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SCADA

Supervisory control And Data

Acquisition

SARATH S NAIRAssistant Professor, Amrita University,India

Sarath S Nair, www.technologyfuturae.com

INDUSTRIAL AUTOMATION

Industrial Power GroupDept. Of Electrical Engineering, NIT Calicut


Process

Automation

Outline:4 Examples of automated processes4 Types of plants and controls4 Automation hierarchy4 Control System Architecture


Automation Applications

� Power generation hydro, coal, gas, oil, shale, nuclear,

wind, solar

� Transmission electricity, gas, oil

� Distribution electricity, water

� Process paper, food, pharmaceutical, metal, processing,

glass, cement, chemical, refinery, oil & gas

� Manufacturing computer aided manufacturing (CIM), flexible � Manufacturing computer aided manufacturing (CIM), flexible

fabrication, appliances, automotive, aircrafts

� Storage silos, elevator, harbor, deposits, luggage handling

� Building heat, ventilation, air conditioning (HVAC), access

control, fire, energy supply, tunnels, highways,....

� Transportation rolling stock, street cars, sub-urban trains,

busses, cars, ships, airplanes, satellites,...


Examples of Automated Plants

Cars�Appliances control (windows, seats,

radio,..)

�Motor control (exhaust regulations)

�ABS and EPS, brake-by-wire, steer-by-wire

�19% of the price is electronics, (+10% per �19% of the price is electronics, (+10% per

year)

Airplanes Avionics�flight control, autopilot

�flight management

�flight recording, black boxes

�diagnostics

�“fly-by-wire”


Examples of Automated Plants

Flexible Automation, Manufacturing

Numerous conveyors,

robots, CNC

machines, paint

shops, logistics.


Examples of Automated Plants:

Oil, Gas and Petrochemicals

Upstream:from the earth to the refinery

(High pressure, saltwater, inaccessibilityexplosive environment with gas) Downstream:

Distribution:

(environmental protection)

with gas) Downstream:

(extreme explosiveenvironment)



Power plants

4 Raw materials

supply

4 Primary process

(steam, wind)

4 Personal, plant

and

neighbourhood

safetysafety

4 Environmental

impact

4 Generation

process

(voltage/frequency

)

4 Energy

distribution

(substation)



Waste treatment, incinerators

4 Raw material supply

4 Burning process

4 Smoke cleaning

4 Environmental control

44 Co-generation process (steam, heat)

4 Ash analysis

4 Ash disposal



Water treatment

Managing pumps, tanks, chemical composition, filters, movers,..


Automation Systems Manufacturers

Company Location Major mergers

ABB CH-SE Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-

Bailey

Siemens DE Plessey, Landis & Gyr, Stäfa, Cerberus,..

Ansaldo IT

Emerson US Fisher Rosemount

General Electric US

Honeywell US

Rockwell

Automation

US Allen Bradley, Rockwell,..

Alstom FR Alsthom, GEC, CEGELEC, ABB Power,..

Schneider Electric FR Télémécanique, Square-D, ...

Invensys UK Foxboro, Siebe, BTR, Triconex,…

Hitachi JP

Yokogawa JP

Technical Necessity of Automation

� Processing of the information flow

� Enforcement of safety and availability

� Reduction of personal costs


Expectations of Automation

� Process Optimisation

– Energy, material and time savings

– Quality improvement, reduction of waste, pollution control

– compliance with laws, product tracking

– Increase availability, safety

– Fast response to market

– Connection to management and accounting � Acquisition of large number of “Process Variables”, data mining� Personal costs reduction

– Simplify interface– Simplify interface

– Assist decision

– Require data processing, displays, data base, expert systems� Human-Machine Interface (MMC = Man-Machine Communication)� Asset Optimisation

– Automation of engineering, commissioning and maintenance

– Software configuration, back-up and versioning

– Maintenance support� Engineering Tools


Data Quantity in Different Plants

4 Power Plant (25 years ago)

– 100 measurement and action variables (called "points")

– Analog controllers, analog instruments

– one central "process controller" for data monitoring and protocol.

4 Thermal power plant (today)

– 10000 points, comprising:• 8000 binary and analog measurement points and• 2000 actuation point

– 1000 micro-controllers and logic controllers– 1000 micro-controllers and logic controllers

4 Nuclear Power Plant

– three times more points than in conventional power plants

4 Electricity distribution network

– 100’000 – 10’000’000 points

4 Data reduction and processing is necessary to operate plants


4 Little difference in the overall architecture of different applications control systems.

4 ANS/ISA standard4 Enterprise Resource Planning:

– Business Planning & Logistics

– Plant Production Scheduling

– Operational Management, etc.

4 Manufacturing Execution System:– Manufacturing

Operations & Control

Manufacturing Execution

Supervision (SCADA)

Enterprise

Automation Hierarchy

Operations & Control

– Dispatching Production, Detailed ProductScheduling, Reliability Assurance,...

