This capstone course is for experienced professionals aiming to design, upgrade, and optimize complex **SCADA systems for high performance and scalability**. It moves beyond basic setup to cover advanced topics like distributed architecture, virtualization, high-speed data handling, and integration with cloud services. Participants will master trade-off analysis between centralized and distributed models, design effective disaster tolerance strategies, and select appropriate technologies to meet demanding operational requirements for speed, volume, and geographical scale.
Advanced SCADA System Architecture and High-Performance Design
Maintenance and Engineering
October 29, 2025
Introduction
Objectives
Upon completion of this course, participants will be able to:
- Design scalable and resilient **Distributed SCADA Architectures** for wide-area networks.
- Master the use of virtualization, containerization, and cloud technologies for SCADA deployment.
- Conduct comprehensive trade-off analysis for selecting centralized versus distributed control models.
- Design and implement **Disaster Tolerance and Business Continuity (BCP)** strategies for control systems.
- Optimize data collection, polling, and buffering techniques for high-volume, high-speed applications.
- Integrate advanced systems (e.g., MES, ERP) with the control network for end-to-end data flow.
- Develop a comprehensive **SCADA System Upgrade and Migration Roadmap**.
- Evaluate the impact of high-performance design decisions on cybersecurity and maintenance.
Target Audience
- Lead SCADA and Control System Architects
- Senior Automation and IT/OT Integration Engineers
- Project Managers responsible for multi-site control system rollouts
- Enterprise Architects and Technology Planners
- Senior Consultants specializing in critical infrastructure
- Executives overseeing control system modernization
Methodology
- Architectural workshop: working in teams to design a distributed SCADA solution for a large regional utility.
- Group activity: developing a comprehensive trade-off matrix for a virtualization vs. bare-metal deployment decision.
- Individual exercises in creating a phased migration plan for a legacy SCADA system.
- Case studies of large-scale SCADA deployments and their architectural challenges (e.g., oil pipeline networks).
- Discussions on the cost justification and ROI of investing in advanced redundancy.
Personal Impact
- Acquire expertise in designing and leading high-value, complex SCADA modernization projects.
- Ability to conduct rigorous trade-off and risk analysis for architectural decisions.
- Mastery of virtualization, cloud, and high-speed networking for industrial applications.
- Enhanced professional credibility as a top-tier control system architect.
Organizational Impact
- Maximized system uptime and operational resilience through optimal architectural design.
- Achieved necessary scalability to support long-term business growth and data volume increases.
- Cost-effective system lifecycle management through virtualization and cloud strategies.
- Superior data integrity and availability for business and regulatory reporting.
Course Outline
Unit 1: Architectural Models and Trade-Offs
Centralized vs. Distributed- Analyzing the benefits and limitations of centralized (MTU) vs. distributed architectures
- Designing multi-tier, multi-server architectures for performance and scale
- The role of communications infrastructure in dictating architectural choices
- Methodologies for accurately sizing servers, historians, and network capacity (data points, I/O counts)
- Planning for future expansion and lifecycle maintenance requirements
Unit 2: High Availability and Disaster Tolerance
Disaster Recovery Design- Designing geographically distributed redundancy and failover systems (hot, warm, cold sites)
- Developing comprehensive **Business Continuity Plans (BCP)** for control centers
- Techniques for optimizing system performance: load balancing, process isolation, and threading
- Best practices for implementing virtualized and containerized SCADA environments
Unit 3: Cloud and IT/OT Integration
Cloud SCADA- Evaluating the feasibility and security requirements of deploying SCADA services to the public or private cloud
- Strategies for secure, high-speed data exchange between the control network and cloud data lakes
- Architectural design for seamless data flow between SCADA/Historian and MES/ERP systems
- Using integration brokers and APIs to decouple systems and improve reliability
Unit 4: Data Handling and Network Optimization
High-Speed Data- Techniques for handling high-frequency data logging and real-time data processing
- Optimizing SCADA and PLC driver configurations for massive data sets and low latency
- Designing the industrial network backbone (Layer 3 switching, fiber optic) for SCADA traffic priority
- Managing bandwidth and quality of service (QoS) for mission-critical protocols
Unit 5: Migration and Governance
System Migration- Developing a detailed, low-risk **SCADA Migration Roadmap** (Phasing, Parallel Operation, Rollback)
- Managing the technical and financial risks of modernizing legacy control systems
- Establishing architectural standards and governance processes for all future SCADA modifications
- Integrating security and maintenance requirements into the long-term design lifecycle
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