Supervisory Control And Data Acquisition System Research Articles

Digital Transformation In The LPG Industry: Leveraging IoT And Data Analytics For Operational Efficiency

This study presents a comprehensive systematic review exploring the transformative impact of Internet of Things (IoT), Supervisory Control and Data Acquisition (SCADA) systems, and automation technologies on the operational efficiency of the Liquefied Petroleum Gas (LPG) industry. Leveraging the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines, a rigorous review process was conducted to identify, screen, and synthesize existing research. A total of 90 high-quality articles were systematically reviewed to assess how digital technologies are revolutionizing key aspects of LPG operations, including inventory management, predictive maintenance, and fleet optimization. The findings reveal that integrating IoT and SCADA systems enhances real-time monitoring, significantly reduces manual errors, and improves accuracy in inventory tracking, leading to cost reductions of up to 30%. Moreover, predictive maintenance enabled by IoT data analytics was shown to decrease unplanned downtime by 40% and maintenance costs by 25%, further ensuring the reliability of equipment in this high-stakes industry. The review also highlights how automation and digitalization streamline logistics, optimize fuel usage, and improve customer satisfaction by reducing delivery lead times by 20%. Additionally, these technologies support sustainability goals by minimizing carbon emissions through optimized fleet management. By providing a detailed synthesis of current research, this review not only underscores the benefits of digital transformation in the LPG industry but also identifies gaps in the literature, suggesting avenues for future studies to enhance operational excellence, safety, and sustainability in this critical sector.

Wind turbine foundation ring fatigue reliability analysis under wind-load using SCADA system

Under the action of wind load, the foundation ring of the fan will generate stress concentration and alternating stress, leading to fatigue failure. Based on the average wind speed obtained from the supervisory control and data acquisition (SCADA) system, the orthogonal expansion method of random pulsating wind field and the number theory point selection method are used to calculate and simulate the corresponding pulsating wind speed time series, and then calculate the wind speed time series and wind load time series. Based on the ABAQUS finite element software, a model of a 5 MW wind turbine is established. The modal analysis is used to obtain the modal vibration pattern and the intrinsic frequency to verify the reasonableness of the structural modeling. Subsequently, the wind load time series is applied to the wind turbine model to obtain the stress time series using instantaneous modal dynamic analysis (Modal dynamics). The stress time series at the location of maximum stress concentration in the foundation ring is extracted, and the stress time series with the same stress amplitude is obtained through conversion, which has Wiener characteristics. After obtaining the stress amplitude using the rainflow counting method, the fatigue reliability is calculated based on the structural fatigue reliability analysis method considering the threshold crossing duration of the random process. This research holds reference significance for the calculation of fatigue reliability under approximate working conditions.

SCADA Systems in Oil and Gas: Driving Innovation and Efficiency in the Digital Age

Abstract: In the oil and gas sector, supervisory control and data acquisition (SCADA) systems have become a revolutionary force that are transforming operations throughout the whole value chain. This in-depth analysis looks at the development, design, and various uses of SCADA systems in the upstream, middle, and downstream domains. It projects that the global SCADA market for oil and gas will grow to $4.52 billion by 2026. Real-time well monitoring, production optimization, and remote operations are made possible by SCADA systems in upstream operations, which greatly increase output and efficiency. The goal of midstream applications is to increase pipeline efficiency and safety by using predictive maintenance, enhanced leak detection, and flow optimization. By streamlining quality assurance, energy management, and process control, SCADA systems can completely transform refinery operations. SCADA deployments are not without difficulties, though, including data management complications, cybersecurity threats, and legacy system interoperability. In addition to addressing these problems, the study looks at new developments that could improve SCADA capabilities, such as edge computing, digital twins, AI and machine learning integration, and 5G technology. According to the research, SCADA is essential for promoting efficiency, safety, and innovation in the oil and gas industry. Businesses that successfully integrate SCADA technologies while overcoming implementation obstacles will be best positioned to prosper in the complicated and fiercely competitive energy market.

