Industrial Controls Corporation By: Philip Marvin D. Joven, R.E.E VP‐ Engineering, Industrial Controls Corp. g g, p Industrial Controls Corporation WHAT IS SCADA? SUPERVISORY CONTROL AND DATA ACQUISITION “PROCESS MANAGEMENT TOOL” DATA MANAGEMENT USER‐CONTROL INTERFACE “VISUAL” WINDOW VISUAL WINDOW HMI (Human Machine Interface) SCADA SYSTEM ARCHITECTURE IN A POWER PLANT IN A POWER PLANT Industrial Controls Corporation A SCADA system performs four functions: 1. Data acquisition q 2. Networked data communication 3. Data presentation 4. 4 Control Industrial Controls Corporation These functions are performed by four kinds of SCADA components: 1. Sensors (either digital or analog) and control relays that directly interface with the managed system. system 2. Programmable Logic Controller (PLC) or Remote telemetry units (RTUs). These are small computerized units deployed in the field at specific sites and locations locations. PLCs and RTUs serve as local collection points for gathering reports from sensors and delivering commands to control relays. 3. SCADA Workstation units. These are larger g computer p consoles that serve as the central processor for the SCADA system. Workstation units provide a human interface to the system and automatically regulate the managed system in response to sensor inputs. 4. The communications network that connects the SCADA Workstation unit to the RTUs in the field. Industrial Controls Corporation Data Acquisition • SCADA system needs to monitor hundreds or thousands of sensors. Sensors measure: 1 Inputs and outputs e.g. 1. e g water flowing into a reservoir (input) (input), valve pressure as water is released from the reservoir (output). 2. Discrete inputs (or digital input) e.g. whether equipment is on or off, or tripwire alarms, like a power failure at a critical facility. 3. Analog inputs: where exact measurement is important e.g. to detect continuous changes in a voltage or current input input, to track fluid levels in tanks, voltage levels in batteries, temperature and other factors that can be measured in a continuous range of input. Data Communication Industrial Controls Corporation A communications network is required to monitor multiple systems from a central location. •TREND: put SCADA data on Ethernet and IP over SONET SONET. • SECURITY: Keep data on closed LAN/WANs without exposing sensitive data to the open Internet. • Encode data in protocol format (use open open, standard protocols and protocol mediation) • Sensors and control relays can’t generate or interpret protocol communication - a remote telemetry y unit (RTU) ( ) is needed to provide p an interface between the sensors and the SCADA network. • RTU encodes sensor inputs into protocol format and forwards them to the SCADA Workstation; • RTU receives control commands in protocol format from the W k t ti and Workstation d ttransmits it electrical l t i l signals i l tto th the appropriate i t control t l relays. Data Presentation Industrial Controls Corporation SCADA systems report to human operators over a Workstation station, HMI (Human-Machine (Human Machine Interface) or HCI (Human-Computer Interface). SCADA workstation station has several different functions: • continuously monitors all sensors and alerts the operator when there is an “alarm” • presents a comprehensive view of the entire managed system, •p presents ese s more o e de detail a in response espo se to o use user requests eques s •performs data processing on information gathered from sensors • maintains report logs and summarizes historical trends trends. Industrial Controls Corporation DATA MANAGEMENT DATA MANAGEMENT Powerful functionality to Manage System and Process Data ‐ Alarm Monitoring – Generate / Save Reports USER CONTROL / HMI USER CONTROL / HMI Industrial Controls Corporation Industrial Controls Corporation S t A hit t f Power P S t SCADA System Architecture for Systems Power Plants Industrial Controls Corporation S t A hit t f Power P S t SCADA System Architecture for Systems Industrial Controls Corporation Conceptual SCADA System Diagram SCADA/EMS SYSTEM OVERVIEW CONCEPTUAL DIAGRAM OF SCADA SYSTEM REGIONAL LOAD AREA LOAD DISPATCH CENTRE (RLDC) ICCP LINKS X21 INTERFACE STATE LOAD AREA LOAD DISPATCH CENTRE (SLDC) AREA LOAD DISPATCH CENTRE (ALDC) Supervisory level Processor Interface level ( ALDC ) CCOMMUNICATION FRONT END PROCESSOR IEC870 –5 –101 MODEM MODEM Communication level MODEM RTU MODEM Data acquisition and RTU command actuation level T T CT PT CT Field Interface level T T CR PANELS CT S/STN /POWER PLANTS POWER GRID CORPORATION OF INDIA LTD PT CT CONCEPTUAL SCADA SYSTEM DIAGRAM Industrial Controls Corporation SCADA Data communication architecture Panel Multi-port Stallion Adapters Modem Panel multi-Port Stallion adapters Splitter Modem Modem Modem Modem RTU Modem RTU Modem Modem RTU Industrial Controls Corporation RTU Through MICROWAVE CFE MUX RADIO TX / RX RADIO TX / RX MUX RTU RTU Th Through h FIBER OPTIC SYSTEM CFE MUX CONTROL CENTRE OLTE OLTE MUX RTU SUBSTATION/ GEN STN SIDE Industrial Controls Corporation Load Dispatch Center Load Dispatch Center Industrial Controls Corporation SCADA SYSTEM SCADA Software (Windows, Linux, Mac) OMRON CX‐Supervisor Invensys Wonderware GE Fanuc iFIX or CIMPLICITY Simatic WinCC ABB Communications and Interface Drivers of Communication Interface PLC and RTU Remote Servers (IO Server, SQL Server) R S (IO S SQL S ) Programmable Logic Controllers (PLC) and Remote Telemetry Unit PT Industrial Computer Sensors Transducers TT M Motors and Actuators SCADA FEATURES SCADA FEATURES Industrial Controls Corporation Develop System Design “FAST & EASY” Tools: ‐ OPC (OLE for Process Control) ‐ SQL/ODBC (Structured Query Languages/ Open Database Connectivity) ‐ VBA (Visual Basic Applications) / ( / ) ‐ TCP/IP (Transmission Control/Internet Protocol) Industrial Controls Corporation OLE for Process Control OLE for Process Control “Object‐Link Embedding” for Process Control Field Equipment/Device SCADA Screen AHU Fan Motor Speed (RPM) AI Motor Speed p DM PLC 1200 RPM TAG M Structured Query Language (SQL) Database Commands Create, Load, Dump, etc. SQL Server, Server MS Access SCADA Screen DATABASE NAME DESCRIPTION Load ITEMS MONITORED Motor 1 Water Pump Motor 1 “Water Pump” Motor 2 Air Blower Motor 2 “Air Blower” Dump ODBC Industrial Controls Corporation Industrial Controls Corporation SCADA FEATURES Wide‐range of Industrial Connectivity Applicable Connections: Se a ‐ Serial > RS‐232C / RS‐485 > Parallel/Printer Port ‐ CAT5/6 (RJ 45) CAT /6 (RJ ) > Ethernet ‐ Fiber Optics Industrial Controls Corporation SCADA TAGS TAGS Variable to Store Data/Value Temp Sensor TAGNAME DATABASE RM_TEMP FIELD DEVICE Room Temperature PLC TYPE: I/O Real ACCESS: CC SS MyPLC C – DB1,D20 Current Value DB1.DBD20 DATA BLOCK 28.489 Industrial Controls Corporation TAG DATA TYPES DISCRETE Binary 0 or 1; 0 = “FALSE”, 1 = “TRUE” INTEGER (32 bits) ‐2,147,483,648 to 2,147,483,647 REAL (32 bits) REAL ( bi ) ‐3.4e38 to 3.4e38 MESSAGE String/Text (131 characters) SCADA SYSTEM ARCHITECTURE IN A POWER PLANT IN A POWER PLANT Industrial Controls Corporation SCADA Maintenance • The SCADA system should be part of the overall preventive maintenance ((PM)) program for the plant. • Preventive P ti maintenance i t schedules h d l f for SCADA System components and subsystems should be coordinated with those for the mechanical/electrical systems theyy serve to minimize overall scheduled downtime. Industrial Controls Corporation Industrial Controls Corporation SCADA Maintenance Electrical/Electronic Systems Lamp Test/Verify Indicators Monthly Inspect Enclosures for Dirt, Dirt Water, Water Heat Monthly Actuate (Stroke) Valves and Actuators 6 Months Actuate Switches 6 Months R PLC/RTU Diagnostics Run Di ti 6 Months M th Calibrate Sensors and Transmitters Yearly Calibrate Meters Yearly C lib t Actuators Calibrate A t t Y l Yearly Test Automatic control Sequences Yearly Verify Alarms Yearly Software Maintenance and Patching 2 Months Anti-virus Definition Updates Monthly Inspect Wire, Cable and Connections Monthly SCADA System Architecture of a Power Plant Industrial Controls Corporation SCADA WORKSTATION Industrial Controls Corporation Industrial Controls Corporation THANK YOU!!! Industrial Controls C Corporation ti The Automation and Instrumentation Systems House 928 Mega Plaza Building, ADB Avenue cor. Garnet Street Ortigas Center, Pasig City, Philippines 687-4814 to 15, 687-1246, 687-2080 924-0957, 687-2443 [email protected] info@industrialcontrolscorp com [email protected] website : http\\www.industrialcontrolscorp.com
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