Engineering SCADA (Introduction) Dr. Sasidharan Sreedharan

Transcription

1 Engineering SCADA (Introduction) Dr. Sasidharan Sreedharan

2 Contents What is a SCADA System Simple SCADA System lay out and working Components of a SCADA System Levels of SCADA - integration Applications of SCADA System

3 SCADA Definition A collection of equipment that will provide an operator at a remote location with sufficient information to determine the status of particular equipment or a process and cause actions to take place regarding that equipment or process without being physically present

4 GENERAL DESCRIPTION OF A SCADA SYSTEM * Normally used for accessing DATA from various equipment and Devices Remotely and to Control them Remotely Process the DATA Presentation in a User friendly way for Monitoring Purpose Analyzing the DATA Remote Control Can be manual based on Decisions or Automatic Control based on Conditions

5 APPLICATIONS In Industry-Production, Processing Units etc. Pipe Line Monitoring Oil and Gas Ship Telecom POWER SECTOR The current scenario is to use SCADA for all Engineering Applications

6 SIMPLE SCADA SYSTEM UTILITY WATER PUMPING SYSTEM

7 ANIMATION OF THE SIMPLE SCADA SYSTEM

8 SCADA SIMPLE MECHANICAL BOILER SYSTEM

9 SCADA - SEWAGE TREATMENT PLANT

10 WEB BASED SCADA SYSTEM

11 SCADA SYSTEM TOPOLOGY

12 COMPONENTS OF SIMPLE SCADA SYSTEM

13 Data Conversion 4 20 ma ADC Digital Signals Parallel Data from ADC P - S Serial Digital Data

14 Remote Terminal Units CT PT R T U Serial Digital Data Status Indications

15 SCADA Hierarchy 5 Planning, Statistics, Finances administration 4 Production planning, orders, purchase enterprise 3 2 Workflow, order tracking, resources Supervisory SCADA = Supervisory Control And Data Acquisition (manufacturing) execution 1 Group control Unit control Field Sensors & actors A V T 0 Primary technology

16 SCADA hierarchy Administration Enterprise Manufacturing Supervision Group (Area) Unit (Cell) Field Finances, human resources, documentation, long-term planning Set production goals, plans enterprise and resources, coordinate different sites, manage orders Manages execution, resources, workflow, quality supervision, production scheduling, maintenance. Supervise the production and site, optimize, execute operations visualize plants, store process data, log operations, history (open loop) Controls a well-defined part of the plant (closed loop, except for intervention of an operator) Coordinate individual subgroups Adjust set-points and parameters Command several units as a whole Control (regulation, monitoring and protection) 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 data acquisition (Sensors & Actors), data transmission no processing except measurement correction. and built-in protection.

17 Field level The field level is in direct interaction with the plant's hardware.

18 Group level Co- ordinates the activities of various unit controls The group control is often hierarchical, can be also be peer-to-peer (from group control to group control = distributed control system)

19 Local human interface at group level Group level has its own man-machine interface for local operation control (here: cement packaging) Maintenance: console / emergency panel

20 Supervisory level: Man-machine interface control room (mimic wall) 1970s... Formerly, all instruments were directly wired to the control room

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22 Supervisory level: SCADA (SCADA = Supervisory Control and Data Acquisition) - displays the current state of the process (visualization) - display the alarms and events (alarm log, logbook) - display the trends (historians) and analyse them - display handbooks, data sheets, inventory, expert system (documentation) - allows communication and data synchronization with other centres

23 Today s control rooms There is no more direct wiring to the plant.

24 Plant management - store the plant and product data for further processing in a secure way (historian), allowing to track processes and trace products -> Plant Information Management System (PIMS) - make predictions on the future behaviour of the processes and in particular about the maintenance of the equipment, track KPI (key performance indicators) -> Asset Optimisation (AO)

25 Engineering workplace The engineering workplace manages the control system, not the plant. The engineer can configure the networks and devices, load the software, assign authorizations, troubleshoot the control system,...