Smart IoT SCADA System for Hybrid Power Monitoring in Remote Natural Gas Pipeline Control Stations

A pipeline network is the most efficient and rapid way to transmit natural gas from source to destination. The smooth operation of natural gas pipeline control stations depends on electrical equipment such as data loggers, control systems, surveillance, and communication devices. Besides having a reliable and consistent power source, such control stations must also have cost-effective and intelligent monitoring and control systems. Distributed processes are monitored and controlled using supervisory control and data acquisition (SCADA) technology. This paper presents an Internet of Things (IoT)-based, open-source SCADA architecture designed to monitor a Hybrid Power System (HPS) at a remote natural gas pipeline control station, addressing the limitations of existing proprietary and non-configurable SCADA architectures. The proposed system comprises voltage and current sensors acting as Field Instrumentation Devices for required data collection, an ESP32-WROOM-32E microcontroller that functions as the Remote Terminal Unit (RTU) for processing sensor data, a Blynk IoT-based cloud server functioning as the Master Terminal Unit (MTU) for historical data storage and human–machine interactions (HMI), and a GSM SIM800L module and a local WiFi router for data communication between the RTU and MTU. Considering the remote locations of such control stations and the potential lack of 3G, 4G, or Wi-Fi networks, two configurations that use the GSM SIM800L and a local Wi-Fi router are proposed for hardware integration. The proposed system exhibited a low power consumption of 3.9 W and incurred an overall cost of 40.1 CAD, making it an extremely cost-effective solution for remote natural gas pipeline control stations.

Design of IIOT Device Based on LoRa for Parsing Data Directly to SCADA System

As the revolution industry 4.0 was started as well as the productivity increases, the need for data analysis increases. Some industries have wide production area and they need long wire to connected between office for transferring data. A wireless system is one of solution to overcome this issue so that the technique of parsing data to expand coverage area for both local and remote systems. In this research, a device that supports IIOT (Industry on Internet of Things) will be designed by utilizing LoRa technology connected to a SCADA (Supervisory Control and Data Acquisition) system for direct parsing data. By using a SCADA system concept and incorporating wireless system as well as connecting to internet so the industrial system can be monitoring from anywhere so productivity can be increased. To test the proposed design, the two scenarios of performance test have been done, they are communicating distance test and the parsing data between two nodes LoRa as well as connecting to SCADA system. The first scenario results in the maximum communication distance that can still carried out reaching 400m. Meanwhile, the experience of second scenario on the IIOT device prototype produces accurate data so that it can be implemented in the wider industry

Reconstruction of environmental site conditions by the integration of SCADA and reanalysis data

For the operational optimization of wind farms, AEP estimation and other tasks, high quality data of environmental conditions at the site are necessary. However, such data is often not available or has insufficient quality. This work tries to fill this gap, by integrating two data sources: the (usually available) operational data from the SCADA (Supervisory Control and Data Acquisition) system, and reanalysis data. SCADA data streams contain measurements from each wind turbine in the farm, but they are affected by various sources of uncertainty (including local flow effects, miscalibration, etc.), and might contain gaps. Meteorological reanalysis datasets can be used to fill gaps and complement SCADA data. However, modelled data can contain a wide range of biases and errors, due to limited model fidelity, coarse spatial and temporal resolution, inaccuracies in the input data feeding the model, etc. This study considers various methods to extract and merge wind speed and direction information from these diverse data sources. The analysis is based on field data measured at two experimental test sites, an offshore site equipped with 111 multi-MW turbines and a lidar buoy, and an onshore site equipped with 14 multi-MW wind turbines and a lidar. The methods are evaluated in the spectral and temporal domains by comparing the reconstructed wind characteristics with measurements from the lidars.

