Things to Consider When Buying SCADA Systems
Things to consider when purchasing SCADA systems include technical, operational, and security criteria, and all these details are critical. Because the SCADA infrastructure to be installed will operate continuously for years, it will directly affect the company’s production efficiency, cost management, and process safety. Therefore, the right SCADA selection not only protects the value of the investment but also determines production continuity and the digitalization capacity of the facility.
Many businesses rush through the SCADA selection process and encounter serious integration, security, and usage problems in the future. To prevent these problems, the needs analysis, infrastructure compatibility, cybersecurity, data management, and integration capabilities must be evaluated in detail. Reltek Energy provides technical guidance in all these stages, ensuring that the business chooses the correct configuration. This prevents performance losses, increases system flexibility, and reduces long-term maintenance costs.
What Do SCADA Systems Cover?
So, what does “What Do SCADA Systems Cover?” mean? SCADA systems are a comprehensive structure that monitors, controls, and reports all industrial processes. It generally includes the following components:
- Data Collection Mechanisms: These mechanisms continuously read physical quantities (temperature, pressure, flow, etc.) from sensors and field devices in the field. These collected raw data are then transmitted to the central system for processing, analysis, and presentation to operators.
- Control and Command Interfaces (HMI): HMI (Human-Machine Interface) is a graphical interface where operators can observe the system and send control commands. These interfaces schematically show the real-time status of the system and allow operators to safely perform operations such as opening/closing valves.
- Communication Protocols: SCADA uses standard communication languages such as Modbus, OPC, and DNP3, which allow devices and software from different manufacturers to communicate with each other. These protocols manage the fast and reliable data flow between field devices and the central server, protecting data integrity and security.
- Alarm – Event Management Modules: These modules instantly alert operators when predefined critical situations occur in the system (e.g., temperature exceeding the limit). In addition, it records every important event in the system (operator intervention, device failure, etc.) with a time stamp and creates a log for later analysis.
- Performance Reporting Tools: These tools use collected historical data to perform analysis of metrics such as production quantity, energy consumption, and failure times. It generates summary reports and trend graphs that help managers and engineers evaluate system efficiency and make improvement decisions.
- Database Management Systems: Ensures the secure and orderly storage of large volumes of real-time and historical data collected by SCADA systems. These systems form the backbone of the system by providing quick and easy access to the data needed by reporting and analysis tools.
- Integration with PLC, RTU, and Field Devices: Control devices such as PLC (Programmable Logic Controller) and RTU (Remote Terminal Unit) are the field-level brains of the SCADA system that directly manage physical processes. SCADA integrates with these devices, transmitting control commands to them while continuously receiving instant status data of the process from them.
It also works integrated with ERP, MES, and IIoT platforms, providing real-time data flow. Consumption and quality values are constantly analyzed with energy monitoring modules.
What Are the Basic Criteria in SCADA Selection?
What are the basic criteria in SCADA selection, which is so important systemically? The right SCADA selection directly affects business efficiency. Therefore, the following criteria must be evaluated.
- Integration Structure and Protocol Support: The SCADA system to be selected must be able to communicate seamlessly with existing PLC, RTU and other field devices in the facility and must support all industry-standard protocols such as OPC, Modbus, DNP3. A strong integration structure ensures the reliability of data flow and future ease of expansion, regardless of different device manufacturers.
- Scalable Architecture: The system must have a flexible architecture that can easily adapt from a small initial application to large and complex facilities with thousands of data points. Scalability ensures both efficient use of existing hardware and software resources and minimizes additional investment requirements as the facility grows.
- Compliance with Cybersecurity Standards: SCADA, which manages critical infrastructures, must comply with encryption, user authorization, and current industrial security protocols to prevent unauthorized access, malware, and cyberattacks. Cybersecurity not only protects data integrity but also directly affects the physical security and operational continuity of the facility.
- HMI Quality: HMI (Human-Machine Interface) must be designed with intuitive, ergonomic, and clear graphics so that operators can quickly understand the process and react to errors instantly. A high-quality HMI speeds up the operator’s decision-making processes by using correct color coding and trend indicators, free from unnecessary complexity.
- Data Processing Capacity: The system must be able to collect, process, and archive hundreds or thousands of sensor data per second without delay. High data processing capacity is vital for making accurate real-time decisions, especially in rapidly changing processes, and for reliably analyzing historical data.
