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A Project report submitted in partial fulfillment of the requirements for the award of
Bachelor of Technology In
Electronics and communication Engineering
R.RAMYA CH.ANITHA BHAVANI
Under the Guidance of
Manager(Telecom) Visakhapatnam Steel Plant Visakhapatnam
VIGNANS INSTITUTE OF INFORMATIONTECHNOLOGY
(Affiliated to JNTU)
This is to certify that the Project work entitled “ SCADA system in VSP” is a bonafide record of work done by K.DIVYA, R.RAMYA, D.SHALINI,CH.ANITHA BHAVANI, students of VIGNAN’S INSTITUTE OF INFORMATION TECHNOLOGY, DUVVADA VISAKHAPATNAM have been sincere, dedicated and the conduct throughout the study has been excellent in partial fulfillment of the requirement for the award of degree in BACHELOR OF TECHNOLOGY under the guidance and supervision in VISAKHAPATNAM STEEL PLANT.
Visakhapatnam Date :
Signature of Guide
We hereby take this opportunity to express our sincere gratitude to the following eminent personalities whose aid and advice helped us to complete this project work successfully without any difficulty. We are thankful to Mr. B.Krupanandam, Manager (Telecom) who has been with us all through the project to spend his valuable time and to share his knowledge. As a token of our feeling, we would like to acknowledge our sincere regards to our HOD Prof. A.SESHA RAO for allowing us to take up a project in a working plant we express our gratitude to Dr.ARJUNA RAO(Principal) VIIT for their cooperation during the project period. We are also thankful to faculty members for their kind cooperation and assistance.
INDEX Abstract Major Department of Visakhapatnam Steel Plant Different Communication Systems in Visakhapatnam Steel Plant Introduction Supervisory control and data acquisition system Architecture • Remote telemetry unit (RTU) – Block Diagrams • Modems • Cables • Master Station • Power supply requirements and specifications • Software - .
. Conclusion ABSTRACT In this modern world of Industrialization and automation. To compete with the changes and to sustain the development. In this modern world of competition. In Vizag Steel Plant. Visakhapatnam Steel Plant is going for upgradation of its existing SCADA system with the latest state of art – technology with the features like using high speed processors having cache – memory and using the powerful PLC’S(Programmable Logic Devices) controls. The objective of this proposed SCADA system is to monitor the energy usage and demands of various consumers of the plant and exercise effective control over their energy consumption optimum utilization of in-house energy resources. energy plays a major role in the growth of any organization. The utilization of energy plays an impacting and direct role in the growth of organizations like Visakhapatnam Steel Plant. the technology is changing very rapidly. there is a supervisory control and data acquisition system (SCADA) present for monitoring of energy networks which are present through out the plant.
boilers. The properties can be manipulated to any extent by proper heat treatment . automobile parts etc. pins. It has got very good strength coupled with ductility and malleability. Steel is versatile and indispensable item. ships.This project makes a brief study of existing “SCADA” system present in Visakhapatnam Steel Plant and the changes that are going to come to in the proposed SCADA system that is to be installed in the near future. railway materials. It alloys easily with many of the common elements. it is used for such small items as nails. The economy if any depends on strong base of iron and steel industry in that nation. agricultural implements. through surgical instruments. However its use is innumerable to mention a few. History has shown base of iron and steel industry in that nation. Steel is such a versatile commodity that every object we see in our day to day life has used steel either directly or indirectly. etc. The versatility of steel can be traced to mainly three reasons: It is the only material item.. needles. History has shown that countries having a string potentiality for iron and steel production have played a prominent role in the advancement of civilization in the world. frigates. Steel industry is both a basic core industry. GROWTH AND IMPORTANCE OF STEEL INDUSTRY IN INDIA Steel comprises one of the most important inputs in all sectors of economy. which can be conveniently produced in tonnage quantities. the great investment that has gone in to the fundamental research in iron and steel technology has helped both directly and indirectly many modern fields of today's civilization without steel. Its property can be changed over a wide range..