Dynamic Clustering of Wind Turbines Using SCADA Signal Analysis

This work explores the ability to dynamically group the Wind Turbine (WT) of a Wind Farm (WF) based on the behavior of some of their Supervisory Control And Data Acquisition (SCADA) signals to detect the turbines that exhibit abnormal behavior. This study is centered on a small WF of five WTs and uses the observation that the same signals from different WTs in the same WF coherently evolve temporally in a time domain, describing very similar waveforms. In this contribution, averaged signals from the SCADA system are used and omit maximums, minimums and standard deviations, focusing mainly on velocities and other slowly varying signals. For the temporal analysis, sliding windows of different temporal durations are explored. The signals are encoded using the Discrete Cosine Transform, which reduces the problem’s dimensions. A hierarchical tree is built in each time window. Clusters are formed by pruning the tree using a threshold interpretable in terms of distance. It is unnecessary to work with an a priori known number of clusters. A protocol for enumerating the clusters based on the tree’s shape is then established, making it easier to follow the evolution of the clusters over time. The capability to automatically identify WTs whose signals differ from the group’s behavior can alert and program preventive maintenance operations on such WTs before a major breakdown occurs.

An Open-Source Supervisory Control and Data Acquisition Architecture for Photovoltaic System Monitoring Using ESP32, Banana Pi M4, and Node-RED

To overcome the issues of the existing properties and the non-configurable supervisory control and data acquisition (SCADA) architecture, this paper proposes an IoT-centered open-source SCADA system for monitoring photovoltaic (PV) systems. The system consists of three voltage sensors and three current sensors for data accumulation from the PV panel, the battery, and the load. As a part of the system design, a relay is used that controls the load remotely. An ESP32-E microcontroller transmits the collected data to a Banana Pi M4 Berry (BPI-M4 Berry) through the Message Queuing Telemetry Transport (MQTT) protocol over a privately established communication channel using Wi-Fi. The ESP32-E is configured as the MQTT publisher and the BPI-M4 Berry serves as the MQTT broker. Locally installed on the BPI-M4 Berry, the Node-RED platform creates highly customizable dashboards as human–machine interfaces (HMIs) to achieve real-time monitoring of the PV system. The proposed system was successfully tested to collect the PV system voltage/current/power data and to control the load in a supervisory way under a laboratory setup. The complete SCADA architecture details and test results for the PV system data during the total eclipse on 8 April 2024 and another day are presented in this paper.

Wind turbine fault detection and identification using a two-tier machine learning framework

A proactive approach is essential to optimize wind turbine maintenance and minimize downtime. By utilizing advanced data analysis techniques on the existing Supervisory Control and Data Acquisition (SCADA) system data, valuable insights can be gained into wind turbine performance without incurring high costs. This allows for early fault detection and predictive maintenance, ensuring that unscheduled or reactive maintenance is minimized and revenue loss is mitigated. In this study, data from a wind turbine SCADA system in the southeast of Ireland were collected, preprocessed, and analyzed using statistical and visualization techniques to uncover hidden patterns related to five fault types within the system. The paper introduces a conditional function designed to test two given scenarios. The first scenario employs a two-tier approach involving fault detection followed by fault identification. Initially, faulty samples are detected in the first tier and then passed to the second tier, which is trained to diagnose the specific fault type for each sample. In contrast, the second scenario involves a simpler solution referred to as naive, which treats fault types and normal cases together in the same dataset and trains a model to distinguish between normal samples and those related to specific fault types. Machine learning models, particularly robust classifiers, were tested in both scenarios. Thirteen classifiers were included, ranging from tree-based to traditional classifiers, neural networks, and ensemble learners. Additionally, an averaging feature importance technique was employed to select the most impactful features on the model decisions as a starting point. A comparison of the results reveals that the proposed two-tier approach is more accurate and less time-consuming, achieving 95% accuracy in separating faulty from normal samples and approximately 91% in diagnosing each fault type. Furthermore, ensemble learners, particularly bagging and stacking, demonstrated superior fault detection and identification performance. The performance of the classifiers was validated using t-SNE and explainable AI techniques, confirming that the impactful features align with the findings and that the proposed two-tier solution outperforms the naive solution. These results strongly indicate that the proposed solution is accurate, independent, and less complex compared to existing solutions.