4 Control & Command System:– Batch control

– Continuous Control

– Discrete control

Group Control

Individual Control

Field

Primary technology


Example: Siemens WinCC


Large control system hierarchy

enterprise

Group Control

Supervisory

Workflow, Resources,

Interactions SCADA =Supervisory ControlAnd Data Acquisition

administrationPlanning, Statistics, Finances

supervision

2

3

4

Group Control

Unit Control

Field

Sensors & Actuators A V

Primary technology

T

1

0



4 Administration:

– Production goals, planning

4 Enterprise:

– Manages resources, workflow, coordinates activities of different sites

quality supervision, maintenance, distribution and planning

4 Supervision:

– Supervision of the site, optimization, on-line operations, Control room, – Supervision of the site, optimization, on-line operations, Control room,

Process Data Base, logging (open loop)

4 Group (Area):

– Control of a well-defined part of the plant (closed loop, except for

intervention of an operator)• Coordinates individual subgroups, Adjusting set-points and parameters• Commands several units as a whole



4Unit (Cell):

– Control (regulation, monitoring and protection) of

a small part of a group (closed loop except for maintenance)

• Measure: Sampling, scaling, processing, calibration

• Control: regulation, set-points and parameters

• Command: sequencing, protection and interlocking• Command: sequencing, protection and interlocking

4Field:

– Sensors & Actuators, data acquisition, digitalization, data

transmission

– No processing except measurement correction and built-in

protection


Field level

4Field level is in

direct

interaction with

the plant's

hardwarehardware


Group level unit controllers

4Group level coordinates

the activities of several

unit controls

4Distributed Control

Systems (DCS)

commonly refers to a commonly refers to a

hardware and software

infrastructure to perform

Process Automation


Local human interface at group level

Sometimes, the group level has its own man-machine interface for local operation control (here: cement packaging)

Maintenance console / emergency panel


Supervisory level: Man-machine interface

4Control room (mimic wall) 1970s...

4All instruments were directly wired to the control room


Supervisory level:

SCADA = Supervisory Control and Data Acquisition

4 Displays the current state of

the process (visualization)

4 Display the alarms and

events (alarm log, logbook)

4 Display the trends

(historians) and analyse them

4 Display handbooks, data 4 Display handbooks, data

sheets, inventory, expert

system (documentation)

4 Allows communication and

data synchronization with

other centres


Operator workplace: Three main functions

1. Current state 2. Trends and

history

3. Alarms

and

events


Response time and hierarchical level

PlanningLevel

ExecutionLevel

ERP(Enterprise Resource Planning)

MES(Manufacturing Execution System)

SCADALevel

ControlLevel

SupervisoryLevel

ms seconds hours days weeks month years

DCS

PLC(Programmable Logic Controller)

(Distributed Control System)

(Supervisory Control and Data Acquisition)

SCADA


Complexity and Reaction Speed in Hierarchical levels

MES

Supervision

ERP

days

months

minutes

Group Control

Individual Control

Field

SiteComplexity Reaction Speed

seconds

0.1s

0.01s


Operation and Process Data

4Normally, the operator

is only concerned by

the supervisory level,

but exceptionally,

operators (and

engineers) want to engineers) want to

access data of the

lowest levels

4The operator sees the

plant through a fast

data base, refreshed in

background


Brief history of SCADA

� The first ‘SCADA’ systems utilized data acquisition by means of panels of meters, lights and strip chart recorders.

�The operator manually operates various control �The operator manually operates various control knobs and exercise supervisory control.

�These devices are still used to do supervisory control and data acquisition on plants, factories and power generating facilities.


Sensors to panel


Mimic SCADA system


Mimic SCADA systems

Advantages:

� It is simple, no CPUs, RAM, ROM or software programming

needed

� The sensors are connected directly to the meters, switches and

lights on the panel

� It could be (in most circumstances) easy and cheap to add a

simple device like a switch or indicator


Mimic SCADA systems

Disadvantages:

�The amount of wire becomes unmanageable

after the installation of hundreds of sensors

�The quantity and type of data are minimal and rudimentary

� Installation of additional sensors becomes progressively � Installation of additional sensors becomes progressively harder as the system grows

�Re-configuration of the system becomes extremely difficult

� Simulation using real data is not possible

� Storage of data is minimal and difficult to manage

� No off site monitoring of data or alarms

� 24 Hour around monitoring is required.


Modern SCADA systems

� SCADA refers to the combination of

telemetry and data acquisition.

� SCADA encompasses the collecting of the

information, transferring it back to the central site,

carrying out any necessary analysis and control carrying out any necessary analysis and control

and then displaying that information on a number

of operator screens or displays.

� The required control actions are then conveyed

back to the process.


Continued….

� With the advent of the

microprocessors and other

electronic devices,

manufacturers

incorporated digital

electronics into relay logic

equipment.equipment.

� As Monitoring and control

of devices in the plant

grew, the PLCs were

distributed and the

systems became more

intelligent and smaller in

size


SCADA Architecture


EVOLUTION

Of SCADA Architecture


PC to PLC / DCS SCADA system with a field bus

and sensors


PLC / DCS SCADA system

Advantages:

� The computer can record and store a very large amount of data

� The data can be displayed in any way the user requires

� Thousands of sensors over a wide area can be � Thousands of sensors over a wide area can be connected to the system

� The operator can incorporate real data simulations into the system

� Many types of data can be collected from the RTUs

� The data can be viewed from anywhere, not just on site


PLC / DCS SCADA system

Disadvantages:

� The system is more complicated than the

sensor to panel type

�Different operating skills are required,

such as system analysts and programmersuch as system analysts and programmer

�With thousands of sensors there is still a

lot of wire to deal with

� The operator can see only as far as the

PLC


PC to IED using a field bus

� As smaller and smarter systems grew, sensors were designed with the intelligence of PLCs and DCSs. These devices are known as IEDs (intelligent electronic devices).

� The IEDs are connected on a fieldbus, such as Profibus, Devicenet or Foundation Fieldbus to Profibus, Devicenet or Foundation Fieldbus to the PC.

� They include enough intelligence to acquire data, communicate to other devices, and hold their part of the overall program.


Continued….

�Each of these super smart sensors can have more

than one sensor on-board.