100% continous casting of liquid steel. Gas expansion turbine for power generation utilizing blast furnace top gas pressure. Evenching of coke Conveyor charging and bell less top for blast furnace.. .techniques. educational recreational etc. some of them for the first time in the country. Taking these factors in to consideration. Modern technology has been adapted in the many areas of production. power supply. "V ISAKHAPATNAM PLANT " STEEL PLANT IS AN INTEGRATED STEEL CHARACTERISTICS OF INTEGRATED STEEL PLANT: This integrated steel plant has large capacities. TECHNOLOGY IN STEEL PLANT: Visakhapatnam steel plant is the most sophisticated and modern integrated steel plant in the country. This would reduce the extent of dependency on outside agencies. it can be said without committing a serious error. highly capital intensive. testing and inspection facilities. township facilities. medical. all under one administrative control. water supply. that the types of steel available are innumerable. among these are : Selective crushing of coal. which would help the smooth running of the plant. labour intensive and they would have all facilities including raw material resources.
Computerization for process control. HALL OF FAME: Visakhapatnam steel plant has the distinction to be first integrated steel plant in India to become a fully ISO9002 certified company. service units. Myanmar. Besides purchase systems.Visakhapatnam steel plant was awarded "STAR TRADING HOUSE" status during 1997-2000.RINL.20 branch . which is the best in the country and is comparable with the international levels. Middle East . Having establishing a fairly dependable export market. Sophisticated. The certificate covers the quality systems of all operational.USA and South East areas. Etensive treatment facilities for effluents for ensuring proper environment protection. Visakhapatnam steel plant exports quality pig iron and steel products to Srilanka. Hot metal desulphurization.Nepal. Visakhapatnam steel plant by successfully installing and operating efficiency Rs. Having a total man power of 17250 Visakhapatnam steel plant has envisaged a labour productivity not less than 230 tonnes of liquid steel per man. training and marketing functions spreading over regional marketing offices. high speech and high production rolling mills.480 crores worth of pollution control and environment equipments and converting barrel landscape by planting more than three million plants has made the steel plant township and surroundings in to heaven of greenery. offices and 22 stock yards located all over the country. maintenance.
As a by-product a CO gas is produced in this processes and this gas is having a very high calorific value for about 2400-2700KCAl and is produced throughout the plant as a fuel.26 MT dry coke.MAJOR DEPARTMENTS OF VISAKHAPATNAM STEEL PLANT RAW MATERIAL HANDLING PLANT(RMHP): The RMHP receives the basic materials required for the steel making process from various sources through wagons which are stacked and reclaimed by stackerd and reclaimed by stackers-cum reclaimers and distributed to various departments of Visakhapatnam steel plant through conveyor systems. each with 7 meters tall 67 ovens. . COKE OVENS (CO): Coke is a hard. Each battery is provided with facilities for dry cooling of coke using nitrogen as quenching media for dry cooling of coke as well as for recovering sensible heat of coke. porous mass obtained by fractional distillation of coal in the absence of air at a temperature above 200deg. Three coke oven batteries for production of 2.centigrade for period of 16 hrs to 18 hrs. It is used as a fuel and reducing agent of iron ore in blast furnace.
one for each furnace and one stand by common to both furnaces are provided with 12 MW top pressure recovery turbo generating power.where carbon should be less than 2%. Three turbo blowers . which will be used as fuel in plant.SINTER PLANT: Sintering is one of the most widely used and economic agglomeration techniques. The furnace is named as BF as it is run with blast at high temperature and pressure of 1500 deg.. sulphur. silicon etc. These are the three L. coke. improves the quality of pig iron and decreases the consumption of coke rate. BLAST FURNACE(BF): Pig iron or hot metal is produced in the Blast Furnace. high pressure scrubber and is distributed through out the plant as a fuel. Each furnace is designed for 205 at mg top pressure. C.Hot metal produced in B. The steel melt shop complex comprising two 1300-ton hot metal mixers. STEEL MELT SHOP(SMS): Steel is an alloy iron and carbon .26 MT sinter. . Each converter is being provided with gas cleaning plant for cleaning and recovery of LD gas. BF gas is produced from each furnace is being cleaned in gas cleaning plant comprising dust catcher. There are two 3200 cubic meter blast furnace to meet 3. limestone . Sinter is a hard and porous lump obtained by agglomeration of fines of iron ore. coke.0 MT annual metal requirement. sinter. Each furnace is provided with a set of four hot blast furnace stoves designed for supplying air blast up to 1300 deg. and lime stone. these impurities will be removed in steel making by oxidation process. and will be belt charged and equipped with bell-less Paul-wurth top.C. three 130-ton LD converters (two operating) and six 4-stand bloom casters. and metallurgical waste.D convertors to convert hot metal in to steel.F contains impurities like carbon. Two 312 square meter sinter machines with 420 square meter straight stand type coolers for annual production of 5. Sinter increases the productivity of blast furnace. Raw materials required for pig iron and iron are iron making ore. phosphorous.