A Survey of Security Challenges in Cloud-Based SCADA Systems

Supervisory control and data acquisition (SCADA) systems enable industrial organizations to control and monitor real-time data and industrial processes. Migrating SCADA systems to cloud environments can enhance the performance of traditional systems by improving storage capacity, reliability, and availability while reducing technical and industrial costs. However, the increasing frequency of cloud cyberattacks poses a significant challenge to such systems. In addition, current research on cloud-based SCADA systems often focuses on a limited range of attack types, with findings scattered across various studies. This research comprehensively surveys the most common cybersecurity vulnerabilities and attacks facing cloud-based SCADA systems. It identifies four primary vulnerability factors: connectivity with cloud services, shared infrastructure, malicious insiders, and the security of SCADA protocols. This study categorizes cyberattacks targeting these systems into five main groups: hardware, software, communication and protocol-specific, control process, and insider attacks. In addition, this study proposes security solutions to mitigate the impact of cyberattacks on these control systems.

Cycle Time Analysis Of AS/RS (Automated Storage & Retrieval System) Using SCADA

AS/RS is not just a replacement for conventional warehouses, but has become a key element in modern manufacturing systems. However, in its use there are still problems and shortcomings, including the unavailability of a system that can control, supervise, and acquire data from AS/RS and the cycle time when AS/RS performs data storage and retrieval tasks is still below industry standards. To overcome this, a system that is generally called SCADA (Supervisory, Control, and Data Acquisition) is needed. This research uses Arduino Mega 2560 as an AS/RS controller, while the VTSCADA application is used to build a SCADA system on AS/RS. This research uses two approaches. First, calculating the AS/RS cycle time when performing storage and retrieval tasks. Second, comparing the cycle time of the storage system and the retrieval system. The first test results show that the fastest cycle time in the storage system occurs at storage rack point 1 with a time of 3.17 seconds, while the fastest cycle time in the retrieval system occurs at retrieval point 1 with a time of 12.74 seconds. The second test resulted in a difference in cycle time between the storage and retrieval systems, namely 0.42 seconds at storage point 1, 0.38 seconds at storage point 2, 0.51 seconds at storage point 3, 0.31 seconds at storage point 4, and 0.43 seconds at storage point 5. It can be concluded that the application of SCADA to AS/RS is able to increase the cycle time of AS/RS.

Analysing Smart Power Grid against different Cyber Attacks on SCADA System

The integration of information and communications technology (ICT) with traditional power grid is transforming the power grid into a more reliable and smarter cyber physical system. A supervisory control and data acquisition (SCADA) system is used to implement the cyber layer for power grid, which is responsible for real-time monitoring and control of power grid and power delivery network. A SCADA system combined with other devices creates smart power grid environment, but it also makes power grid vulnerable against different cyber-attacks as it requires connection with various kinds of open networks. Smart power grids are a extremely critical infrastructure and attack of any kind can affect socio economical condition of the region. In this paper we present a non-complex co-simulation environment for analysing smart power grid and also includes two different cyber-attack scenarios. Index Terms- co-simulation; smart power grid; SCADA system; cyber-attack scenarios.

Multi-Stage Learning Framework Using Convolutional Neural Network and Decision Tree-Based Classification for Detection of DDoS Pandemic Attacks in SDN-Based SCADA Systems

Supervisory Control and Data Acquisition (SCADA) systems, which play a critical role in monitoring, managing, and controlling industrial processes, face flexibility, scalability, and management difficulties arising from traditional network structures. Software-defined networking (SDN) offers a new opportunity to overcome the challenges traditional SCADA networks face, based on the concept of separating the control and data plane. Although integrating the SDN architecture into SCADA systems offers many advantages, it cannot address security concerns against cyber-attacks such as a distributed denial of service (DDoS). The fact that SDN has centralized management and programmability features causes attackers to carry out attacks that specifically target the SDN controller and data plane. If DDoS attacks against the SDN-based SCADA network are not detected and precautions are not taken, they can cause chaos and have terrible consequences. By detecting a possible DDoS attack at an early stage, security measures that can reduce the impact of the attack can be taken immediately, and the likelihood of being a direct victim of the attack decreases. This study proposes a multi-stage learning model using a 1-dimensional convolutional neural network (1D-CNN) and decision tree-based classification to detect DDoS attacks in SDN-based SCADA systems effectively. A new dataset containing various attack scenarios on a specific experimental network topology was created to be used in the training and testing phases of this model. According to the experimental results of this study, the proposed model achieved a 97.8% accuracy rate in DDoS-attack detection. The proposed multi-stage learning model shows that high-performance results can be achieved in detecting DDoS attacks against SDN-based SCADA systems.

