that they meet certain minimum requirements for things like short circuit current rating, overcurrent protection, and marking requirements.
The UL 508A standard includes specific requirements for the use of related control circuit devices, such as pilot lights and interconnecting wiring, as well as for the use of power circuit components, such as circuit breakers and overload relays. This ensures that the control panels are designed and constructed in a way that ensures safe and reliable operation, even under extreme conditions such as high ambient temperature or in hazardous locations.
In addition to the UL 508A standard, many industrial control panels also follow the National Electric Code (NEC), which is a nationally recognized safety standard for electrical equipment and wiring methods. The NEC requires that industrial control panels be designed and constructed in a specific way, and that they meet certain minimum requirements for things like short circuit current rating, overcurrent protection, and marking requirements.
It's important for panel builders to consider the importance of meeting UL 508A standard to ensure the safety and reliability of their control panels. While it may cost more upfront to build a panel that meets UL 508A standards, it can save money in the long run by avoiding costly safety issues and ensuring the panel can be used for a longer period of time. Many companies also offer third-party certification services, where they can test and certify their own control panels, as well as those built by other companies, to ensure they meet UL 508A standards.
In case of rejection from an inspector, it's important to address and rectify any issues found to meet the UL 508A standard. This will ensure that the control panel is built to the highest safety standards and suitable for use in a wide range of industrial settings.
What is the UL 508A Standard for Control Panels?
UL508 is a standard set by Underwriters Laboratories (UL) for the safety of industrial control panels. This standard is an important aspect of ensuring that industrial control panels are safe and reliable, and can protect against hazards such as electrical shock and fire. As a company that specializes in industrial controls, Industlabs is well-versed in the requirements of UL508 and how to design and build control panels that meet these standards.
Industrial control panels are used in a wide range of industrial settings to control and monitor various types of equipment and machinery. These control panels are often made up of a combination of electrical and electronic components, including circuit breakers, motor controllers, and terminal blocks, among others.
To meet UL508 standards, industrial control panels must be designed and constructed with specific materials and components, and must be tested for things like electrical and thermal performance, as well as environmental factors like vibration and humidity. This ensures that the panels are safe and reliable and can protect against hazards such as electrical shock and fire.
The UL508 standard is based on the National Electric Code (NEC), which is a nationally recognized safety standard for electrical equipment and wiring methods. The NEC requires that industrial control panels be designed and constructed in a specific way, and that they meet certain minimum requirements for things like short circuit current rating, overcurrent protection, and marking requirements.
One of the key requirements of UL508 is that industrial control panels must be tested and certified by UL before they can be used in industrial settings. This ensures that the panels are safe and reliable, and can protect against hazards such as electrical shock and fire. UL508 certification also ensures that the control panels are designed and constructed with specific materials and components, and that they meet certain minimum requirements for things like short circuit current rating, overcurrent protection, and marking requirements.
The UL508 standard is based on the National Electric Code (NEC), which is a nationally recognized safety standard for electrical equipment and wiring methods. The NEC requires that industrial control panels be designed and constructed in a specific way, and that they meet certain minimum requirements for things like short circuit current rating, overcurrent protection, and marking requirements.
To meet UL508 standards, industrial control panels must be designed and constructed with specific materials and components, and must be tested for things like electrical and thermal performance, as well as environmental factors like vibration and humidity. This ensures that the panels are safe and reliable and can protect against hazards such as electrical shock and fire.
At Industlabs, we have a team of engineers and technicians who are experienced in designing and building industrial control panels that meet UL508 standards. Our control panels are made with high-quality materials and components, and are rigorously tested to ensure they meet all UL508 requirements.
In addition to designing and building control panels, we also offer UL508 certification, The UL508 standard also includes specific requirements for the use of power circuit components, such as circuit breakers and overload relays, as well as for the use of related control circuit devices, such as pilot lights and interconnecting wiring. This ensures that the control panels are designed and constructed in a way that ensures safe and reliable operation, even under extreme conditions such as high ambient temperatures or in hazardous locations.
In addition to the UL508 standard, Industlabs also follows the UL508A standard for the construction of industrial control panels. This standard includes additional requirements for the use of air conditioning and other types of equipment in control panels, as well as for the use of specific types of wiring methods and terminal blocks. By following both the UL508 and UL508A standards, we ensure that our control panels are built to the highest safety standards and are suitable for use in a wide range of industrial settings.
When it comes to the cost of industrial control panels, it's important to consider the long-term value of a panel that meets all the necessary safety standards. While it may cost more upfront to build a panel that meets UL508 and UL508A standards, it can save money in the long run by avoiding costly safety issues and ensuring the panel can be used for a longer period of time.