5 MW. In this plant. THERMAL POWER PLANT(TPP): The estimated power requirement for V. 6000 Nm^3/min turbo blowers are being provided for supplying cold air blast furnaces. The generating capacities 286. These blooms have to be reduced in size and properly shaped to fit for various jobs.S. The rolling mill complex comprises : Light and medium merchant mill (LMMM) Wire rod mill (WRM) Medium merchant and structured mill (MMSM). the peak load being 292 MW essential loads being 49 MW. Rolling is one of the mechanical processes to reduce large size sections in to smaller ones.ROLLING MILLS(RM): Blooms cannot be used as they are in daily like. The cast blooms from CCM are heated and rolled in to long products of different specifications like high capacity. each furnace is provided with evaporative cooling system for generation of steel for plant consumption. . Each mill is well equipped with required number of walking beam furnaces for heating of walking beam furnaces for heating of blooms or billets and except for wire rod mills. A captive power having 3*60 MW turbo-generator sets and 5*330 ton/hr steam generators.0 MT stages.P in 280 at 3. sophisticated high-speed rolling mills.
TYPES OF COMMUNICATION EQUIPMENT AVAILABLE In this modern age of industrialization telecommunications plays a very important role in coordinating the activities of various departments / sections and in achieving the set targets and also in improving the performance of any organization. In Visakhapatnam Steel Plant. 100 lines Electronic Exchange in Visakha Steel General Hospital. GENERAL PURPOSE COMMUNICATION SYSTEMS : The following facilities are provided under category of general purpose communication systems: 3000 lines Electronic Exchange in Plant. General purpose communication systems. Monitoring & Signaling Systems. . 44 lines Electronic exchange in Hill Top Guest House. b. Process communication systems. These are broadly classified as follow: a. different types of communication systems are being used to meet the internal and external communication needs. 2500 Lines Electronic Exchange of Bharat Sanchar Nigam ltd (BSNL) in Project Office is catering to the needs of Plant area and Sectors-I to VII in township. 2000 lines Electronic Exchange in Township. c.
Due to this interconnection all the subscribers of this exchange can receive incoming calls from any part of the world. The 3000 Lines electronic exchange in plant and 2000 lines exchange in township are having the following facilities: Extension (subscriber) to extension call. A few subscribers are provided with facility to contact subscribers connected to the BSNL network and cellular and mobile phones in and around Visakhapatnam.Another 2000 Lines Electronic Exchange of Bharat Sanchar Nigam ltd (BSNL) in Township is catering to the needs of Sectors-VIII to XI in Township. the following process communication systems are provided: a) Despatcher communication system b) Loudspeaker intercom systems c) Loudspeaker broadcasting systems d) Loudspeaker conference communication system e) Industrial public address system f) Hotline communication systems . All exchanges working in the steel plant are interconnected by means of junction lines and have closed numbering scheme. The 2000 lines exchange in township is interconnected to the BSNL network. maintenance & service departments. Malicious call tracing facility. Auto call back. Hot lines. operation & management activities of production. For communicating with any subscriber of any exchange no extra digits have to be dialed and only the desired number is to be dialed. Music on hold. Faults man ring back. – connection pattern given at fig 1. Reminder Alarm. Automatic line testing facility. 3 party conference Facility and Howler Tone alert etc. PROCESS COMMUNICATION SYSTEMS : To facilitate coordination. Call consult facility.