- Maintenance Costs and License Model: In addition to the initial purchase cost of the SCADA software, the total cost of annual maintenance, updates, and new licensing models (e.g., subscription or perpetual license) should be examined in detail. A transparent and predictable licensing model prevents unexpected expenses in the long run while guaranteeing continuous technical support and access to up-to-date software.
- Remote Access Capabilities: It provides great convenience for authorized users to connect to the system from outside the facility via secure VPN or other encrypted tunnels to perform monitoring and necessary interventions. Remote access significantly increases operational flexibility and response time, especially in case of failures or when mobile teams need to get information quickly.
Frequently Asked Questions When Buying SCADA Systems
Frequently asked questions when buying SCADA Systems are usually about security, integration, and investment cost issues. Frequently asked questions when buying SCADA Systems are usually about security, integration, and investment cost issues. Frequently asked questions are usually: Is the security structure sufficient? What is the total cost of ownership? Is there mobile/web access? What are the alarm and reporting capabilities? These and similar questions are frequently asked when buying SCADA. Now, let’s take a look at the most frequently asked questions on this subject.
How to Choose the Best SCADA for Industrial Automation?
The best SCADA is the one that best suits your facility’s needs. It is the one that fully meets the needs. First, an equipment inventory should be taken. Then, the protocols should be determined and the future plan should be analyzed. Finally, reference projects should be examined and an idea should be obtained about the final result. Remember, SCADA selection is a process management.
System Architecture and Scalability
Modern SCADA architecture must be flexible. Modern SCADA architecture should be designed in a modular, flexible, and expandable structure. This modular structure allows new sites, devices, or software features to be easily added without the need to change the main system from scratch. The
What Should the SCADA Infrastructure Be Like?
What should the SCADA infrastructure be like, the selection of which is so important? We can summarize the answer to this question under 5 headings.
- Fiber or Industrial Ethernet Infrastructure: High speed and reliability are essential for data communication in SCADA systems. Therefore,
fiber optic cabling orindustrial Ethernet standards resistant to harsh industrial environments should be used to provide wide bandwidth and resistance to electromagnetic interference. This infrastructure selection guarantees that critical data is transmitted from field devices to the control center uninterruptedly and accurately. - Redundant Server Structure: It is vital that the servers, which are the heart of the SCADA system, continue to operate even in the event of a possible failure. Therefore, a redundant structure consisting of primary (active) and secondary (passive or standby) servers should be established. This structure minimizes system interruptions by automatically transferring (failover) control and data collection functions to the other server in the event of a server crash.
- UPS Supported Energy Structure: Power outages can cause data loss and interruption of control processes in SCADA systems. To eliminate this risk, energy support should be provided to all critical control and communication equipment (servers, network devices, RTU/PLCs) using uninterruptible power supplies (UPS). UPSs keep the system running during short-term interruptions or provide sufficient time for the system to shut down safely during long-term interruptions.
- Network Segmentation: It is mandatory to divide the network into different levels (segmentation) for the security and performance of SCADA networks. This approach prevents unauthorized access and the spread of cyberattacks by isolating the
control network (OT) from the general corporate network(IT) . Segmentation also makes it easier to manage data traffic in large networks and prevents a possible failure from affecting the entire system. - Durable Field Devices: The field components of SCADA systems (RTU, PLC, sensors) are often exposed to harsh industrial conditions such as temperature, humidity, vibration, and dust. Therefore, the devices used must be industrial-grade equipment designed to have wide operating temperature ranges, high IP protection classes, and resistance to physical impacts. This durability ensures that the devices are long-lasting and continue to perform reliable data collection and control operations even in harsh environments.
SCADA Integration Structure and Communication Protocols (OPC UA, Modbus, MQTT)
The basis of the SCADA integration structure is formed by various communication protocols that provide reliable and standardized data flow from the field to the center. In particular, protocols such as
SCADA User Interface (HMI) Selection
SCADA user interface (HMI) selection should have the following features:
- It should be intuitive
- It should quickly show critical values
- Alarm management should be strong
- It should be mobile compatible.
The Impact of Correct SCADA Selection on Production Performance
Choosing the right SCADA system reduces downtime: Thanks to its advanced monitoring and diagnostic capabilities that detect equipment failures in advance and quickly inform maintenance teams, the SCADA system minimizes unplanned production downtimes. The right SCADA system increases overall equipment effectiveness (OEE). The right SCADA selection directly increases the OEE rate by continuously monitoring and improving equipment utilization, production speed, and quality, and by identifying improvement opportunities.