�Typically, an IED could combine an analog input

sensor, analog output, PID control,

communication system and program memory in communication system and program memory in

one device.



Advantages:� Minimal wiring is needed

� The operator can see down to the sensor level

� The data received from the device can include information such as serial numbers, model numbers, when it was such as serial numbers, model numbers, when it was installed and by whom

� All devices are plug and play, so installation and replacement is easy

� Smaller devices means less physical space for the data acquisition system



Disadvantages:

�More sophisticated system requires better trained

employees

� Sensor prices are higher (but this is offset

somewhat by the lack of PLCs)somewhat by the lack of PLCs)

�The IEDs rely more on the communication system


SCADA hardware

�A SCADA system consists of a number of

remote terminal units (RTUs) collecting field data

and sending that data back to a master station, via

a communication system.

�The master station displays the acquired data and �The master station displays the acquired data and

allows the operator to perform remote control

tasks.

�The RTU provides an interface to the field analog

and digital sensors situated at each remote site.


Diagram of a typical SCADA system


Functions of SCADA System

A SCADA system performs four functions:

1.Data acquisition 2.Networked data communication 3.Data presentation 4.Control

These functions are performed by four kinds of These functions are performed by four kinds of SCADA components .

1.Sensors 2.Remote telemetry units (RTUs )3. SCADA master units

4. communications network


SCADA System Hierarchies

Field level instrumentation and control devices

Marshalling terminals and RTUs

Communications system

The master station(s)

The commercial data processing department computer The commercial data processing department computer

system


SCADA system hierarchies


� The communications system provides the pathway

for communication between the master station andthe remote sites.

� This communication system can be wire, fiber optic,radio, telephone line, microwave and possibly evensatellite.

� Specific protocols and error detection philosophiesare used for efficient and optimum transfer of data.

� Specific protocols and error detection philosophiesare used for efficient and optimum transfer of data.

� The master station (or sub-masters) gather data fromthe various RTUs and generally provide an operatorinterface for display of information and control ofthe remote sites.

� In large telemetry systems, sub-master sites gatherinformation from remote sites and act as a relayback to the control master station.


Benefits

� The accurate and timely data allows for

optimization of the plant operation and process.

� More efficient, reliable and most importantly, safer

operations.

� This results in a lower cost of operation compared to� This results in a lower cost of operation compared to

earlier non-automated systems.


SCADA software

Proprietary software:

� Companies develop proprietary software to

communicate to their hardware.

� These systems are sold as ‘turn key’ solutions. The mainproblem with this system is the overwhelming reliance on thesupplier of the system.

Open software:Open software:

� Open software systems have gained popularity because of theinteroperability they bring to the system.

� Interoperability is the ability to mix different manufacturers’equipment on the same system.

� Available scada softwares are

� GE IFIX

� PCIM,

� Wonderware,

� Intellution etc.Sarath S Nair, www.technologyfuturae.com

Open software

Citect

WonderWare

Typical SCADA systemSarath S Nair, www.technologyfuturae.com

Features of SCADA software

�User interface

– • Keyboard

– • Mouse

– • Trackball

– • Touch screen– • Touch screen

� Graphics displays

– • Customer-configurable, object orientated and bit

mapped

– • Unlimited number of pages

– • Resolution: up to 1280 x 1024 with millions of colors


� Alarms

– • Client server architecture

– • Time stamped alarms to 1 millisecond precision (or better)

– • Single network Acknowledgment and control of alarms

– • Alarms shared to all clients

– • Alarms displayed in chronological order

– • Dynamic allocation of alarm pages

– • User-defined formats and color

– • Up to four adjustable trip points for each analog alarm

– • Deviation and rate of change monitoring for analog alarms– • Deviation and rate of change monitoring for analog alarms

– • Selective display of alarms by category (256 categories)

– • Historical alarm and event logging

– • Context-sensitive help

– • On-line alarm disable and threshold modification

– • Event-triggered alarms

– • Alarm-triggered reports

– • Operator comments that can be attached to alarms


� Trends

– • Client server architecture

– • True trend printouts (not screen dumps)

– • X/Y plot capability

– • Event based trends

– • Trend gridlines or profiles

– • Background trend graphics

– • Real-time multi-pen trending

– • Short and long term trend display– • Short and long term trend display

– • Length of data storage and frequency of monitoring that can be

– specified on a per-point basis

– • Archiving of historical trend data

– • On-line change of time-base without loss of data

– • On-line retrieval of archived historical trend data

– • Exact value and time that can be displayed

– • Trend data that can be graphically represented in real time


� RTU (and PLC) Interface

– • All compatible protocols included as standard

– • DDE drivers supported

– • Interface also possible for RTUs, loop controllers, bar code readers

– and other equipment

– • Driver toolkit available

– • Operates on a demand basis instead of the conventional predefined

– scan method

– • Optimization of block data requests to PLCs

– • Rationalization of network user data requests


� Scalability

– Additional hardware can be added without replacing or

modifying existing equipment. This is limited only by the PLC architecture (typically 300 to 40,000points)

� Access to Data

– • Direct, real-time access to data by any network user

– • Third-party access to real-time data, e.g. Lotus 123 and EXCEL

– • Network DDE

– • DDE compatibility: read, write and exec

– • DDE to all IO device points

– • Clipboard


� Database

– • ODBC driver support

– • Direct SQL commands or high level reporting

� Networking

– • Supports all NetBIOS compatible networks such as NetWare, LAN

– Manager, Windows for Workgroups, Windows NT (changed from

– existing NT)