Communication is made possible using microphones and loudspeakers provided in the subscriber stations. These would also be replaced very soon.g) VHF communication systems A) DESPATCHER COMMUNICATION SYSTEMS: Initially cordless switch board type manual exchanges of electromechanical version were provided. This system helps to establish communication between any two stations having interconnectivity on selection basis. c) LOUDSPEAKER BROADCASTING SYSTEMS: Loudspeaker broad casting systems are provided in C&CCD. By using group call facility it is possible to communicate to all the subscribers in the group at a time. D) LOUDSPEAKER CONFERENCE COMMUNICATION SYSTEMS: . these despatcher systems are being replaced by Electronic exchanges progressively. B) LOUDSPEAKER INTERCOM SYSTEMS: Loudspeaker intercom systems are working LMMM & WRM. These systems are used for communication between various sections of the same production shop. SP and SMS departments. Production coordination at plant level being conducted by ED (Works) with all HODs in the morning every day is facilitated with the help of the digital EXCOM system provided in the plant control room. Except the ones in CCCP other systems have been replaced. BF. Since manufacture of such systems and their spares is discontinued in the country. This system is useful to make general announcements to the entire area of working and so can be used to locate operation / maintenance personnel working on the shop-floor so as to pass-on important instructions from the control room. This system is very useful in noisy environment where conventional telephones are ineffective.
BF. These systems are provided with both paging and private channel communication facilities. They are hand-held units (walkie-talkie). vehicle . By using the hot lines specified locations are connected permanently. These hot lines are initially provided with direct line communication systems which are electro mechanical systems. DNW and WMD departments. G) VHF COMMUNICATION SYSTEMS: VHF communication systems are used in our plant to establish two way communication between two or more when either or one of them is moving. E) INDUSTRIAL PUBLIC ADDRESS SYSTEM: Industrial Public Address System is working in TPP. MMSM. Due to obsolescence electronic systems are now being used for most of the locations. This is useful to pass-on urgent messages. When one subscriber lifts his telephone the other will immediately get a ring and communication can be had without any loss of time. Communication is possible only between these two locations. It is a combination of loudspeaker broadcasting system and conference communication system. F) HOTLINE COMMUNICATION SYSTEMS: To ensure direct telephone communication between closely related critical locations hot lines are provided. WRM. In case of paging a general announcement can be made which is heard on all the stations. Hot lines are working in CCCP. PPM. LMMM. In the private mode communication is possible between two selected stations only.SMS. From certain locations the communication can also be established through handsets in private mode with the main control room. From the main control room it is possible to make announcements which are heard on the shop-floor. There are three models working in our plant. Here also communication is carried out by means of microphones and loudspeakers provided in the subscriber stations. TPP.Loudspeaker conference communication systems is working in CCCP.
lifters and CDCP area. LMMM. pan and tilt head and zoom lens are also used. CISF (Security). SMS. BF. . In CCCP these can be seen in pusher cars. Administration. WRM and MMSM departments. CISF (Fire) and CISF (security). the following monitoring and signaling systems are provided: a) Closed Circuit Television Systems (CCTV): b) Central fire alarm signaling system c) SCADA system d) Shift change Announcement Siren System A) CLOSED CIRCUIT TELEVISION SYSTEMS (CCTV): For monitoring critical operations in different production units continuously from the concerned control rooms / pulpits CCTV systems are used in SP. Walkie-talkies are used by operation and service personnel in almost all of the production shops. These are interconnected by means of control cables and / or coaxial cables Necessary protection is provided for the CCTV equipment depending on the locations where they are used B) CENTRAL FIRE ALARM SIGNALING SYSTEM: The central fire alarm system is provided for communicating the exact location of outbreak of fire in any part of the steel plant complex to the central fire station and simultaneous actuation of sirens to alert personnel of the affected plant zone. MONITORING AND SIGNALING SYSTEMS : To facilitate monitoring production.mounted – mobile units and base station units. CCTV system comprises of CCTV camera with a lens and a CCTV monitor. maintenance & service activities. Base station units are used by CISF (fire). a central control console. The system employs manual call points located all over the plant. Vehicle mounted units are being used by DNW. In some cases a video switcher. charging cars. door extractors. electric locos. DNW and largely by CCCP departments.
