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Automation Systems and Industrial Electronics Engineering

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Study of an innovative SCADA system based on
E Industrial Shields PLC
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MSc in Automation Systems and Industrial Electronics
Electrical Energy Optimization

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S Author: Oriol Filló Claret
Supervisor: Jordi Zaragoza May 2016
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Automation Systems and Industrial Electronics Engineering

1. Objectives
C 2. Scope
3. Justification
O 4. Specifications
N 5. Alternatives
6. Development
T 6. 1 Communications
E 6. 2 HMI
7. Budget & Economical feasibility
N 8. Environmental Impact
9. Planning
T 10. Environmental implications
S 11. Results & Conclusions
12. Future lines
13. Bibliography
14. Acknowledgements
15. Questions
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Automation Systems and Industrial Electronics Engineering

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J • Industrial communication protocols to Industrial
Shields PLCs
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• Development of a SCADA system prototype with
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Industrial Shields PLCs
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• Proof of concept of a SCADA system based on
I alternative and open-source solutions
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Automation Systems and Industrial Electronics Engineering

• Implementation  Modbus RTU over RS-485 (master /slave)

• Development of an HMI  supervision and control purposes


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• Implementation of TCP over Ethernet in a LAN
O (PLC HMI)
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E Sensors

• Integration to the SCADA sytem of Data acquisition equipment

Actuators

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Automation Systems and Industrial Electronics Engineering

J Open-standard systems
• IoT
U • Industry 4.0
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Modbus RTU (Modbus)
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I • widely extended in the industry
• demanded feature
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T TCP-IP

T • Protocol of the Internet


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Case study – Reference plant
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P Water tank in the save water system

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REFERENCE PLANT
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STUDY PLANT
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Automation Systems and Industrial Electronics Engineering

4 Capabilities and system configuration


S • Centralized configuration
controller receives all the variable values (chloride, PH, turbidity).
P operates the dosing pumps accordingly.
• Adjustable variable limits from a remote location.
E • Variables updated on the HMI at a minimum rate of 15 minutes and stored in files.

C User interface
• The user interfaces is an HMI on a remote PC with internet connection.
• All variables and actuators states are visible on the HMI
I • The limits of the variables (max,min) are set manually on the HMI
F Data acquisition equipment and actuators
• Inputs
I o Seko Kontrol 800  chloride, PH, turbidity
o Water intake and water outtake of the tank meters. Water tank level meter.
C • Outputs
o Dosing pumps  Seko Tekna EVO APG800 (ANNEX D: Datasheets).
A o Each dosing pump have a digital control valve.
o Water intake and outtake analog control valves.
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Control of the variables
I Each variable has a maximum and minimum limit and its value must be contained within this range.

O Alarms
• Upgraded compared to the reference plant:
N o including more information on faults when there is an alarm.
o up-to-date communication such as internet, instead of SMS. 8
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PLC
• Industrial Shields (open-source )
o Low-cost
A o Flexibility
o No-licensing
L o Accessibility
o Programmed as an Arduino (C / C++ language)
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• Standard industrial PLC (i.e.: Siemens )
E o Widespread knowledge on the technology
o Ready-to-use solutions.
R o More mature technology

N HMI
A • LabView
o Ready –to-use graphical tools
T o Intuitive programming language
o Extensive documentation and resources.
I o Previous experience

• C# and Visual Studio


V o Not-graphical language
o Not ready-to-use tools
E o Extensive documentation resources
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Automation Systems and Industrial Electronics Engineering

6 6.1 COMMUNICATIONS IMPLEMENTATION

D Modbus RTU (RS-485)


E • Search & adaption of Arduino IDE library SimpleModbus

V • Master & Slave configurations


E RS-485 Slave
Master
(M-Duino) (Ardbox)
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O • Master & Slave simulator
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Master RS-485 Slave simulator
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RS485
/USB
(PC)

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• Final implementation
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Master
T (M-Duino) RS-485
Slave
(Seko)

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Automation Systems and Industrial Electronics Engineering

6 6.1 COMMUNICATIONS IMPLEMENTATION

TCP (LAN)
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E • Search & implementation of Arduino IDE library UIPEthernet