– • Support protocols NetBEUI, IPX/SPX, TCP/IP and more

– • Centralized alarm, trend and report processing - data available from– • Centralized alarm, trend and report processing - data available from

– anywhere in the network

– • Dual networks for full LAN redundancy

– • No network configuration required (transparent)

– • May be enabled via single check box, no configuration

– • LAN licensing based on the number of users logged onto the network, not the number of nodes on the network

– • No file server required

– • Multi-user system, full communication between operators

– • RAS and WAN supported with high performance

– • PSTN dial up support


� Fault Tolerance and Redundancy

– • Dual networks for full LAN redundancy

– • Redundancy that can be applied to specific hardware

– • Supports primary and secondary equipment configurations

– • Intelligent redundancy allows secondary equipment to contribute to

– processing load

– • Automatic changeover and recovery

– • Redundant writes to PLC with no configuration– • Redundant writes to PLC with no configuration

– • Mirrored disk I/O devices

– • Mirrored alarm servers

– • Mirrored trend servers

– • File server redundancy


� Client/Server Distributed Processing

– • Open architecture design

– • Real-time multitasking

– • Client/server fully supported with no user configuration

– • Distributed project updates (changes reflected across network)

– • Concurrent support of multiple display nodes

– • Access any tag from any node– • Access any tag from any node

– • Access any data (trend, alarm, report) from any node


The SCADA Software Package

� Whilst performance and efficiency of the SCADA package with the current

plant is important, the package should be easily upgradeable to handle

future requirement.

� The requirements of SCADA software packages are:

– Modifiable

– Scaleable Architecture

� Two main approaches in designing the SCADA system:� Two main approaches in designing the SCADA system:

– Centralized-a single computer or mainframe performs all plant

monitoring and all plant data is stored on one database which resides on

this computer.

– Distributed-the SCADA system is shared across several small

computers (usually PCs).


Tasks performed by SCADA system

4 • Input/Output Task -This program is the interface between the control and monitoring system and the plant floor.

4 • Alarm Task - This manages all alarms by detecting digital alarm points and comparing the values of analog alarm points to alarm thresholds.

4 • Trends Task - The trends task collects data to be monitored over time.

4 • Reports Task - Reports are produced from plant data. These reports can be periodic, event triggered or activated by the operator.

4 • Display Task - This manages all data to be monitored by the operator and all 4 • Display Task - This manages all data to be monitored by the operator and all control actions requested by the operator.


System Response Times

4Display of analogue or digital value (acquired from RTU) on the Master Station Operator Display (1 to 2 seconds maximum)

4Control request from operator to RTU (1 second critical; 3 seconds non- critical)

4Acknowledge of alarm on operator screen (1 second)4Acknowledge of alarm on operator screen (1 second)

4Display of entire new display on operator screen ( 1 second)

4Retrieval of historical trend and display on operator screen (2

4 seconds)

4Sequence of events logging (at RTU) of critical events ( 1

millisecond)


SCADA Protocols

4 A Protocol controls the message format common to all devices on a

network.

4 Common protocols used in radio communications and telemetry

systems include the HDLC, MPT1317, Modbus protocols and

CSMA/CD protocol.

4Protocols– Communication between master station and the RTUs, use

time division multiplexing. It uses serial digital messages.

– The messages must be efficient, secure, flexible & easily – The messages must be efficient, secure, flexible & easily

implementable in hardware and software.

• Efficiency-Information Bits Transmitted ÷ Total Bits Transmitted

• Security - the ability to detect errors in the original information

transmitted, caused by noise on the communication channel.

• Flexibility – different amounts and types of information to be

transmitted upon command by the master station.

• Implementation in hardware and software - requires the minimum

in complicated logic, memory storage, and speed of operation.


4 All messages are divided into three basic parts as follows

• Message Establishment; which provides the signals to synchronize

• the receiver and transmitter.

• Information; which provides the data in a coded form to allow the

• receiver to decode the information and properly utilize it.

• Message Termination; which provides the message security checks and a means of denoting the end of the security checks and a means of denoting the end of the message.

4 A typical example of commonly used asynchronous message

format


SCADA and local area networks

�Local area networks (LAN) are all about sharing information and resources.

�To enable all the nodes on the SCADA network to share information, they must be connected by some transmission medium. some transmission medium.

�The method of connection is known as the network topology.

�Nodes need to share this transmission medium in such a way as to allow all nodes access to the medium without disrupting an established sender.


� A LAN is a communication path between computers, file-servers, terminals, workstations, and various other intelligent peripheral equipments, which are generally referred to as devices or hosts.

� A LAN allows access for devices to be shared by several users, with full connectivity between all stations on the network.

� A LAN is usually owned and administered by a private owner and is located within a localized group of buildings.

� Ethernet is the most widely use LAN today because it is cheap and easy to use Connection of the SCADA network

Continued…

use Connection of the SCADA network

� LAN allows anyone within the company with the right software and permission, to access the system. Since the data is held in a database, the user can be limited to reading the information. Security issues are obviously a concern, but can be addressed


Ethernet based SCADA system


Modem use in SCADA systems

PC to RTU using a modem

�One of the most cost-effective ways of communicating �One of the most cost-effective ways of communicating

with the RTU over long distances can be by dialup

telephone connection.

�The modems are put in the auto-answer mode and the

RTU can dial into the PC or the PC can dial the RTU.

�The software to do this is readily available from RTU

manufacturers.


