SCADA (Supervisory Control and Data Acquisition) systems have been supporting industrial professionals for years in overseeing and controlling production processes. Modern, web-based, and flexible SCADA solutions are increasingly being introduced, combining quick access to data, advanced analytical capabilities, and user-friendly interfaces. In this article, we explain what SCADA is, how it works, and why it is so important in the industrial sector.
What is SCADA?
SCADA is software (and its associated infrastructure) that:
- Collects data from devices and sensors (e.g., PLCs, controllers, measuring systems).
- Centralizes this data in one system, where it can be monitored and archived.
- Allows the operator to control devices and respond to undesirable situations (alarms, failures).
- Facilitates analysis and reporting, enabling quicker, more informed decision-making.
SCADA systems are most commonly used in industrial environments, ranging from production lines and power plants to water supply systems and sewage treatment plants. As the role of data increases in various processes, SCADA systems are also increasingly being implemented in biotechnology and R&D laboratories.
How Does a SCADA System Work?
The following is a simplified architecture of a SCADA system, highlighting the main components.
SCADA System Principles
Below is a description of the key components and their role in the system.
Devices and Sensors At this level, key process parameters (e.g., temperature, pressure, flow) are measured. Data is sent to PLCs or industrial computers (known as edge devices).
Communication Typical protocols used in SCADA systems include Modbus, OPC UA, and MQTT. The system reads data from PLCs and can also send control commands (e.g., change settings).
Server/Central Database Here, data is collected, processed, and stored (e.g., in InfluxDB, PostgreSQL). In traditional SCADA systems, a closed ecosystem is often used, but modern solutions allow the use of open-source software.
Operator Interface (HMI) The purpose of the operator interface is to provide operators with clear dashboards, alarms, and reports. In traditional SCADA systems, the HMI was usually run on workstations, whereas in modern SCADA applications, the interface is available in a browser or on mobile devices.
Advantages of Modern SCADA Systems
- Real-Time Process Monitoring: Thanks to graphical visualizations and control panels, operators can immediately detect irregularities and respond quickly.
- Analytics and Optimization: SCADA systems are increasingly integrating machine learning modules and advanced analytics, allowing for predictive failure detection, more efficient resource management, and cost optimization.
- Scalability and Flexibility: Web-based SCADA solutions can be deployed in the cloud or on-premises, without limitations on the amount of process data or the number of users.
- Security and Easy Maintenance: Modern SCADA systems rely on client-server architecture and use well-established encryption protocols (TLS, VPN), which greatly facilitates system protection and maintenance.
Applications of SCADA Systems in Industry
- Production Lines: Monitoring quality, efficiency, and raw material consumption.
- Energy Sector: Supervising turbines, transmission networks, and cogeneration systems.
- Water Supply and Sewage Treatment Plants: Remote monitoring of water flow and quality.
- Pharmaceuticals, Biotechnology: Control of parameters in reactors, fermenters, and laboratories.
- Transportation and Logistics: Monitoring automated warehouses, conveyors, and sorting systems.
Benefits of Implementing a SCADA System
Implementing a SCADA system can bring tremendous benefits to companies, both in terms of efficiency and safety. Thanks to advanced monitoring and control features, SCADA systems help optimize processes, reduce the risk of failures, and improve production quality.
- Reduction in Downtime and Better Production Control: One of the main advantages of a SCADA system is the ability to continuously monitor all production elements in real time. This allows operators to have full control over processes, enabling quick detection of abnormalities and immediate responses. Increased process automation and instant alerts about failures significantly reduce the risk of downtime, leading to savings in time and costs.
- Faster Decision-Making with Data: SCADA systems collect and analyze large amounts of data in real time. This information enables managers and engineers to make more informed decisions based on precise data from the entire production facility. Automated reports and trend analysis help to quickly identify potential problems and optimize processes, leading to increased efficiency and reduced operational costs.
Our Process Data Monitoring System
Our solution focuses on modern and flexible technologies:
- Communication Protocol: Modbus (TCP/RTU), MQTT, OPC UA (if the client requires it).
- Data Broker: e.g., RabbitMQ, which can handle thousands of messages per second.
- Database: InfluxDB for time-series storage or PostgreSQL for business analytics.
- Application Layer (Backend): Primarily based on Python, allowing easy integration with machine learning modules and data analysis tools.
- Operator Interface (Frontend): Created in Flutter, making it exceptionally responsive, intuitive, and consistent across different devices (computers, tablets, smartphones).
Why Does Our System Work?
- Scalability: You can start with a small number of sensors and gradually expand the installation.
- Flexibility: New algorithms can easily be added, such as failure prediction, vibration analysis, or image recognition.
- Quick Deployment: By using proven open-source solutions, we can focus on the actual needs of a given industry, rather than being limited by licensing restrictions.
Summary
The SCADA system is the heart of monitoring and controlling industrial processes – from production line automation, through energy installations, to water supply systems and biotechnology. In the era of digitalization, more and more companies are looking for solutions that allow them to react quickly, optimize costs, and leverage the potential of data.
Our proposal is lightweight, web-based, and modular SCADA systems that can be scaled and customized to meet various industry needs. If you’re looking for a flexible SCADA solution – contact us for a free consultation!
