SCADA Integration
SCADA Integration is a subset of the control system enginering. Integrating SCADA systems involves configuring and setting up databases, historians, and developing interfaces to bring together process data from different automation devices and systems.
What do SCADA Engineers Do?
- Analysing process design inputs such as P&IDs and developing HMI graphics.
- Designing and configuring interfaces for external control systems and devices.
- Troubleshooting TCP/IP, Modbus, OPC, and network communications issues.
- Configuring OPC servers to collect data from various sources located at the plant control level.
- Configuring, troubleshooting, and commissioning L2/L3 network devices, such as servers, workstations, switches, firewalls, and routers.
- Supporting I&C teams to troubleshoot field device issues and commissioning of instrumentation (e.g., applying logic forces and bypasses in the live logic, or simulating process inputs).
- Reviewing and analysing alarms and events to investigate plant performance issues or process trips.
- Managing firmware updates and patch updates for SCADA software and associated hardware and network infrastructure devices.
What are the Key Skills Needed for SCADA Integration?
Programming Languages:
- C/C++: Utilized for backend SCADA development and embedded systems, including industrial computers (IPCs) and PLCs like Beckhoff's TwinCAT 3.
- Python: Employed for scripting and interacting with databases. Modern SCADA systems often use Python or its variants (e.g., Jython in Ignition) for data manipulation and automation.
- Java, HTML, JavaScript: Essential for developing customized operator interfaces (HMIs). JavaScript and HTML are used in web-based SCADA systems, while VBA is prevalent in legacy systems like Wonderware and iFix.
- Scripting and Shell Commands: Linux Shell, Windows PowerShell and CMD are often used for automating tasks and troubleshooting network and communication issues during SCADA integration.
Operating Systems:
- Windows: Many SCADA systems are run on Windows servers, so familiarity with configuring and managing Windows Active Directory is important.
- Linux Distros: Increasingly used for edge computing and modern SCADA platforms (e.g., Ignition). Linux-based virtual machines are also used for hosting SCADA servers and clients.
Database Management and Historians:
- Database Management: Knowledge of relational databases such as SQL Server, Oracle, MySQL, and OSIsoft for managing process data, alarms, and events.
- Data Aggregation: Skills in using products like OSIsoft PI and AspenTech for aggregating and historizing operational data.
Industrial Networks:
- SCADA Network Design: Designing industrial networks, specifying cables, switches, IP addresses, and implementing network segmentation with subnetting and VLANs.
- Network Troubleshooting: Experience with Layer 2 and Layer 3 devices, and protocols like OPC, Modbus TCP, DNP3, and Ethernet/IP. Using diagnostic tools like Modscan, Wireshark, and OPC servers (e.g., KEPServerEX, Matrikon) are commonly used.
IT/OT Integration:
- MES, ERP, PLM, AMS, SCM: Developing and testing SCADA interfaces for various systems such as SAP ME, Oracle ERP, Siemens Teamcenter, IBM Maximo, and SAP SCM.
- Edge Devices: Selecting and deploying edge computing devices, such as industrial PCs and gateways (e.g., UNO series, Dell Edge Gateway, Siemens Industrial Edge).
SCADA Platforms:
- Hands-on Experience: Configuring interfaces, setting up databases and historians, and managing HMI development on platforms like Wonderware (AVEVA), WinCC (Siemens), VTScada (Trihedral Engineering), Ignition (Inductive Automation), iFIX (GE Digital), and Intouch (AVEVA).
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