System Troubleshooting

� The RTU and component modules

� Analog input modules

� Digital input module

� Interface from RTU to PLC (RS-232/RS-485)

� Privately owned cable

� Switched telephone line

� Analog or digital data links

� The master sites� The master sites

� The central site

� The operator station and software


Maintenance in a SCADA system


System implementation

�Consideration should be given to integrating new SCADA systems into existing communication networks in order to avoid the substantial cost of setting up new infrastructure and communications facilities.

�This may be carried out through existing LANs, �This may be carried out through existing LANs, private telephone systems or existing radio systems used for mobile vehicle communications.

� Careful engineering analysis must be carried out to ensure that overlaying of the SCADA system on to an existing communication network does not degrade or interfere with the existing facilities.


Comparison of SCADA, DCS, PLCComparison of SCADA, DCS, PLC


SCADA system

�A SCADA (or supervisory control and data acquisition) system means a system consisting of a number of remote terminal units (or RTUs) collecting field data connected back to a master station via a communications system.

�The master station displays the acquired data and also allows the operator to perform remote control tasks.

�The accurate and timely data (normally real-time) allows for optimization of the operation of the plant and process.


Distributed control system

�The data acquisition and control functions are performed by a number of distributed microprocessor-based units situated near to the devices being controlled or the instrument from which data is being gathered.

�DCS systems have evolved into systems providing �DCS systems have evolved into systems providing very sophisticated analog (e.g. loop) control capability.

�A closely integrated set of operator interfaces (or man machine interfaces) is provided to allow for easy system configurations and operator control.

�The data highway is normally capable of fairly high speeds (typically 1 Mbps up to 10 Mbps).


Distributed control system


Programmable logic controller

4Replaced hardwired relays with a combination of

ladder– logic software and solid state electronic

input and output modules.

4They are often used in the implementation of a

SCADA RTU as they offer a standard hardware SCADA RTU as they offer a standard hardware

solution, which is very economically priced.


Programmable logic controller system


Considerations of SCADA system

Overall control requirements

Sequence logic

Analog loop control

Ratio and number of analog to digital points

Speed of control and data acquisition

Master/operator control stations

Type of displays required

Historical archiving requirementsHistorical archiving requirements

System consideration

Reliability/availability


Continued….

Speed of communications/update time/system scan rates

System redundancy

Expansion capability

Application software and modeling


Benefits of SCADA

Improved operation of the plant or process resulting in savings due to optimization of the system

Increased productivity of the personnel

Improved safety of the system due to better information and improved controlinformation and improved control

Protection of the plant equipment

Safeguarding the environment from a failure of the system


Continued..

Improved energy savings due to optimization of

the plant

Improved and quicker receipt of data so that

clients can be invoiced more quickly and

accuratelyaccurately

Government regulations for safety and metering of

gas (for royalties & tax etc)


EXAMPLES

SCADA SYSTEMS


Level

transmitter

senses the

water level

and pass it

to RTU

MOTOR ONMOTOR OFF

WATER

FROM

THE

RTU RTU

REGIONAL CONTROL CENTRE

THE

MAIN

HEADER


Vishakapattanom Industrial Water supply Project


ENERGY & AUTOMATION

NITC SCADA Laboratory

ENERGY & AUTOMATION

Training Programme on Industrial AutomationSarath S Nair, www.technologyfuturae.com

Introduction

SCADA

Overview of SCADA Laboratory

Transmission Line Model

Overview

Interface with SCADA

IED’s

Experiments

Contents

Experiments

Distribution Line ModelOverview

Interface with SCADA

Experiments

Scope

Conclusion


Supervisory Control and Data Acquisition (SCADA)

SCADA is a software program that gathers real time

information for process control of field equipment. SCADA can

be used in industries such as telecommunications, power

systems, oil and gas refining, water and waste control and

transportation.

Main Components of SCADA

Introduction

Main Components of SCADA

Control Center

Intelligent Electronic Devices (IEDs)

Programmable Logic Controllers (PLCs)

Electrical Transducers


General SCADA Architecture

Introduction


Applications of SCADA in Power Systems

1. Power Plant Automation

2. Energy management Systems (EMS)

3. Sub-Station Automation

4. Distribution Management systems (DMS)

Introduction

4. Distribution Management systems (DMS)

5. HVDC


Overview of SCADA Laboratory

� National Institute of Technology, Calicut (NITC) is setting up a

laboratory

� The Laboratory setup consists of three main Units

1. 400/220kV substation and 220kV transmission line model with

SCADA

2. 11kV Distribution station model with SCADA

Introduction

2. 11kV Distribution station model with SCADA

3. Control center

� Electrical SCADA Lab for Education and Research to provide hands-

on experience for the students with systems used for Power System

Monitoring, Control, Protection, Automation and Communication.


Overview of TLM


The model consists of 400/220 kV receiving substation with a

220 kV out going line.

One typical 220 kV transmission line also is modeled for a

distance of 200 KM.

The Communication System is built on the newest substation

Communication Architecture of IEC 61850.Communication Architecture of IEC 61850.