This system consists of two(2) nos quartz crystal controlled master clocks in the Energy & Telecom Centre. The RTUs are connected to the master station by under ground telephone cables. The system comprises of a master station equipment with supervisory consoles and mimic panels located in the Energy & Telecom Building. The RTUs will be collecting the signals from the local instrumentation & electrical systems and transmitting to the master station by means of RTUs. This is placed at Energy and Telecom centre. the signal will be transmitted for energizing the sirens located at strategic points in plant area simultaneously at the preset timings. 23 Nos Remote Telemetry Units (RTUs) installed in different plant units and 3 local RTUs for driving the mimic panel in the Energy centre.c) SCADA SYSTEM : To monitor the consumption of energy by various users in the plant SCADA system is provided. D) SHIFT CHANGE ANNOUNCEMENT SIREN SYSTEM: The shift change announcement siren system is provided for ensuring uniform and accurate shift timings throughout the plant. Apart from the above facilities Telecom department maintains the following cable networks also a) DATACOM cable network in plant b) Telephone cable network in plant and township . At the specified time. The shift timings are programmed in the Master Clock.
such as one that monitors environmental conditions of a small office building. or incredibly complex. SCADA systems can be relatively simple. A SCADA system gathers information. energy. and displaying the information in a logical and organized fashion. such as a system that monitors all the activity in a nuclear power plant or the activity of a municipal water system. SCADA systems were first used in the 1960s. The RTUs will be connecting in the signals from the instrumentation and electrical systems and transmitting to the Master station when polled by the latter. such as determining if the leak is critical. water and waste control. oil and gas refining and transportation. alerting the home station that the leak has occurred. The RTUs are connected to the master station by under ground .INTRODUCTION Acronym for supervisory control and data acquisition. transfers the information back to a central site. such as where a leak on a pipeline has occurred. a computer system for gathering and analyzing real time data. SCADA systems are used to monitor and control a plant or equipment in industries such as telecommunications. carrying out necessary analysis and control. CENTRAL SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEMS : The system comprises of Micro VAX ll based Master station equipment with supervisory consoles and mimic panels located in the energy and telecom building and 23 RTUs installed in different plant units and 3 local RTUs for driving the mimic panel in the energy centre .
printers . communication controller module ( CCM ) and Process the information for displays . RTUs of the CSCS will be in stalled in these main control rooms and the tele -. responsible for Acquisition of inputs from the plant units and convert them in to digital code for Tele -. The signals for a plant unit will normally be concentrated in the control room of the unit from where the unit is being operated .transmission to the Master station computer of CSCS through the 5 pair telephone cable . The RTUs are micro processor based intelligent units . communication Ports etc… which are common requirements for the computer system are Connected through a peripheral transfer switch ( PTS ) to the computers . A junction box will be installed in the control room ( instead of an RTUs) for the termination of inputs and these inputs are further connected to the nearest RTUs through the multi – core control cables. The RTU are called as Remote terminal / telemetry units. The system consists of computer based Master station with dual hot Stand by computers .telephone cables . The maintenance of RTUs mimic panel and the cable network between the field / local RTUs & modem panel in the Master station is carried out by the telecom department . are also provided in MRS & EMD The system enables continuous monitoring of the energy networks in the steel plant and generation of reports as required for taking strategic decisions in times of crisis . The Master station located in the Central Dispatcher station ( C D S ) of the through RTU and Visakhapatnam steel plant will acquire all Information and report generation . The 23 RTU s are located in different parts of the plant are connected to the center Master station through modems in a multi dropped fusion to different channels Of communication controller .transmission signals identified for the units will be wired to the RTUs . Supervisory consoles departments in area shop office of utilities . The peripherals like terminals . Some plant unit where few signals are available for tele – transmission .