A Scada system used for monitoring virtual chemical plants via Modbus communication

AbstractMany chemical processes commonly use many instruments to meticulously gauge and regulate critical system variables. Automation within the industrial sector hinges upon deploying a Supervisory Control and Data Acquisition (SCADA) system. However, the software typically employed for this purpose is endowed with substantial added value, rendering its application in smaller‐scale projects economically impractical. In the context of this study, our primary objective was to develop a SCADA system tailored for a virtual plant. To realize this aim, we simulated a heat exchanger network process unit using UniSim®. We integrated it with the ScadaBR software through a Python script, capitalizing on the Modbus communication protocol. It encompasses essential functionalities such as real‐time variable supervision, dynamic graph and report generation. For the proposed example, 28 variables were monitored. The results revealed that statistical analysis of the variables could be performed graphically and computationally, evidencing that the ScadaBR tool was successfully connected to the Unisim® simulator.

A Blockchain Architecture to Increase the Resilience of Industrial Control Systems from the Effects of a Ransomware Attack: A Proposal and Initial Results

The motivation of this research (and also one of the nation’s cyber goals) is enhancing the resilience of Industrial Control Systems (ICS)/Supervisory Control and Data Acquisition (SCADA) systems against ransomware attacks. ICS and SCADA systems run some of the most important networks in the country: our critical infrastructure (i.e., water flow, power grids, etc.). Disruption of these systems causes confusion, panic, and in some cases loss of life. We propose a SCADA architecture that uses blockchain to help protect ICS data from ransomware. We focus on the historian. In a SCADA system, the historian collects events from devices in the control network for real-time and future analysis. We choose to use Ethereum and its Proof of Stake (PoS) consensus protocol. The other goal of this research focuses on the resilience of blockchain. There is very little research in protecting the blockchain itself. By performing encryption testing on an Ethereum private network, we explore how vulnerable blockchain is and discuss potential ways to make a blockchain client more resilient.

A wavelet-LSTM model for short-term wind power forecasting using wind farm SCADA data

Supervisory Control and Data Acquisition (SCADA) system collects massive operation and environment information which directly or indirectly affects the output power in wind farms. Therefore, it becomes an imperious demand to analyze the underlying information from SCADA data for improving the performance of short-term wind power prediction. In this paper, an effective deep learning framework for short-term wind power forecasting based on SCADA data analysis is proposed. A data denoising scheme is designed based on wavelet decomposition. In this method, all SCADA signals (except the wind power signal itself) are decomposed into low-frequency component A and high-frequency component D respectively by the wavelet transform. Then, the maximum information coefficient (MIC) method is applied to choose features that have strong correlation with wind power. Finally, all the selected features and wind power are defined as input vector that are used to train long short-term memory networks. The simulation results based on real data extracted from a SCADA system installed in wind farm indicate that the designed deep learning framework can significantly improve the accuracy of short-term wind power prediction.

Vulnerability of the Load Frequency Control Against the Network Parameter Attack

By integrating the communication-enabled high-voltage electronic devices into the supervisory control and data acquisition (SCADA) system, the smart grid achieves flexible, economic, controllable operations of remote and real-time electricity transmission and distribution. However, it has been widely recognized that the SCADA system is vulnerable to unprecedented cyberattacks. In this paper, we propose a novel attack, namely, a network parameter attack (NPA), on the physical parameter of the branch to affect the load frequency control. The idea is to modify the control signal sent to the thyristor-controlled series compensator (TCSC) device to change the reactance of the transmission line, thus, inflicting the grid frequency stability. We first provide a sufficient condition for NPA to cause frequency instability. To further provide more insights, we analyze the impact of NPA on frequency stability based on the eigenvalue sensitivity. The vulnerable transmission lines are screened out based on the error caused by the NPA on the eigenvalues. Furthermore, we develop a least-effort but maximum-impact attack strategy considering the attacker’s limited resources. Finally, we conduct extensive simulations to validate the effectiveness of the attack and evaluate its impact on the system’s operation.