V • TCP communication configuration

E TCP
TCP Client TCP server
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message=mes+iter;
M CLIENT i=i+1;
(M-Duino) client.print(message.length());
E client.print(message);

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T SERVER
(LabView)

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6 6.1 COMMUNICATIONS IMPLEMENTATION

D TCP (LAN)

E • TCP communication configuration


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message = s_Var[0] + c + s_Var[1]…
O string MinFl+ c +MaxFl…

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Automation Systems and Industrial Electronics Engineering

6 6.2 HMI
• ForcedVariables
D • Non-forced variables
E • Logic state / motion

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6 6.2 HMI
• Alarm Notifications
D • Save
E • Controls

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6 6.2 HMI
• DSC Modul
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B • Low cost of the controller FESEABILE PROJECT
I • Development price within market range
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V Upgrade of the management & maintenance system
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R Savings of resources & time. i.e.: on plant check-ups
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Industrial Shields Flexibility & adaptability  reduced incompatibilities

I Savings of resources . i.e.: retrofitting & extensions


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Automation Systems and Industrial Electronics Engineering
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Industrial communication protocols to Industrial Shields PLCs
• Modbus RTU over RS-485 (master /slave)
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E • TCP over Ethernet in a LAN
(PLC HMI)
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Already has an effect for customers and projects
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L Development of a SCADA prototype with Industrial Shields PLCs
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• Interaction between HMI and PLC
S • Meet the set sepcifications

Proof of concept of a SCADA system based on open-source tech

• Open-source based SCADA prototype

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Industrial communication protocols to Industrial Shields PLCs

C • All the set objectives at the beginning of this project have been
O achieved.
N • The developed communications and prototype have proved to be a
C useful realization. All parts of this project have already been applied
L by Industrial Shields customers.
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S • Industrial Shields dispose now of a prototype or SCADA example
I developed with its PLCs which serves as model.
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N • It was shown that a SCADA system based on open-source is possible
S and already an alternative to standard automation systems.

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F Possible lines to be explored in a second phase of this study
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T Development of a thorough reconnection capability.
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Creation of a database and web server application.
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Development of security protocol.
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• AEG Schneider Automation. (1996). Modicon Modbus Plus Network Planning and Installation Guide.
November 2015.Schneider Electric:
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• Arduino. (2005). Arduino. January de 2016. https://www.arduino.cc/en/Main/Software
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• Arduino Robotics. (2014). Send an Email from Labview. December de 2015. Youtube:
B https://www.youtube.com/watch?v=_wsoQevRDAM
L • arduino.cc. (2012). SoftwareSerial. November 2015. arduino.cc:
https://www.arduino.cc/en/Reference/SoftwareSerial
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O • arduino.cc. (2012). TwoPortReceive. November 2015. arduino.cc:
https://www.arduino.cc/en/Tutorial/TwoPortReceive
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• Armengol, S. (2014). Modbus-Master-Slave-for-Arduino. github.com:
R https://github.com/smarmengol/Modbus-Master-Slave-for-Arduino

A • Bester, J. (2012). Simple Modbus. November 2015. code.google.com:


https://code.google.com/archive/p/simple-modbus/
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• Bies, L. (2002). RS232 Specifications and standard. November 2015.
H http://www.lammertbies.nl/comm/info/RS-232_specs.html
Y • Boot & Work Corp, S.L. (2016). Industrial Shields. http://www.industrialshields.com/es/

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• Forouzan, B. A. (2010). TCP/IP Protocol Suite. Mcgraw-Hill.