water etc….13 KSCG. LBDSS .The SCADA system shall acquire various electrical & utility parameters for effective monitoring & control operation . • • • • • • • Fuel gases system : CO. fire and drinking water. Stream Distribution system: Stream at 40 KSCG. 6. stream . Acetylene. Oxygen . Utility systems Electrical systems UTILITY SYSTEMS : The utility system covers the services like fuel . 2 . Compressed air system: Compressed air and instrumentation grade air Chilled water system: Chilled water. LBSS . pressures .Mixed & converter gases. currents . The various parameters acquired shall be such as electric power . etc … for operation and functional convenience the system categorized in to 2 following systems. comprised air. Process gas system : Nitrogen.11 KV. Water systens: make up water.Argon. 4 and 5 . temperatures. The services covered by the utility systems of CSCS are broadly classified in to following groups. HVLCS and HUMCCS.6 KV systems in MRS. etc… under electrical monitoring and parameters such as flows . ELECTRICALSYSTEM The electrical system covers the complete electrical distribution network Inside the Visakhapatnam steel plant like 220 KV . gases . BF . voltages . For centralized supervisory of above services in utility and electrical systems and also to exercise control over their optimum utilization. following types of signals are .LDO and LTF. 1. 3 . Fuel oil system : LSHS.
Analog input (AI) Digital input (DI) Analog output(AO) Digital output (DO) Pulse input (PI) The input signals acquired by the RTUs are tele-transmitted to the Master station and are sorted out according to the above subsystem division i. Modems are provided for both the ends of communication link for inter connection of Remotely placed units to the MS. Full graphic type of mosaic wall boards one for utility system and another for electrical system displaying the distribution network of various services and power flow inside the VSP envisaged. printers & power supply unit like U P S . These are placed to make up the cost . distribution board will be housed in the second floor of the CDS building where separate rooms with A. Peripheral devices like operator stations. Among these 5000 signals 1500 signals are catered to monitor utility system and 3500 signals are electrical system. False flooring is provided for inter connection cables. The MS is provided with separate operator stations for utility &electrical system for independent operations. SCADA systems monitors a total no 5000 different signals originating at different dept in VSP.e. The CSCS MS hard ware comprising of Micro computer. Remote video terminals and MS. utility and electrical.considered for the uses . batteries. Junction box and the RTU.C facilities are provide in VSP. The wall boards are located in the main control room of the supervisory center where the operator console of the CSCS is located. There are interconnecting cables between # # # RTU and the MS.
performing application programs etc… The maintenance of RTUs mimic panel and cable network between the field / local RTUs and the modem panel in the MS is carried out by the telecom dept.trending . The RTUs will be collecting the signals from the local Instrumentation & Electrical systems and transmit to the MS when they are polled by the latter. Software in the Ms is also required to meet all the functional requirements such as data acquisition. REMOTE TELEMETRY UNIT (RTU) The micro processor based RTU s are installed at various plant Units. reporting . display. The RTUs are connected to the MS by under ground telephone cables with ac MODEMS at MS end and dc MODEMS at RTU end.potential in the line . OUTSTATION RTU HARDWARE: The RTU H/W has the following contents: (1) RTU cabinet (2) Gland plates / field cables (3) Terminations and interposing relays (4) Basic Tier (5) I/O Tier (6) Power Supply Arrangements (7) Basic Modules (8) I/O Modules (9) RTU I/O configuration .
RTU CABINET : The RTUs are houses in standard fabricated steel cabinets of Rugged construction. Power connection and mainly the field cable connecting to the plant Instrumentation. Mounting the Power supply unit for providing the logic supplies to all cards. Mounting the electronics comprising PCCs fitted in tires. A signal cabinet can accommodate a basic tier and an I/O tier. further expansion requires two I/O tiers can be added. The external connections are communications connection. TERMINATION & INTERPOSING RELAYS : . Mounting the terminations and interposing relays. If GLAND PLATES / FIELD CABLES : All external connections to the RTU enter the cabinet through Gland plates. The general layout of the RTU cabinet is attached. Routing the I/O cables from the termination and interposing relays to the electronic tires. The RTU cabinet has an internal structure for: # # # # # Routing the field cable to the terminations.