26 SCADA standard classification Level 4 Business Planning & Logistics Plant Production Scheduling Operational Management, etc. Enterprise Resource Planning Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Product Scheduling, Reliability Assurance,... Manufacturing Execution System Levels 2,1,0 Batch Control Continuous Control Discrete Control Control & Command System ANSI Standard: Source: ANSI/ISA

27 SCADA: Power plant

28 Generic control Enterprise level Production level Process level

29 Response time and hierarchical level Planning Level Execution Level Supervisory Level Control Level DCS PLC (Programmable Logic Controller) MES (Manufacturing Execution System) SCADA (Supervisory Control and Data Acquisition) (Distributed Control System) ERP (Enterprise Resource Planning) ms seconds hours days weeks month years

30 Data Quantity & Quality - Hierarchical Higher Levels Lower Levels Level When ascending the control hierarchy, data are reduced: Higher level data are created (e.g. summary information) Timing requirements are slackened. Historical data are stored SCADA level Presentation of complex data to the human operator. Aid to decisions (expert system) and maintenance. Requires a knowledge database in addition to the plant's database Lowest levels (closest to the plant) are most demanding in response time. Quantity of raw data is very large. Processing is trivial (was formerly realized in hardware). These levels are today under computer control, Except in emergency situations, for maintenance or commissioning.

31 Complexity and Hierarchical level Complexity Reaction Speed ERP months Command level MES days Supervision minutes Group Control seconds Individual Control 0.1s Field 0.1s Site

32 Operation and Process Data base Consideration of human intervention breaches this hierarchy. Normally, the operator is only concerned by the supervisory level, but exceptionally, operators (and engineers) want to access data of the lowest levels. The operator sees the plant through a fast data base, refreshed in background. This database is the pivot for logging and simulation. knowledge base man-machine communication operator history logging process data base simulation instructor maintenance engineer actualization process data plant

33 The process database is at the centre

34 OIL and GAS SCADA

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36 SCADA for Renewable Integration

37 SCADA - Chemical Industry

38 SCADA Applications Power generation Transmission Distribution Process Manufacturing Storage Building Transportation hydro, coal, gas, oil, nuclear, wind, solar electricity, gas, oil electricity, water paper, food, pharmaceutical, metal, processing, glass, cement, chemical, refinery, oil & gas computer aided manufacturing (CIM), flexible fabrication, appliances, automotive, aircrafts elevator, harbor, deposits, luggage handling heat, ventilation, air conditioning (HVAC), access control, fire, energy supply, tunnels, highways,... rolling stock, street cars, sub-urban trains, busses, cars, ships, airplanes, satellites,...

39 SIMPLE SCADA - Automobile Cars Appliances control (windows, seats, radio,..) Motor control (exhaust regulations) ABS Airplanes Avionics Flight control, autopilot Fighter plane management Flight recording, black boxes Diagnostics

40 SCADA Manufacturing Plants Numerous conveyors, robots, CNC machines, paint shops, logistics.

41 SCADA: Oil, Gas and Petrochemicals Upstream: from the earth to the refinery (High pressure, saltwater, inaccessibility explosive environment with gas) Distribution: (environmental protection) Downstream: (extreme explosive environment

42 SCADA: Power plants Raw materials supply Primary process (steam, wind) Personal, plant and neigh bourhood safety Environmental impact Generation process (voltage/frequency) Energy distribution (substation)

43 SCADA: Waste treatment, incinerators Raw material supply Burning process Smoke cleaning Environmental control Co-generation process (steam, heat) Ash analysis Ash disposal

44 SCADA Water Treatment Plant Managing pumps, tanks, chemical composition, filters, movers,..

45 Regards, Dr. Sasidharan Sreedharan YBL Systems and Solutions (Note: Please visit the website to download the resource materials) 6/11/