In addition to designing and building industrial control panels that meet UL508 and UL508A standards, Industlabs also offers third-party certification services. This means that we can test and certify our own control panels, as well as those built by other companies, to ensure they meet UL508 and UL508A standards. This service is important as it guarantees that the control panel is built to the highest safety standards and that it is suitable for use in a wide range of industrial settings.
In order to ensure that our control panels continue to meet UL508 and UL508A standards, we conduct periodic audits of our panel shop and documented adherence to the standard. This ensures that our control panels are built to the highest safety standards, and that any safety issues are identified and resolved quickly.
In conclusion, UL508 and UL508A are important standards to ensure safety in industrial control panels and as a company that specializes in industrial controls, Industlabs has the expertise and experience to design and build control panels that meet these standards, and also offer third-party certification services. By working with Industlabs, customers can be confident that their industrial control panels are safe and reliable, and will meet all necessary safety standards. Our expertise in UL508 and UL508A and our commitment to building high-quality control panels make us a leader in the industry and guarantees public safety.
What are Industrial Control Panels?
Industrial control panels are specialized electrical systems that are used to control and automate industrial processes and equipment. These panels typically include a variety of electrical components, such as circuit breakers, fuses, relays, and timers, that are wired together to control the flow of electricity to different pieces of equipment. They also include control devices, such as push buttons, switches, and sensors, that are used to monitor and adjust the process. Industrial control panels can be used in a wide range of industries, including manufacturing, power generation, oil and gas, and more. They are designed to be robust and reliable, and to withstand the harsh conditions found in industrial environments.
How do I calculate the Short Circuit Current Rating of a Control Panel based on UL 508A Supplement SB?
The Short Circuit Current Rating (SCCR) of a control panel is the maximum amount of current that a panel can safely withstand in the event of a short circuit. According to the UL 508A Supplement SB, the SCCR of a control panel is determined by a combination of several factors, including the panel's design and the components used.
To calculate the SCCR of a control panel based on UL 508A Supplement SB, you will need to consider the following steps:
Determine the available short-circuit current at the point of the control panel. This is usually provided by your utility company or an electrical engineer.
Identify the panel's main overcurrent protective device (OCPD), such as a circuit breaker or fuse, and determine its interrupting rating.
Identify the panel's other components, such as relays, contactors, and motor controllers, and determine their short-circuit current ratings.
Determine the lowest short-circuit current rating among the panel's main OCPD and other components. This is the SCCR of the control panel.
Ensure that the SCCR of the control panel is greater than or equal to the available short-circuit current at the point of the control panel
How do I obtain the SCCR for a panel I am building?
It's important to note that the UL 508A Supplement SB also requires that the control panel has a label indicating the SCCR, the specific components used in the panel, and the name of the certifying organization. Also, it's important to note that the SCCR calculation is a crucial step in the design and construction of an industrial control panel and should be done by a qualified professional with knowledge of the UL508A standards.
How does UL relate to the National Electric Code (NEC)?
UL (Underwriters Laboratories) and the National Electric Code (NEC) are two separate entities that have different roles and responsibilities when it comes to ensuring the safety of electrical equipment and installations.
UL is a non-profit organization that tests, evaluates and certifies products to ensure they meet industry safety standards and regulations. UL sets safety standards for a wide range of products and materials, including industrial control panels. UL's certification process involves testing and evaluating a product to ensure it meets the safety standards set by the organization, and then issuing a UL Mark, which indicates that the product has been certified as safe by UL.
The National Electric Code (NEC) is a set of national standards developed by the National Fire Protection Association (NFPA) that govern the installation and maintenance of electrical equipment and wiring. The NEC sets minimum standards for the safe installation and use of electrical equipment, including industrial control panels. The NEC is adopted by most states and municipalities in the US and it's enforced by local building codes, electrical inspectors and insurance companies.
In summary, UL is an organization that certifies products to meet safety standards and the NEC is a set of standards that govern the installation of electrical equipment and wiring. UL is focused on the safety of the product itself and the NEC is focused on the safety of the installation and the use of the product. UL and NEC work together to ensure the safety of industrial control panels and other electrical equipment. UL provides the safety testing and certification, while the NEC provides the installation and use guidelines.
Need a UL508A Motor Starter for your control panel?
At Industlabs, we have a team of engineers and technicians who are experienced in designing and building industrial control panels that meet UL508 standards. Our control panels are made with high-quality materials and components, and are rigorously tested to ensure they meet all UL508 requirements.
In addition to designing and building control panels, we also offer UL508 certification services. This means that we can test and certify our own control panels, as well as those built by other companies, to ensure they meet UL508 standards. This service is important for panel builders, as inspector will reject any control panel that does not have a UL label.
By working with Industlabs, customers can be confident that their industrial control panels are safe and reliable, and will meet all necessary safety standards. Our expertise in UL508 and our commitment to building high-quality control panels make us a leader in the industry.