3. Dia : Testing of in coming signals to RTU from field. Power supply Adapter card to distribute the supplies to PCBs. Upto 8 input / output cards. Analog/Digital INPUT / OUTPUT TIER : The input / output tier is fitted below Accommodate upto 19 input / output cards. It houses 1. BASIC TIER : The basic tier is fitted at the top of the cabinet . The connections are made by standard multicore twisted pair Cables and gold ribbon connectors.The field cables entering the RTU are terminated on screwed Terminals mounted on vertical rails. the basic tier and can POWER SUPPLY ARRANGEMENTS : All RTUs are provided with 230 KV AC operation. The interposing relays are plug in type and are accommodated in power supply cabinet installed adjacent to RTU cabinet. The RTU Power . The basic cards comprising microprocessor card (MP 3) the converter (ADC 4) and the master control / test Cards (MCT 2). 2. The interposing relays are provided where the output control Logic power is not sufficient to operate a high voltage and current Points.
b) Master control test card ( MCT 2 ) : .3A and -12V at 0. The input 24 V DC is derived from local mains power supply with a Battery back –up provisiopn with maintenance free sealed lead acid batteries for 8 hours.supply unit operates on 24 V DC input and generates all logic Supplies +5V. +12V and -12V required for the oprations of the RTU. BASIC MODULES : a) Micro Processor Module (MP 3) :The MP 3 is a signal printed circuit board designed for general Use in telecontrol systems to provide intelligence at the out station. # The units is based on 8 bit Motarola M6800 micropocessor. Master station front end to the main computers operation. # This card provides I /O bus catering to the I /O modules end serial communication interface to modem for communication. The logic requires the following supplies for a fully fitted card +5 at # 2A. communication and telecontrol test Equipment and standby system housekeeping information of the RTU are performed using this module with memory. +12V at 0. # The data acquisition. data processing. # The module incorporates a maximum of 8K bytes of PROM and 4 K bytes RAM.15A. Facility has been provided for memory extension.
# # # This card is degigned to fit a standard I / O card position. # This card is used to convert analog input signals into digital . Internal power required +12V at 28mA +12V (HU) at 1mA +15V (ISOL) at 1mA External power required 24 V or 48 V.# This module provides the number of RTU house keeping and security checking functions.5 volts full scale into 11 bits plus sign digital value. # Generation of ADC calibration check reference voltage . Main functions : Supply of powre to state control relays with local isolation racllities. c) Analog to digital conversion card ( ADC 4 ) : This card provides successive approximation A / D converter which Converts 1. LEDs are provided to indicate controls. # Generation of check logic pattern on a spection monitor adderss.
ANALOG INPUT MODULE (AMFS 3) : . # When the cycle is complete. First byte consists of 8 MSB bits includes sign bit ( if bipolar ) Second byte contains the 4 LSB bits. Voltages to be digitized.binary data (2’s complement or unipolar or offset binary ) # Opto Isolater s -> to form a barrier between the floating analog conversion side and an 8 bit moniter high way. # # The basic conversion time is 300ms. Maximum voltage is 50 V dc & value is –80 bd. I / O MODULES : I/O module unit comprises of the following five I/O cards. Then data transfer complete signal resets the clock control and also generates an ADC interrupt / Resets to indicate data is ready to transfer. the digital data is transferred to shift register and clocked out across the isolation barrier to a second shift register. # A start conversion signal starts the ADS digitizing cycle and resets the clock control at the end of conversion.byte transfer of digitized data on to the moniter highway . An ADC output enable signal enables the two. # Analog input are superimposed on common mode. 1.
4 and 6.The AMFS cardscales and filter 8 high level analog current or Voltage input which are multipexed by relays on to a common output circuit . # The card operates from a + 12 V source at 1mA . The card function address ( lower ) is set by switches or liens on the card # For an 8 bit A/D conversion 1 function adderss is required . STATE MONITER BARRIER ( SMB 11 ) : The SMB 11 card provides an electrically isolated interface between 32 signal bit plant status inputs and an 8 bit monitor high way . limiter and opto .2. 8 bits of each of 4 digitized values are allocated byte position 0. # # # # It accepts voltage or current input presented by the instrumentaion. The remainder of each value is placed in the adjacent add byte. The card multiplxexes 8 input to the ADC The card accepts either 4—20 m Amps or 1—5 Volts Signals . ( for CMOS Logic ) (2). # In cases of Ms. For more than 8 bit conversion 2 function adderss is required . Plant input is typically a dry contract switching 24 volts ( negative ) to a filter .