Load Model

(R,L &C Load)

200 KM


(8 pi Sections each of 25 km)

400/220 kV SS


Fuse

3-Ph Supply

L, 1 kVAR, 0.33 kVAR/Ph,5 A, 38.5 mH/Ph

Contactor 110 V4 pole 32 A

Contactor 110 V4 pole, 32 A

R, 1 kW, 0.33 kW/Ph5 A, 110 V

12.1 Ohm/Ph

Load Model

3 ph, 4 Wire12 ohm Dimmer

3 ph, 4 Wire12 ohm Dimmer

MCB

32 A

400/220 kV Substation Model

220 kV, 200 KMTransmission Line

Model

C1

415/110 V1 KVA, 12.5%

EM 3

Prot CT 2.5/1 A

MeteringCT 2.5/1

Metering

CT 5/1 AMeteringCT 5/1 A

C2 C3 IN

R

XTransmission Line8-Pi sections

Relay 1

Breaker4 pole 32 A

C4

C3

C2

C1Fault Throw

Switch

EM 1

C10

Capacitor Bank0.1 KVA/Ph0.3 KVA/3-Ph

10 Nos.

Series Compensation

1 KVA, 12.5%

EM 2

CBM

Auxiliary Supply415/110 V

500 VA, 1-Ph



Interfacing with SCADA

Local Area Network

SCADA Work station TLM Control Centre

IEC 61850

IEC 101

RS 232

Kalki Sub-Station Gateway Lite (M)

EM EM EMNR

Field Devices

RS 485

RS 232

Hardwired I/O

RS 485

PLC



Experiments

Simulation of Faults

L-G Fault –Relay sensing and tripping and observe the fault current

L-L Fault - Relay sensing and tripping and observe the fault current

L-L-G Fault - Relay sensing and tripping and observe the fault

current

L-L-L Fault - Relay sensing and tripping and observe the fault

current

Ferranti Effect – Observe the voltage profile at sending and

receiving end

Loading of Transmission line

Resistive Load – Observe Voltage and current profile

Inductive Load - Observe Voltage and current profile

R & L Load -Observe Voltage and current profile


VAR Compensation

Series Compensation - Observe the bus voltage profile

Shunt Compensation

Regulation of bus voltage – Observe the bus voltage profile

Loading of transformer - Observe the current profile and relay sensing,


Experiments

Loading of transformer - Observe the current profile and relay sensing,

tripping.

Sudden Load rejection – Voltage regulation at sending end.

Operation of OLTC transformer – Voltage regulation at sending end.


IED’s

4PLC

(Programmable Logic Controller)

4Relay

4Energy Meter


4 Introduction of PLC

4Basic PLC Operation

4Example

4Advantages of PLC

4GE Fanuc PLCs4GE Fanuc PLCs

4VersaMax Micro

4Terminologies

4Basic Requirements


Introduction of PLC

4 used in commercial and industrial applications.

4 Monitors inputs, makes decisions based on its program, and controls outputs to automate a process or machine.


PLC Basic Operation

PLCs consist of input modules or points, a Central Processing

Unit (CPU), and output modules or points.

4An input accepts a variety of digital or analog signals from

various field devices (sensors) and converts them into a logic various field devices (sensors) and converts them into a logic

signal that can be used by the CPU.

4The CPU makes decisions and executes control instructions

based on program instructions in memory.


4Output modules convert control instructions from the CPU

into a digital or analog signal that can be used to control

various field devices (actuators).

4A programming device is used to input the desired

instructions. These instructions determine what the PLC instructions. These instructions determine what the PLC

will do for a specific input.

4An operator interface device allows process information to

be displayed and new control parameters to be entered.


Example:

Pushbuttons (sensors), in this simple example,

connected to PLC inputs, can be used to start and

stop a motor connected to a PLC through a

motor starter (actuator).


Advantages of PLC

4Smaller physical size than hard-wire solutions

4 Easier and faster to make changes

4 PLCs have integrated diagnostics and override functions

4Diagnostics are centrally available

4Applications can be immediately documented4Applications can be immediately documented

4Applications can be duplicated faster and less expensively


GEFanuc PLCs

GEFanuc makes several PLC product lines

They are:

490-30 series

490-70 series

4Micro/ Nano4Micro/ Nano


Micro

4This is referred to as a Micro PLC because of its small

size.

4The Micro has a brick design which means that the power

supply and I/O are on-board.

4The Micro can be used on smaller, stand-alone applications The Micro can be used on smaller, stand-alone applications

such as elevators, car washes, or mixing machines.


Micro


Terminology

The language of PLCs consists of a commonly

used set of terms; an understanding of these terms is

necessary.

4Sensor: A sensor is a device that converts a physical4Sensor: A sensor is a device that converts a physical

condition into an electrical signal for use by the PLC.

Sensors are connected to the input of a PLC.


Actuators:

Actuators convert an electrical signal from the PLC into a

physical condition. Actuators are connected to the PLC

output.

4A motor starter is one example of an actuator that is A motor starter is one example of an actuator that is

connected to the PLC output. Depending on the output

PLC signal the motor starter will either start or stop the

motor.


Basic Requirements

In order to create or change a program, the following items

are needed:

4 PLC

4 Programming Device

4 Programming Software4 Programming Software

4Connector Cable


Distribution Sub-Station Model


Overview of DSM

The model consists of 11 kV substation with four outgoing

feeders and a capacitor bank

Each feeder is designed as RL load.

The Communication System is built on the newest substation

Communication Architecture of IEC 61850.


11 kV SubStation

Feeder 2

Feeder 1

Feeder 4

Feeder 3

Capacitor Bank


Fuse1-Ph

Supply

MCB1-Ph

16 A

16 A

16 A

Feeder 1

Feeder 2

Feeder 3

L, 4 taps230 V, 50 Ohm


R 1KW230 V, 52.9 Ohm

R, 1 KW230 V, 52.9 Ohm

R, 1 KW230 V, 52.9 Ohm


Prot CT

25/1 A

Metr CT

25/1 A

Metr CT

5/1 A

Metr CT

5/1 A16 A

415/230 V, 1:1

5 KVA, 1-Ph, 5%

32 A

Metr CT

5/1 A

Relay

11 KV Distribution Model

EM

EM

EM

EM

IN

F1

F2

F3

16 AFeeder 4

230 V, 50 Ohm

R, 1 KW230 V, 52.9 Ohm


Metr CT

5/1 A

Relay

EM

Capacitor Bank0.5 KVAR

1-Ph, LT, 5 Nos.

