Application And Practical

Design of SCADA System

Industrial Automation Research Group

Program Studi Teknik Fisika
2007

HANDAL CONSULTING 1-1

 Schedule
Hari
1 2 3 4
Sesi
Tagname
1 SCADA System MTU/RTU PID Controller
Dictionary and
(08.00 – 09.45) Overview Communication Programming
Animation Link

Coffee break (09.45 – 10.15)

Typical SCADA Ladder Logic and Trending and

2
System Sequential OPC Server Alarm
(10.15 – 12.00)
Applications Programming Management

Istirahat dan makan siang (12.00 – 13.00)

3 MTU/RTU Polling and Data Historical

HMI Overview
(13.00 – 14.15) Hardware Logging Database System

Coffee break (14.15 – 14.45)

MTU/RTU System
4 Software and System HMI Graphic Link to Office
(14.45 – 16.00) Configuration Redudancy Development Applications
Setup

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 Overview of SCADA
Systems

Industrial Automation Research Group

Program Studi Teknik Fisika
2007

HANDAL CONSULTING 1-3

 SCADA Terminology
 SCADA is an acronym for Supervisory Control and
Data Acquisition
 Data Acquisition :
Gathers information from widely distributed
processes
 Supervisory Control :
Calculate and give limited control instructions to
distant process facilities

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 Terms & Terminology
 Field Instrumentation
 Data Acquisition
 Control Loop
 Supervisory Control
 Remote Terminal Unit (RTU)
 Master Terminal Unit (MTU)
 SCADA Server
 Communications Equipment

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 Historical Background (1)

 1960s:
• Radio Telemetry : weather monitoring using unmanned
balloon/rocket
• Hardwired Remote Monitoring : oil & gas and processing
industries
 1970s :
• Two-way radio telemetry
• Mini-computer
• Distributed Process Control System (DCS)
• Programmable Logic Controller (PLC)

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 Historical Background (2)
 1980s :
• Low cost microcomputer (PC)
• Satellite Communications
• Cellular Telephone
 1990s :
• Local Area Network (LAN)
• High Speed Communication Devices
• Internet

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 Data Acquisition
Device Status

PROCESS
valve status (open/close)
switch position (on/off)
pump (start/stop)

FIELD- INTERFACE
Variables
pressures
flow rates
temperatures
tank levels

Alarms
Low Tank Level Alarm
High Tank Level Alarm
Fire Alarm

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 Data Acquisition on an ESP System

Load
Current (A)

ESP Compensator
Pressure (Mpa)
Line
Frequency (A)
Intake
Pressure

Intake
Vibration (Hz) Temperature (oC)

Current
Leakage (A)
Motor Winding
Temperature (oC)

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 Types of Field Devices
 Conventional  Fieldbus based
• 4-20 mA analog signal • Microprocessor and
• Discrete status (0/1) embedded system
• technology
Point-to-point configuration
• • Digital signal
Dedicated wiring for each
devices • Point-to-point or point-to-
multipoint
• Simplified wiring, drawings,
and control engineering
Conventional 4-20 mA Fieldbus • Embedded control algorithm
I/O
Modules
Bridge • example :
 Foundation Fieldbus
Transmitter
 Profibus Transmitter
 HART transmitter

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 Control Loop

P&ID
ON-OFF
Sequential
Fuzzy Logic
Neural Network
Set Point
Process
Manipulated Variable
 Temperature
Variable  Pressure
 Flow rate CONTROLLER  Level
 Heat in  Flow rate

Actuator Sensor

input output

PROCESS
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 Example : Flow Control Loop
 Objective :
• maintain flow rate at a desired value (set point)
 Control elements :
• Sensor : Flow Transmitter
• Controller : PLC (PID)
• Actuator : Control Valve

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 Supervisory Control
 Set point management for several control loops
 Optimization to achieve “the best operating point”
 Use advanced control algorithm
• cascade controller
• ratio controller Supervisory Control

• override control Set Point 1 Set Point 2 Set Point 3

• etc
CONTROLLER

CONTROLLER
Actuator Sensor

Actuator CONTROLLER
Sensor
PROCESS
LOOP #1 Actuator Sensor
PROCESS
LOOP #2
PROCESS
LOOP #3
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 Goals to Achieve
 Technical :
• Safety
• Increased productivity
• Equipment protection and maintenance
• Operational optimization
• Energy saving
• Immediate access to inventories, receipts, deliveries, etc.
 Economical :
• Plant-wide optimization
• Optimization of personnel utilization

