Role of Interfaces in SCADA Systems

Operators see the plant only through the SCADA interface, and when an alarm goes off they often have seconds to react. A cluttered or outdated screen slows them down at exactly that moment.

The role of UX/UI design in modern software development has grown significantly over the last decade. The success or failure of a mobile app is often decided by how it looks and how easy it is to use. App developers know it very well.

Unfortunately, the same can't be said about systems for more industrial or production purposes, SCADA (supervisory control and data acquisition) systems in particular.

Supervisory control and data acquisition (SCADA) is a type of system primarily used in factories and industrial facilities. Its role is to collect, process, analyze, and present data from different machines, devices, and sensors across the facility. It provides both real-time and historical data to allow companies to monitor and optimize processes all across the board.

Depending on the case, SCADA systems can have some of the following capabilities:

1. Detecting and alarming about possible risks, errors, and malfunctions.
2. Monitoring wear of parts and components and allowing predictive maintenance.
3. Remote control of various machines and processes.

That, of course, can mean very different things for each case because SCADA systems are used pretty much everywhere, from toothpaste factories to power plants.

It's fair to say that a large percentage of SCADA systems still widely used today are outdated. Even if their hardware is still sufficient for a given purpose, their interfaces look and behave as if they had been created in the Windows 95 era. And it's not that unlikely that they actually were.

In a SCADA system, the interface is the part people actually work with. Everything the system collects reaches the operator only through it.

Take a production line that uses IoT sensors, a digital twin and augmented reality.

All of it can be monitored and controlled from a SCADA system, but only if the system has a well-designed, easy-to-use interface, because in the end people operate it.

That is why building a good SCADA system starts with research and consultation with as many end users as possible. The interface should give them the tools they need to do their job efficiently.

Improved maintenance and crisis management

Every company wants to detect problems before they unfold, and a SCADA system is often where they show up first.

Instead of a spreadsheet and a series of colored numbers, a modern interface can show every important part of a facility visually. In our project for KYOTO, for example, we added augmented reality elements to the operator's camera view to present key plant data.

With such tools, analysts and maintenance crews can react to potential problems faster.

Easier adaptation for users

With large systems like SCADA there is always some pushback. Users are used to the old ways, so adaptation can be painful. The risk is real: there are many cases of poorly designed products that were scrapped because they were not fit for purpose.

That is why the design process for such systems involves consultation with everyone who will use them: the end product must answer their actual needs. It should make processes more efficient and the workplace safer, and the interface decides much of both.

Easier to sell

For companies that sell SCADA software, a well-designed interface is also a selling point. Buyers see the benefits above in the first demo, and many competing systems still look dated.

Use cases vary widely, but a few elements belong in every system.

Easy customization

SCADA software is rarely used by one department or role. More often than not, there will be elements in the system that are crucial only to a few people. So, depending on the specialist or purpose, a SCADA interface should be easily customizable to give users exactly the information they need without overloading them with unnecessary data.

The ability to present and analyze historical data

The analytical capabilities of SCADA systems are one of their key values. Thanks to them, companies can reduce costs, detect and eliminate bottlenecks and make much better decisions.

Provided, of course, that the system interface gives them sufficient tools to analyze and present the data.

Scalability

An interface built from customizable views is also easier to expand. As the facility grows, more devices and sensors will be connected, and more users will need the system to work according to their needs.

Accessibility

Modern SCADA systems can be built as web apps, which can be launched on different devices, including mobile phones and tablets.

Legibility

Reaction speed matters in environments that use SCADA systems. That's why the operator must be able to interpret every type of data and the status of components and devices in a split second.

No distractions (focus)

The interface is usually displayed 24/7 in the control room, so there is no need for animations and other distractions that pull attention away from essential things (real-time data).

Conservative palette of colors and icons

Colors are usually standardized and tied to statuses, so the interface scheme shouldn't interfere with that. Icons are often taken from the documentation or industry standards (like symbols in electrical circuits).

Simple to the bone

Micro-interactions, animations, detailed illustrations and renders usually come second when the budget for a SCADA interface is set. Sometimes, though, using those elements can be justified, especially when it serves the user story (or some operator routine), or when you sell the system to the customer.

Schematic

A good SCADA interface should show the physical layout of devices and sensors in the system, so the operator knows exactly where an error occurred.

What is the difference between SCADA and HMI?

The HMI (human-machine interface) is the part of SCADA that people see: plant schematics, trends, alarm lists and command dialogs on the operators' screens. SCADA is the whole system behind those screens: field devices, the controllers wired to them (PLCs and RTUs), servers that track every signal and raise alarms, and a historian. Our SCADA glossary entry covers each layer.

What are the best practices for SCADA HMI design?

Design for operators who watch the screen all day and have seconds to react. Keep the color palette conservative and tie colors to statuses. Add a schematic so a fault is easy to locate, drop animations that pull attention from live data, and let each role customize its view. The ISA-101 standard covers HMI design for process automation.

How do you design a SCADA interface?

Start with the people who will use it. Talk to as many operators, maintenance staff and analysts as you can, because a system that ignores how they work meets resistance and can end up scrapped. Then build the screens around the facility's own devices, alarms and historical data, since each plant has its own requirements.

Can a modern SCADA interface run in a web browser or on a phone?

Yes. A modern SCADA system can be built as a web app that opens on desktops, tablets and phones. Newer systems often send data to the cloud for analytics while control stays on site. The EMS we built for Skyfri splits the work the same way, and its control keeps running fully offline.

Although there certainly are elements or characteristics that every SCADA system should have, there is no universal way of creating them. A good SCADA system should be built individually and based on the specific requirements of a particular facility and its users.

Our SCADA and energy projects, including KYOTO and Skyfri, are on the Energy Hub. If you are planning such a system, arrange a call with us and we will help you find the right approach.