B • Google. (2011). Allowing less secure apps to access your account. December 2015. google.com:
https://support.google.com/accounts/answer/6010255?hl=en
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• Google. (2012). Configuración de SMTP de Google Apps para enviar correo desde una impresora, un escáner o
B una aplicación. December 2015.Google: https://support.google.com/a/answer/176600?hl=es
L • HMS Industrial Networks. (2006). Modbus Plus - Local Area Network. November 2015 .HMS Industrial
Networks: http://www.anybus.com/technologies/modbusplus.shtml
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O • IndView. (2014). SCADA in LabVIEW - Animating a fan. September 2015. Youtube:
https://www.youtube.com/watch?v=SfYPvzCQRQk
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• Maxim Integrated Products, Inc. (2012). Low-Power, Slew-Rate-Limited RS-485/RS-422 Transceivers.
R November 2015. Maxim Integrated: http://datasheets.maximintegrated.com/en/ds/MAX1487-
MAX491.pdf
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• Microsoft. (2005). Technet.microsoft. November 2015. https://technet.microsoft.com/en-
P us/library/cc775383(v=ws.10).aspx
H • Modbus Organization, Inc. (1996). Modicon Modbus Protocol Reference Guide. January 2016. modbus.org:
http://modbus.org/docs/PI_MBUS_300.pdf
Y
• Modbus, I. (2006). Modbus messaging on tcp/ip implementation guide v1. 0b. January 2016. modbus.org:
http://www.modbus.org/docs/Modbus_Messaging_Implementation_Guide_V1_0b.pdf
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• National Instruments. (2012). National Instruments Corporation-Labview. January 2016.
http://www.ni.com/labview/esa/
B
• National Instruments Corp. (2011). TCP Listen VI. January 2016. http://zone.ni.com/:
I http://zone.ni.com/reference/en-XX/help/371361H-01/lvcomm/tcp_listen/

B • National Instruments Corporation. (2013). When to Use UDP Instead of TCP. November 2015. National
Instruments Corporation.
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• National Instruments Corporation. (2015). Basic TCP/IP Communication in LabVIEW. January 2016.
I National Instruments Corporation: http://www.ni.com/white-paper/2710/en/
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• Saboya, N. G. (2012). Serial Communication Standards: RS-232,RS-422 y RS-485. November 2015.
G unilibre.edu.co: http://www.unilibre.edu.co/revistaingeniolibre/revista-11/art13.pdf

R • Siemens Energy & Automation. (2005). Modbus and ION Technology. January 2016. Siemens
Corporation:
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• Simplymodbus. (2006). Data Communication Solutions.November 2015. .Simplymodbus:
P • http://www.simplymodbus.ca/
H • SparkFun Electronics. (2013). Serial Communication. November 2015. SparkFun Electronics:
https://learn.sparkfun.com/tutorials/serial-communication
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• Texas Instruments Incorporated. (2011). RS-485 Unit Load and Maximum Number of Bus. November
2015.Texas Instruments Incorporated: http://www.ti.com/lit/an/slla166/slla166.pdf
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• Texas Instruments Incorporated. (2011). The RS-485 Design Guide. November 2015. Texas Instruments
B Incorporated: http://www.ti.com/lit/an/slla272b/slla272b.pdf

I • Thomas, J. (2012). TCP/IP Application Layer, Application Layer Protocols. November 2015.
OmniSecu.com: http://www.omnisecu.com/tcpip/application-layer.php
B
• Trexon Inc. (2002). Modbus Protocol Specification. November 2015. Trexon Inc:
L http://irtfweb.ifa.hawaii.edu/~smokey/software/about/sixnet/modbus/modbus_protocol.pdf
I • Truchsess, N. (2015). Arduino UIP. November 2015. github.com:
https://github.com/ntruchsess/arduino_uip
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Special thanks and gratitude are extended to:
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K o Project supervisor : Jordi Zaragoza
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O o Project collaborators: Industrial Shields team
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THANK YOU VERY MUCH


Q
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FOR YOUR ATTENTION
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QUESTIONS?
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3 MILLORES REPORT:
S DEFINIR MILLOR LES ESPECIFICACIONS (INPUTS OUTPUTS/COM EN LA PRESENTACIÓ
)
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E AFEGIR ESQUEMA PLANTA REFERÈNCIA DE CONTROL GPRS!!? Com es transmet el SMS

C ESQUEMA PLANTA HADRWARE (configuració dipòsit, válvules, bombes i equip de mesura)

I EXPLICACIÓ EMMAGATZEMATGE DE DADES (comentar els valors que s’emmagatzemen i


F POSAR DESAVANTATGES EN LES ALTERNATIVES
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AFEGIR APARTAT CONCLUSIONS & RESULTS
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• Alternatives (labview-industrial shields Arduino

• Structure of the protocol


• Budget
• Environmental implic
• concusions

• acknowledgements)

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