Overview

In a critical project at a large industrial facility equipped with an extensive SCADA system, our team was tasked with addressing and mitigating graphical action delays affecting operational efficiency. The facility’s network architecture included 9 dedicated servers and 6 multi-window operator workstations, presenting a complex environment for troubleshooting and optimization.

Challenge

The client was experiencing significant delays in SCADA graphical actions, which impacted the timely monitoring and management of operational processes. The primary challenge was to identify the root cause of these delays within a network comprising various communication protocols and data transmission speeds.

Approach

Investigation of Network Protocols:

Conducted a thorough review of the specifications for PLC, SCADA, and instrumentation network cables as defined by the manufacturer.

Analysed three different protocols to understand their impact on data transmission speeds and system performance.

Network Performance Analysis:

Utilized RJ45 route testers and Wireshark for in-depth network speed testing and device mapping.

Aimed to optimize system operation by pinpointing time-sensitive functions and reducing their processing time, thereby enhancing overall system efficiency.

Communication and Integration Analysis:

Investigated the communication between PLCs and system servers, as well as device integration and the engineering station of the SCADA platform.

Considered site network specifications and functional requirements to ensure the proposed solutions aligned with operational needs.

Solutions and Improvements

Optimization of SCADA Communication:

Proposed increasing SCADA communication scan time from 70ms to 100ms to alleviate network traffic on RJ45 cables. This recommendation was based on detailed network analysis findings.

Presented the solution to client management during meetings, ensuring clear communication and alignment on the proposed changes.

Standardization of Communication Cabling:

Advised the client to standardize the type of communication cabling throughout the plant. A mix of CAT5 and CAT5E cables was found in the admin PLC panel and main server panels, contributing to inconsistent network performance.

Highlighted the importance of maintaining a robust and secure system while meeting user requirements.

Results

The implementation of the proposed solutions resulted in a significant reduction in SCADA graphical action delays, improving the speed and reliability of operational monitoring and management.

Standardizing the communication cabling across the facility led to more consistent and reliable network performance, further contributing to operational efficiency.

Client management recognized the value of the technical solutions provided, noting improvements in system responsiveness and a reduction in operational downtime.

Conclusion

This case study highlights our consultancy’s capability to diagnose and resolve complex network performance issues within industrial SCADA systems. Through detailed analysis, strategic recommendations, and effective stakeholder communication, we were able to enhance the operational efficiency of a major industrial facility, demonstrating our commitment to delivering high-quality engineering solutions.

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