16 A

16 A

16 A

16 A

16 A

F4

CB1CB

CB2

CB3

CB4

CB5


Interfacing with SCADA


Local Area Network

SCADA Work station DLM

IEC 61850

EM

RS 485

EM

Kalki Sub-Station Gateway Lite (M)

EM EM

EM

EM

NR

Field Devices

Hardwired I/O

RS 485

PLC


Experiments

Relay Coordination

Voltage Regulation

Demand Side Management

Load Shedding



Experiments in SCADA


Experiments in SCADA


Scope

4 The entire system is completely expandable to accommodate

any additional hardware equipments.

4 The RTU is modular expandable so that addition of I/O s are

possible later.

4 The communication networks are multi drop serial. One RS485

loop can support up to 32 devices.

4 The Gateway can be configured to accommodate any number of

devices and data points. The SCADA system supports devices and data points. The SCADA system supports

unlimited tags. User can configure the required tags later.

4 The SCADA supports client server networking over TCP/IP

LAN. Any number of servers or clients can be connected to the

network. Web server features provide the data access through

web clients over LAN/Intranet/Internet.

4 During future expansion the Ethernet LAN provided can be

changed to Ethernet switch to accommodate more servers or

clients.


Conclusion

� This SCADA Lab serves the purpose of providing hands-on

experience for the students with systems used for Power System

Monitoring, Control, Protection, Automation and Monitoring, Control, Protection, Automation and

Communication.


SCADA AND ITS SCADA AND ITS

IMPLEMENTATIONIMPLEMENTATION

IN INDIAN POWER SECTORIN INDIAN POWER SECTORIN INDIAN POWER SECTORIN INDIAN POWER SECTOR


Power Sector SCADA

Used to monitor & manage the Power System Networks-

Generation – Transmission – Distribution – Metering –

Billing etc


TYPICAL HIERARCHICAL CONTROL CENTRE SETUP

ERLDC WRLDC SRLDC NRLDC NERLDC5 Nos.

NLDC

RTU RTU RTU

SUB LDC SUB LDC SUB LDC

SLDC SLDC SLDC32 Nos.

41 Nos.

1160 Nos.


RSCCREGIONAL SYSTEM CO-ORDINATION CENTER

RSCC Bangalore

CENTRAL PROJECT CONTROL CENTER

CPCC Bangalore

SLDCs

Andhra Pradesh

SLDC

Mamidipally

Karnataka

SLDC

Bangalore

Tamil Nadu

SLDC

Chennai

Kerala

SLDC

Kalamassery

UT of Pondy

SCC

Pondicherry

Sub-LDC Sub-LDC Sub-LDC Sub-LDC

HIERARCHICAL STRUCTURE OF CONTROL CENTERs

Sub-LDCs

Sub-LDC

Hyderabad

Sub-LDC

Cuddapah

Sub-LDC

Bangalore

Sub-LDC

Chennai

Sub-LDC

Kalamassery

Sub-LDC

Vijayawada

Sub-LDC

Warangsl

Sub-LDC

Hubli

Sub-LDC

Davanagere

Sub-LDC

Madurai

Sub-LDC

Erode

Sub-LDC

Kannur

Sub-LDC

Trivandrum


Southern Region Southern Region

KPTCL

• 1 SLDC

• 3 Sub-LDC

• 22+21 RTUs APTRANSCO

• 1 SLDC

• 4 Sub-LDC

• 82 RTUs

TNEB

• 1 SLDC

• 3 Sub-LDC

• 40+35 RTUs

KSEB

• 1 SLDC

• 3 Sub-LDC

• 30 RTUs

PONDY

• 1 SCC

• 5+9 RTUs

RLDC

+

CPCC

22 RTUs


Regional Level SCADA Overview


REMOTE STATION DEVICES

DEVICES ARE RTUS (Remote Terminal Units) WHICH TAKES THE FIELD INPUTS

TYPES OF MONITORING POINTS

ANALOG VALUES : MW,MVAR,V,F,I

STATUS INDICATION : CB CLOSED, CB OPEN, ISOLATOR CLOSED.

DIGITAL CONTROL : CB TRIP, CB CLOSE


REMOTE STATION RTU

REMOTE TERMINAL UNIT AT REMOTE STATIONS FROM

WHERE DATA IS COLLECTED AND SENT TO CONTROL CENTRE

GE HARRIS’S RTU SUPPLIED IN ULDC SCHEME HAS 3 TYPES OF

CARDS(PERIPHERAL CARDS)

D20A - HANDLES ANALOG I/PS

D20S - HANDLES STATUS I/PSD20S - HANDLES STATUS I/PS

D20K - HANDLES CONTROL PTS.