The current for each input is 5 mA and the 32 inputs have a common positive return.( 1500 volt isolated ) which provide an output of 100 mA at 24 V DC . 32 bits .This is achieved by use of the uniqe outstation address encoded in the hardware of each RTU. (4). this system normally time — division multiplexing between RTU’s . An ‘on’ output sinks into a common negative rail . STATE CONTROL BARRIER ( SCB 8 ) : The SCB 8 provides 8 signal bite stae control output an 8 bit control Highway . The filter time constant is nominally set to 10 mA . in to 8 digit BCD counters . Electrical isolation is provided by the use of opto-isolators. can be read by the appropriate function address on to the moniter highway in 4 byte each of 8 bits . . Where the MS has to communicate with a number of RTU’s uses time – division multidropped on a common communication circuit . (3).isolators which gives 1500 volts plant to logic isolaction . PRINCIPLES OF SYSTEM OPERATION : The basic principle of this system of data transmission between the Master Station ( MS ) and any particular RTU in either direction is multiplexing . Each total . TOTALISER CARD ( TL 3 ) : The TL 3 card count 4 independent pulse stream .
the interrogation message directed from MS to RTU s . Information bytes: function address and data bytes. In interrogation mode the word comprises two message .These bytes may be used to transmit information to the RTU.27 internal DIP switches. jumpers and modem commands control the mode of operation.27 bits/tier compatable leased line modem. It can be operated at 2400 or 4800 baud. in either two or four wire synchronous modes. MASTER STATION OBJECTIVE: .This is the unique address of the RTU being MODEMS The multi-tech computers multi 748 A is a microprocessor controlled CCIT V. The multi modem 748 A incorporates fall back to 2400 baud when operating the V. INTERROGATION MODE WORD STRUCTURE: Address byte: interrogated. or to define which information to the RTU is to transmit back to the MS. Byte count Byte: this is the number of information bytes in the message.The basic of data transmission is the word . Two-wire operation is only half duplex. out station address.
The typical host consists of a computer unit .tape and/or disk drives and alarm . The host contains the S/3 application S/W and is responsible for the bulk data storage functions . The master station hardware comprises of the following: • • • • • • • • • • • • Host computer Micro VAX II Communication concentrator module(CCM) S/3 intelligent colour console Peripheral transfer switch (PTS) DELNI System Console Magnetic tape subsystem Hard disk subsystem VT-320 Digitizer pad Communication transfer switch Common controller interface module HOST COMPUTER: The host computer is the main controlling element of the S/3 SCADA system.The Master Station located in the CDS building in VSP will acquire all information through RTUs and CCMS and process the information for displays and report generations which are very important at the times of crisis to take strategic decisions.
The host computer is one of the Digital Equipment Corporations (DEC) VAX family of general -purpose computers . Earlier due to lack of sophisticated equipment it was very difficult to predict whether the channel corrupted the data coming to the monitoring station or it is the date pertaining to a functional error in a particular department. etc. voltages. Also there was no privilege to track the position that is responsible for the error. The proposed SCADA System for Vizag Steel Plant shall acquire various electrical and utility parameters for effective monitoring and control operations. It has host computer in the master station to store the data for a long period of time so that it can be sued to take strategic decisions sat the time of crisis. temperatures pressures. CONCLUSION Supervisory control and data acquisition system is a versatile network of intelligent sub systems. Further it was a very time consuming process to undo the effect causing the problem (only after making sure the data received is correct). currents. These parameters are logged into the system using a suitable database management system. . In the mean time a lot of energy is waste and sometimes even unacceptable hazards also used to take place. under utility monitoring. etc.types. The supervisory control and data acquisition system over comes all the above bottlenecks. which has brought revolution in the field of monitoring and controlling systems. under electrical monitoring and parameters such as flows. The various parameters acquired shall be such as electric power. The data is processed and presented in the plant to the concerned officials and operators using user-friendly graphical interfaces.