SCADA for waste sorting system as an environmental conservation effort

Improperly managed household waste has led to environmental pollution. The methods of reducing, reusing, and recycling are effective in reducing waste volume. Therefore, waste needs to be sorted by type. Automated waste sorting using the SCADA (Supervisory Control and Data Acquisition) system consists of Capacitive Proximity Sensors, Inductive Proximity Sensors, and Infrared Proximity Sensors to detect the types of waste, a PLC TM221CE40R as the controller, and an Android-based HMI (Human Machine Interface) to monitor real-time waste bin fill levels. The types of waste to be sorted are organic, inorganic, and metal. The system comprises 1 main bin for users to deposit waste and 3 waste bins for the sorted materials. When users deposit a certain type of waste, the sensors detect the type of waste. This information triggers the motors of the 3 waste bins to rotate and stop right beneath the main bin, matching the waste type. The bottom of the main bin opens, allowing the waste to enter the appropriate container. Test results have shown that the system is capable of correctly sorting all types of organic and metal waste. However, for inorganic waste, the system correctly sorts only when the waste is clear in color.

FPGA-Based Implementation of SCADA System for Fuel Management

With the emergence of Digital Processors and Logic Design technologies, like FPGAs, the trend of using IC-based plug-and-play modules has been minimized. The focus is commercial off-shelf designing and developing modules and sub-modules on new FPGA technology. Some of the critical factors that make FPGA more suitable include enormous computational power, capabilities to perform logic operations, high-speed clocks, fast memory, and various built-in primitives for computation-intensive arithmetic operations. FPGA becomes suitable for implementing data capturing and processing systems with these characteristics. This paper is about designing and developing an FPGA-based Supervisory Control and Data Acquisition (SCADA) System to monitor and control the fuel level transition between two tanks that generally are designed using PLC. PLC-based SCADA systems are easy to implement, but when discussing performance, PLC cannot replace FPGA. The FPGA chosen is Spartan-3 due to its low cost and meeting the industrial temperature needs. At the same time, it may be translated into any advanced FPGA, producing fewer sources and power consumption benefits. The simulator is Xilinx 14.7 ISE, along with SDK. The implemented system provides the inherent amenities of SCADA along with the benefits of high speed, more accuracy, reduced and predictable delay, and a purely digitized system facilitated by the FPGA.

Ensemble Learning Framework for DDoS Detection in SDN-Based SCADA Systems.

Supervisory Control and Data Acquisition (SCADA) systems play a crucial role in overseeing and controlling renewable energy sources like solar, wind, hydro, and geothermal resources. Nevertheless, with the expansion of conventional SCADA network infrastructures, there arise significant challenges in managing and scaling due to increased size, complexity, and device diversity. Using Software Defined Networking (SDN) technology in traditional SCADA network infrastructure offers management, scaling and flexibility benefits. However, as the integration of SDN-based SCADA systems with modern technologies such as the Internet of Things, cloud computing, and big data analytics increases, cybersecurity becomes a major concern for these systems. Therefore, cyber-physical energy systems (CPES) should be considered together with all energy systems. One of the most dangerous types of cyber-attacks against SDN-based SCADA systems is Distributed Denial of Service (DDoS) attacks. DDoS attacks disrupt the management of energy resources, causing service interruptions and increasing operational costs. Therefore, the first step to protect against DDoS attacks in SDN-based SCADA systems is to develop an effective intrusion detection system. This paper proposes a Decision Tree-based Ensemble Learning technique to detect DDoS attacks in SDN-based SCADA systems by accurately distinguishing between normal and DDoS attack traffic. For training and testing the ensemble learning models, normal and DDoS attack traffic data are obtained over a specific simulated experimental network topology. Techniques based on feature selection and hyperparameter tuning are used to optimize the performance of the decision tree ensemble models. Experimental results show that feature selection, combination of different decision tree ensemble models, and hyperparameter tuning can lead to a more accurate machine learning model with better performance detecting DDoS attacks against SDN-based SCADA systems.