THESE PERIPHERAL BOARDS COLLECTS THE FIELD INPUTS

D20M++ - CPU CARD OF THE RTU

THIS COMMUNICATES TO THE PERIPHERAL BOARDS AS WELL AS TO THE MASTER STATION


Manjeswaram Mylatti Kanhirode

Nallalam Areakode Kuttiady

Kaniyampetta Palakkad Shornur

Madakathara Chalakudy Poringal

Sholayar Idamalayar Pallivasal

Sengulam Neriamangalam Lower Periyar

RTU STATIONS

Sengulam Neriamangalam Lower Periyar

Idukki Kalamassery Brahmapuram

Pallom Edappon Kundara

Sabarigiri Kakkad Edamon

Pothencode Parassala Punnapra

Kayamkulam

(Central Sector)

TVM 400kV (PGCIL) Thaliparambu


COMMUNICATION MEDIUM

DIRECT CABLE CONNECTION

MICROWAVE

OPTICAL FIBEROPTICAL FIBER

PLCC

MICROWAVE & PLCC

OPTICAL FIBER & PLCC



CD

WT

FEP RTU

POWER LINE

MOD

EMDC FEP RTUMOD

EM

PLCCCD

WT

(DIRECT CABLE)

LAN 2

MOD

EMFEP PLCC PLCC

MOD

EMRTU

FEP MUX MW RTUMUXMWMW



FEP MUX OLTE RTUMUXOLTEOFCOFC

NODAL STATIONS

VB PCOD PRPY KDRA KYLM PLLM VIKM KLSY

CHDYMDRAARKDKNRD

OFC

MW


Parassala

Pothencode

Edamon

VB TVM KND KYM PLM KSY

Edappon

KakkadEdamon

Kundara Sabarigiri

BDPP

Idukki

Pallivasal

SengulamNeriamangalam

PallomKsy

Punnapra

WIDEBAND LOCATIONS AND RTUs

TCRNARKDKNR CLDY

Chldy

Idlyr

ShlyrMDRA

LP

KJKD Arkd

KnyptaKZDE

Mnjm

MLTYKnr

Kttdy

PorlSHNR

Sarath S Nair,

www.technologyfuturae.com

MASTER STATION SOFTWARE

OS - IBM UNIXDATABSE - SYBASEDISPLAY EDITOR - ACAD SCADA/EMS APLLN. - XA/21

HARDWARE

SERVER: IBM RISC/6000 43P MODEL 260

137

SERVER: IBM RISC/6000 43P MODEL 260200MHz POWER3 630 PROCESSOR1GB MEMORY

WORKSTATION : IBM RISC/6000 43P MODEL 140200 MHz 604E POWER PC PROCESSOR

FEP: MOTOROLA POWERPC PROCESSOR 300MHz (3604)

RTU : WESDAC D20 SERIESMOTOROLA 68020 PROCESSOR–16 MHz


MASTER STATIONSub LDC

AP/WS1 AP/WS2 FEP 1 FEP 2

LAN 1

LAN 2

ROUTERS

WAN

LAN 1

LAN 2

SCADA

SERVER

DATA

SERVER

BACKUP

SERVER

EMS

SERVER 1

EMS

SERVER2

EMS

BACKUP

WS 1 WS 2 WS 3 WS 4

AP 1

FEP 1

AP 2 AP 3 AP 4 AP 5 AP 6

FEP 2

LAN 1

LAN 2

ROUTERS

WAN

SLDC


POWER SYSTEM OPERATION USING MODERN SCADA

I. FUTURE PLANNING II. REALTIME OPERATION III. HISTORICAL ANALYSIS

I. FUTURE PLANNING

* Load Forecast

* Network Study


II. REAL TIME OPERATION

* Supervision of Generation, Loads and Frequency

* Control of System Frequency and Power Exchange

* CB Position Control

III. HISTORICAL ANALYSISIII. HISTORICAL ANALYSIS

* Fault Analysis

* Power View

* Data Logging


Thank You


GE Fanuc IFIX Software

4 iFIX® is the Windows-based HMI/SCADA component

of GE Fanuc's family of software automation products

4Allow easy integration and interoperability between your

plant floor and business systems.

4The SCADA portion of iFIX provides monitoring, 4The SCADA portion of iFIX provides monitoring,

supervisory control, alarming, and control functions.

4 Provides a distributed architecture.

4 iFIX is built on standard technologies, such as ActiveX,

OPC, VBA, and Component Object Model (COM).


Understanding the iFIX Nodes


Data acquisition is the ability to retrieve data from the plant floor and process that data into a usable form. Data can also be written to the plant floor, thereby establishing the critical two-way link required by control software. iFIX uses OPC to request and utilize plant floor data.

Once data is acquired, it is manipulated and channeled according to requests from your application software. This process is known as data management.


MonitoringMonitoring is the ability to gather anddisplay real-time plant-floor data to allrelevant personnel. Powerful numeric,text, and graphical formats are availableto make real-time data more accessible,easier to read, and easier to understand.

Supervisory ControlSupervisory control is the ability to monitor real-timedata coupled with the ability to change set points andother key values directly from your computer. With iFIX,you can easily control who has access rights to this dataand which data points can be changed.


AlarmingAlarming is the ability to recognize exceptionalevents within your process and immediately reportthose events to the appropriate personnel. Alarmsare generated based on the control limits youestablish and can be reported in a variety of ways.

ControlControl is the ability to automatically apply algorithms thatadjust process values and thereby maintain those valueswithin set limits. Control goes one step beyond supervisorycontrol by removing the need for human interaction. iFIXincludes continuous control, batch control, and statisticalprocess control capabilities. It can be used to control yourwhole process or part of your process.


Reporting FunctionsReal-time data is only one level ofinformation processing. Many plants requirethe ability to report or store real-time datafor later analysis. iFIX allows you to use anythird-party reporting application that supportsODBC queries to create reports based oncritical system and process information. Thecritical system and process information. Thefollowing figure illustrates the reportingfunctions.


Acknowledgement

4Industrial Power Group, NIT calicut,

INDIA

4Kalki Communications


THANK YOU


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