It also provides energy optimization. SCADA provides significant energy efficiency and cost savings by analyzing energy consumption points in production processes in detail and automatically optimizing energy-intensive processes. An advantage of choosing the right SCADA is that it increases decision speed. Thanks to its ability to visualize and report instant and accurate data, SCADA enables operators and managers to respond quickly to critical situations and performance changes, making more accurate and timely decisions.
SCADA Licensing Model and Total Cost of Ownership (TCO) Analysis
- License costs: In the Total Cost of Ownership (TCO) analysis, the initial license fee of the software and possible future expansion costs should be examined in detail.
- Maintenance support: The long-term impact of license renewal fees, technical support agreements, and annual maintenance costs on TCO should be evaluated.
- Training expenses: The initial and continuous training costs to be given to operators and engineers for the successful adoption and efficient use of the new system should be included in the TCO.
- Hardware requirements: The purchase, installation, and energy consumption costs of the server, network equipment, and field equipment on which the SCADA software will run should be added to the TCO calculation.
What are the Cybersecurity Standards in SCADA Systems?
The security standards that must be in place for a fully compatible, secure, and usable SCADA system can be listed as follows:
- IEC 62443 compliance: Compliance with IEC 62443, an internationally recognized standard for industrial automation and control systems, is fundamental to systematically managing cybersecurity risks.
- Data encryption: Strong encryption methods should be used in communication channels to ensure the security of sensitive control and operational data between the SCADA center and field devices.
- Access control: Strict role-based access control mechanisms should be implemented to ensure that users can only access the functions and data they are authorized to access.
- Up-to-date patches: SCADA software, operating systems, and other components should be regularly supported with up-to-date patches to protect the system against known security vulnerabilities.
- Disaster recovery plan: A detailed disaster recovery and business continuity plan should be prepared to quickly restore the system’s functionality and prevent data loss in the event of a major cyberattack or natural disaster.
SCADA Supplier Vendor and Consultant Selection
As with all matters and services, the selection of SCADA suppliers, vendors, and consultants directly affects both the efficiency of the system and the view of SCADA systems. The following should be considered when selecting SCADA suppliers, vendors, and consultants:
- Vendor references: The supplier’s successful applications and customer feedback in similar industrial facilities are critical to understanding the company’s competence.
- Technical support period: The duration and quality of the support agreement offered after purchase is a vital factor for the long-lasting and uninterrupted operation of the system.
- Independent consulting: Receiving services from a consulting firm independent of the supplier ensures that the system is analyzed objectively and the most suitable solution is selected.
- Sectoral experience is important: The supplier’s in-depth knowledge and experience in the sector where the project will be implemented (e.g., energy, water, manufacturing) directly affects the success of the project.
What are SCADA Hardware Requirements?
- High processor power: SCADA servers must have powerful and modern processor units to perform fast data processing and complex visualization tasks smoothly.
- Sufficient RAM: A high amount of random access memory (RAM) capacity should be provided to maintain system performance, especially when analyzing historical data and running multiple applications simultaneously.
- SSD storage: Solid state drives (SSDs) should be preferred for servers instead of traditional hard drives in order to maximize data access speed and shorten system startup time.
- Durable HMI/IPC: It is important that the Human-Machine Interface (HMI) or Industrial PCs (IPCs) selected for field or control room use are durable, fanless, and touch-sensitive to withstand harsh environments.
- Redundant power supplies: Servers and critical network devices must be equipped with multiple power supplies to prevent them from being affected by power outages and to ensure continuous operation.
Things to Consider When Choosing PLC, RTU, and Sensors
PLCs, RTUs, and sensors determine the data flow. There are many points to consider when selecting PLCs, RTUs, and Sensors. The first of these is industrial durability. It is essential that PLCs and RTUs, which are field control devices, have a body structure that is resistant to harsh temperature, humidity, and vibration conditions and complies with industrial standards. In addition, protocol compatibility is also very important. All selected field devices (PLCs, RTUs, Sensors) must support the specified communication protocols (Modbus, Profinet, etc.) in order to communicate seamlessly with the SCADA center. Calibration certificate is another point to be considered. It is critical for the accuracy of the system that especially measuring sensors have current calibration certificates in order to provide reliable and accurate data. In addition, f
Why is Redundancy Necessary for SCADA System Reliability?
