Analysis of SCADA System of Coca cola, Lahore

1. Analysis of SCADA System in corporation with
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2. Group Members:
• Muhammad Umar Farooq 2015-IM-07 Presenter
• Muhammad Yasir 2015-IM-08
• Zaib Hassan 2015-IM-25 Presenter
• Akash Gill 2015-IM-41
• Muhammad Usman 2015-IM-42
• Hamza Anwar 2015-IM-49
• Muhammad Shoaib Khurshid 2015-IM-50

3. Coca-Cola Lahore: Type: Cola
Manufacturer: The Coca-Cola Company
Introduced: ~1886 (131 Years)
Daily Customers: 1.8 Bn
Production Rate: 4 Lac Litter Syrup/ 24 hrs.
(Lahore Plant)
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6. Department of Operational Management
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7. SCADA SYSTEM
Supervisory Control and Data Acquisition (SCADA) is a system of
software and hardware elements that allows industrial organizations to:
• Control industrial processes locally or at remote locations.
• Monitor , gather and process real time data.
• Directly interact with devices such as sensors, valves, pumps, motors
and more through human machine interface(HMI) software.
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8. PLC Circuits used in implementation of SCADA
SCADA
• SCADA system are crucial for industrial
organizations since they help to maintain
efficiency, process data for smarter
decisions and communicate system issues
to help mitigate downtime.
• SCADA system quickly notifies an
operator that a batch of product is
showing a high incidence of errors.
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9. MAJOR BRANDS OF COCA-COLA
Coca-Cola is the most popular and biggest-selling soft drink in history,
as well as one of the most recognizable brands in the worlds.
Brands:
• Coca-Cola
• Sprite
• Fanta
• Diet coke
• Kinley
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10. Project: SCADA System Failure & SCADA Network Failure
Project Objectives:
1. Review each critical process area to identify operational
and data reporting problems that could occur if SCADA
was disrupted.
2. Conduct network or SCADA failure modes and effect
analysis (FMEA).
3. Document the evaluation and recommendation in an
organized format.
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Select the process and diagram the process if needed.
Brainstorm potential failure modes and determine their effects.
Identify the causes of failures.
Prioritize failure modes and redesign the process.
Analyze and test changes
Implement and monitor the redesigned process
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FMECA
Steps
Followed

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Identify potential failure modes and their causes
Evaluate the effects on the system of each
failure mode
Recommend measures to reducing the risks
associated with each failure mode
Provide information to operations and
maintenance to achieve best performance and
reliability of the system
Benefits of FMECA

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14. 14
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FMECA SHEET of SCADA System
Project Name SCADA System Failure & SCADA Network Failure Group No. 07,08,25,41,42,49,50
Person Responsible Dated Start: Oct. 26, 2017 Revised: Nov. 15, 2017
Key
Inputs
Failure Modes Failure Causes Sev Impacts Occ Detection Det RPN Remediations
MITECO/CompanyExperts,Automatic
CloudingSystemInputs,Sensors
SCADA Sever
Failure
Both Server
Fail
8 Loss of monitoring of
entire plant
2 All HMI screens
are lost
1 16 Thoubleshoot
and fix
SCADA Network
Failure-
Complete
-Server Switch
Software
Failure
-Undesireable
link
-Software Bug
8 -Shutdown of the
plant or pocess areas
-Loss of compliance
reporting
-Loss of control of
the plant
3 SCADA freezing 1 24 Shutdown the
system and
reboot the
switches one by
one
SCADA Network
Failure-Partial
Server Switch
Hardware
Failure
5 Loss of process areas
directly served by
this switch
3 Communication
alarm to
affected PLCs
1 15 Test, reboot or
replace the
switch
PLC Hardware
Failure-Major
PLC Power
Supply Failure
7 Loss of control of
some equipment
2 All PLC circuits
lights are off
3 42 Replace power
supply of PLC

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Failure Modes Failure Causes Sev Impacts Occ Detection Det RPN Remedaitions
PLC Hardware
Failure-Minor
I/O Module Failure 7 -Mix reading signal
from I/O module
3 Status light
flashing red
1 21 Replace
defective I/O
module
Instrument
failure
Compliance
Instrrument Failure
8 Loss of
Compliance data
1 -Fault Alarm
-Loss of Echo
5 40 Manual Sampling
and recoding
Power Failure All Major Power
Failure
7 Loss of control and
Monitoring for the
affected process
7 Power loss alarm,
all the processes
will stop
1 49 Replace UPS
Physical Security
Breach
-Unauthorized
network devices
-Unauthorized access
6 Disruption to plant
operation
2 Unusual network
behavior
5 60 Block
unauthorized
access
FMECA SHEET of SCADA System
Project Name SCADA System Failure & SCADA Network Failure Group No. 07,08,25,41,42,49,50
Person Responsible Dated Start: Oct. 26, 2017 Revised: Nov. 15, 2017

16. Recommendations:
• Use high potential and unbreachable firewall.
• Use direct satellite connections for network access.
• Use UPSs and own power system to prevent power failure.
• Store SCADA Cards and major PLC circuits on backup.
• Design Improvement of PLCs must be done.
• Emergency Preparedness for beakdown.
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