This essential course provides the administrative and technical skills required to ensure the continuous operation and reliability of mission-critical **SCADA systems**. It covers crucial topics such as server management, data backup, licensing, and the implementation of high-availability features like **redundancy and failover**. Participants will master the procedures for system patching, disaster recovery, and continuous monitoring to minimize downtime and maintain data integrity. This program is vital for administrators tasked with safeguarding the system's operational lifecycle and availability.
SCADA System Administration, Redundancy, and Maintenance
Maintenance and Engineering
October 29, 2025
Introduction
Objectives
Upon completion of this course, participants will be able to:
- Configure and manage **SCADA Server Redundancy** and automatic failover procedures.
- Develop and implement a comprehensive **data backup and disaster recovery plan** for the SCADA environment.
- Master the procedures for applying system patches and updates safely in an **OT (Operational Technology)** environment.
- Manage user accounts, privileges, and access control lists (ACLs) across the system.
- Monitor key SCADA server performance metrics (e.g., CPU, memory, I/O rates) for proactive maintenance.
- Manage software licensing, version control, and configuration documentation.
- Perform routine preventive maintenance and system diagnostics to ensure high availability.
Target Audience
- SCADA System Administrators and IT/OT Support Staff
- Control System Engineers responsible for system uptime
- Maintenance and Reliability Managers
- Disaster Recovery and Business Continuity Planners
- Project Managers overseeing SCADA upgrades and infrastructure
Methodology
- Hands-on lab exercises configuring and testing server redundancy and automatic failover in a simulated environment.
- Group activity: developing a prioritized **Disaster Recovery Plan** for a high-consequence SCADA system.
- Individual exercises in documenting a safe patch management procedure for a control system server.
- Case studies of major outages caused by lack of redundancy or failed recovery attempts.
- Discussions on balancing system security requirements with operational maintenance needs.
Personal Impact
- Mastery of critical skills in high-availability SCADA system administration.
- Ability to design and manage a robust disaster recovery and business continuity plan.
- Increased effectiveness in preventing system failures through proactive monitoring.
- Confidence in leading safe and controlled system maintenance and patching activities.
Organizational Impact
- Minimized system downtime and reduced loss of production through redundancy and failover.
- Guaranteed data integrity and compliance via secure, verifiable backup procedures.
- Extended system lifecycle and predictable maintenance costs.
- Faster and more reliable recovery from catastrophic system failures.
Course Outline
Unit 1: SCADA Server Management
System Architecture- Review of the core SCADA server roles: Historian, I/O Server, Application Server
- Best practices for operating system configuration and hardening for OT environments
- Managing software services and dependencies for optimal performance
- Implementing a robust user management framework (e.g., role-based access control, LDAP integration)
- Auditing user activity and managing security event logs
Unit 2: High Availability and Redundancy
Redundancy Concepts- Understanding the need for **SCADA Server Redundancy** (Hot Standby, Cold Standby)
- Configuring automatic synchronization and state replication between primary and secondary servers
- Developing and executing controlled **failover testing** procedures to ensure functionality
- Configuring network and communication redundancy for critical data links
Unit 3: Maintenance, Patching, and Lifecycle
Patch Management- Developing a safe and systematic process for applying OS and SCADA software patches in OT
- The importance of vendor approvals and testing before applying any updates
- Managing software licensing and compliance for all SCADA components
- Developing a system lifecycle roadmap for hardware and software obsolescence planning
Unit 4: Backup and Disaster Recovery
Backup Strategy- Identifying all critical system files for backup (configuration, code, database archives)
- Implementing an automated, verified, and geographically diverse backup schedule
- Developing a detailed **Disaster Recovery (DR) Plan** with documented recovery time objectives (RTO)
- Practicing system restoration from backup in a test environment
Unit 5: Performance Monitoring and Auditing
Proactive Monitoring- Using system tools to track key server health metrics (memory usage, I/O bandwidth, disk latency)
- Implementing proactive alerts for server performance degradation
- Procedures for auditing system configurations against documentation standards
- Maintaining meticulous records of all system changes, updates, and maintenance activities
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