Taking backups is critical for the reliability of every system. Here’s what to do for SCADA systems:
- Failover structure: A “failover” mechanism should be established that allows control and data collection functions to automatically and seamlessly switch to the backup server in the event of a main server failure.
- Redundant network: Redundant network connections should be created using dual-path (ring or mesh) topologies to eliminate a single point of failure in the communication infrastructure.
- Reducing the risk of downtime: The overall operating time of the system is maximized and the risk of downtime is minimized thanks to redundant hardware and software configurations in energy, communication, and processing components.
Real-Time Data Management and Factors Determining SCADA Performance
The first factor determining this performance is a low-latency network. Since the data reaching the SCADA center from the field devices affects instant decisions, a high-speed network infrastructure that minimizes the latency in data transfer is required. Another factor is a fast database. A high-performance database structure optimized for fast writing, reading, and querying of the collected large-volume operational data should be used. In addition, high data processing capacity also affects this performance. SCADA servers must have sufficient processing power to process thousands of tags per second, manage alarms, and visualize.
SCADA Pre-Installation Analysis and Needs Assessment Process
- Facility analysis: A detailed examination of existing production processes, control cycles, and operational workflows is the first step in determining the requirements of the SCADA system.
- Operator expectations: The needs, interface expectations, and feedback of the operators who will use the system on a daily basis should be taken as the basis for a user-friendly HMI design.
- Infrastructure review: A comprehensive audit should be conducted to determine whether the existing electrical, network, and physical hardware infrastructure meets the new requirements of SCADA.
- Specification creation: At the end of the analysis process, a detailed and clear technical specification containing all functional and technical requirements should be prepared so that the offers to be received from the suppliers can be compared.
Advantages of Remote Access with Mobile and Web-Based Management in SCADA Systems
As with many issues, Remote Access and Mobile Management provide many advantages in SCADA systems. The first of these is mobile monitoring. Managers and authorized personnel should be able to instantly monitor the operational status of the facility and critical alarms via mobile phone or tablet. Another advantage is web-based management. Flexibility is provided by being able to access the system and perform basic management operations via a standard web browser without the need for additional software installation. In addition, offering VPN security is another advantage. All mobile and web connections must be encrypted with strong Virtual Private Network (VPN) protocols to prevent unauthorized persons from accessing remote access and to protect data integrity.
Benefits of Cloud-Based Architecture When Choosing a SCADA System
The most obvious benefit of using Cloud-Based SCADA is its low investment cost. The fact that it does not require a large capital expenditure (CAPEX) at the beginning for local server hardware and infrastructure is an important advantage of cloud-based SCADA. In addition, automatic redundancy is another advantage. System reliability is automatically increased thanks to the built-in geographic backup and disaster recovery services offered by cloud providers. Easy scalability is another advantage of cloud-based SCADA. It is possible to easily increase or decrease system resources when needed in order to quickly adapt to increases in production capacity or growth in data volume.
New Generation Advantages of SCADA Compatibility with Industrial IoT Integration
- Predictive Maintenance: Real-time data from IIoT sensors integrated into the SCADA system enables the detection of potential equipment failures before they occur; in this way, unexpected downtimes are prevented with planned interventions.
- Data Analytics: The large volume of operational data collected by SCADA is processed with advanced analytical algorithms to reveal bottlenecks, inefficiencies, and root causes of quality problems in production processes.
- Energy Optimization: IIoT integration feeds the SCADA’s energy management module by very precisely monitoring instantaneous changes in energy consumption; this allows consumption to be automatically balanced and energy costs to be reduced.
The Impact of SCADA Maintenance and Support Services on the Purchasing Decision
Undoubtedly, the maintenance and support services to be provided after receiving the service directly affect the purchasing decision. In this context, the following supports directly affect the decision-making;
- 24/7 Support: In order to ensure the uninterrupted continuation of critical production processes, uninterrupted technical support service must be provided that can instantly intervene remotely or on-site in the event of any failure or emergency.
- Regular Updates: It is mandatory to periodically update SCADA software and hardware drivers in order to close security vulnerabilities, add new features, and maintain system performance.
- Support Scope Clarity: Clearly defining service details such as troubleshooting times (SLAs), covered modules, and authorized personnel access in maintenance and support agreements facilitates expectation management and provides quick solutions.