This foundational course introduces industrial personnel to the core concepts and components of **SCADA systems**. It demystifies the technology used to remotely monitor and control processes across various critical infrastructure sectors, such as utilities, oil and gas, and manufacturing. Participants will learn the basic architecture, understand the roles of key elements like RTUs, PLCs, and HMIs, and grasp the significance of real-time data acquisition and telemetry. This program provides the essential literacy needed for non-engineering staff to safely and effectively interact with their plant's control system environment.
SCADA System Fundamentals for Industrial Personnel
Maintenance and Engineering
October 29, 2025
Introduction
Objectives
Upon completion of this course, participants will be able to:
- Define SCADA and its primary functions in industrial operations and infrastructure.
- Identify the core components: **Master Terminal Unit (MTU), HMI, RTU, and PLC**.
- Understand the concept of telemetry and the role of communication in SCADA systems.
- Locate key system information and understand the flow of data from field device to control room.
- Differentiate between control functions and monitoring functions within the system.
- Explain the importance of the Historian for data logging and compliance.
- Recognize alarm categories and the basic procedure for alarm acknowledgement.
Target Audience
- Plant Operators and Control Room Staff (Non-Engineering)
- Field Technicians and Maintenance Personnel
- Safety and Environmental Compliance Officers
- Operational Supervisors and Managers
- Administrative Staff needing system overview
Methodology
- Interactive presentations with system screenshots and functional diagrams.
- Group activities simulating a control room scenario and interpreting an HMI screen.
- Individual exercises on navigating a simulated SCADA environment and locating key assets.
- Discussions on the differences between manual, local, and remote control.
- Case studies of incidents caused by operator error or misinterpretation of data.
Personal Impact
- Enhanced understanding of the core processes they are responsible for monitoring.
- Increased confidence in interacting with the control system safely and effectively.
- Ability to quickly identify and report system anomalies or unusual data points.
- Improved communication with engineering and maintenance teams.
Organizational Impact
- Reduced operational errors and fewer safety incidents caused by human factors.
- Improved data quality through timely identification and reporting of sensor issues.
- Increased system reliability due to better collaboration between operations and maintenance.
- Faster response times to process upsets and critical alarms.
Course Outline
Unit 1: What is SCADA?
Basic Definitions- The purpose and scope of **Supervisory Control and Data Acquisition**
- SCADA's role in the ISA-95/Purdue model of industrial networks
- Understanding the "Supervisory" function versus direct control
- Key application areas: Water, Power, Pipelines, and Manufacturing
- Overview of the five main layers of a SCADA system
- The function of the central **SCADA Server** and its services
Unit 2: Field Devices and Data Flow
Remote Devices- The difference between **PLCs (Programmable Logic Controllers)** and **RTUs (Remote Terminal Units)**
- Understanding digital and analog signals (ON/OFF vs. continuous values)
- Introduction to basic sensor and actuator types
- How field data (e.g., pressure, temperature) is collected and sent to the HMI
- The concept of a "poll cycle" and communication time delays
Unit 3: The Operator Interface (HMI)
HMI Functions- The role of the **Human-Machine Interface (HMI)** in visualization
- Navigating typical plant displays and process graphics safely
- Interacting with controls: setpoints, valve commands, and pump starts
- How to locate and interpret historical trends and real-time data displays
- Understanding the importance of reliable time stamping in the system
Unit 4: Alarms and Basic Operational Response
Alarm Fundamentals- Defining an alarm, a warning, and a system event
- Understanding alarm priority levels (e.g., Critical, High, Low)
- The correct procedure for **acknowledging and clearing alarms**
- Consequences of ignoring or suppressing alarms without authorization
- Following standard operating procedures (SOPs) based on HMI status
- The process for safely requesting and taking a device out of service
Unit 5: Safety and System Integrity
SCADA Safety Role- Understanding the relationship between SCADA and **Safety Instrumented Systems (SIS)**
- Recognizing security alerts and reporting suspicious system activity
- Importance of maintaining a secure physical environment for control equipment
- Following correct login and access control protocols
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