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 Applicable Processes
 Widely distributed processes; spreading over large
areas
 Require frequent, regular, or immediate intervention
 High cost of routine visits to monitor facility operation
 Examples :
• Oil and gas production facilities
• Pipelines for gas, oil, chemical, or water
• Electric power transmission system
• Railroad traffic
• Feed water purification plant
• Building automation

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 SCADA System Architecture

RTU
01 transducers/
transmitters

Enterprise Network Modem

RTU
02 transducers/
transmitters

Modem
Plant Level Network
Engineer (Supervisory)
Station Modem
RTU
03
Modem

Modem transducers/
Manager transmitters
Station
MASTER TERMINAL Radio
Radio
UNIT (MTU) Field Device Network
RTU
Database 04
Server

Modem transducers/
transmitters

Radio

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 One MTU can exchange
data with one or more RTUs
 Data exchange within MTU
and RTUs follows a pre-
defined set of rules called
communication protocol
 Data is encoded as binary
signal (series of ones and
zeros)
 This binary signal is
modulated before it
propagates through
communication medium
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Data Communications
 Two-way communications
(half or full duplex)
 serial transmission
(asynchronous/synchronous)
 Leased or non-leased line
 Guided or wireless medium :
• radio link (UHF, VHF,
microwave, satellite)
• cable link (telephone,
twisted pair, coaxial, power
line carrier)
• fiber optic
• etc
1-17
 Remote Terminal Unit (RTU)
 Placed at remote plant location
 Integrated with instrumentation and
control systems (PLC or DCS)
 Functions :
• Gathers information from the field
• Send the information to MTU
• Process the supervisory control
instruction from MTU

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 Communications

Windows 3.1
Windows-95
Windows NT Business Management
Client Applications

Windows NT
Operator Console
RT/History Data
Server

Windows NT Windows NT Plant Highway

Operator Console RT/History Data
Server

Plant Highway

Process Management
Controller

Fieldbus

PD Meters Analytical
Common Head -Simple -Analog I/O Handheld
Fis her

Measurement
Coriolis Configuration and
-Pressure -Complex -Discrete I/O PDA
Valves -TC/RTD Maintenance
-Temp
Positioners
-Flow
-Level Field Management

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 Actuator/Sensor Level Device Network
 Analog signals of the conventional
sensors and actuators are
Field Level
transmitted via two-wire cable  Intelligent field devices are
 One dedicated two-wire cable is configured in multidrop/bus
required for each sensor/actuator topology
 Analog-to-digital and digital-to-  Single or multi-master mode
analog converters are required to
is supported
enable interfacing
and communications  The numbers of field devices
with other in a field level network is
intelligent devices limited
(programmable
controllers,
 Interoperability issue
smart transmitter,
fieldbus devices)

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 Plant Network
 RTU to Sub-MTU to MTU
connection
 Medium
• guided : cable, telephone,
ISDN, optical fiber, etc.
• wireless : broadcast radio,
microwave, satellite
 Protocol
• DH, DH+, DH-485,
ControlNet
• Modbus, ModbusPlus,
ModbusTCP
• Hostlink
• DNP

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 Corporate/Enterprise Network
 Ethernet
 TCP/IP
 Corporate Applications
• Real time asset management
• Business support
• Marketing & sales
• Procurement
• Manufacturing
• Distribution
• Data warehouse

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 Master Terminal Unit (MTU)
 Customized configuration for each applications
 Connected to Local Area Network (LAN)
 Equipped with auxiliary devices (data storage, console,
pointing devices, etc)
 Functions :
• Collect process information from RTUs and share the
information on the LAN
• Online operator interface (MMI)
• Send supervisory control instruction to RTUs
• Alarm management
• Report generation
• System security
• Central data processing

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 Man Machine Interface (MMI)
 Provides human access to field automation system
• Operational
• Maintenance & troubleshooting
• Development
 Function :
• Communicates with field I/O from Programmable Logic
Controllers (PLCs), Remote Terminal Units (RTUs), and
other devices.
• Gives up-to-date plant information to the operator using
graphical user interface
• Translates operator instruction into the machine
• Engineering development station
• Operator station

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 Man Machine Interface
 Plant information :  Presentation Method :
• Process Variables • Graphics Trending
• Device status • Charts
• Alarms • Reports
• Control Loops • Animation
• etc • etc
 Equipment :
• Keyboard
• Mouse or other pointing
devices
• Touchscreen or CRT
• etc.

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 User Applications
 Development tools is provided by SCADA system supplier
(scripting tools)
 Examples :
• Meter gross/net computation
• Pipeline terminal display
• Pipeline inventory
• Transient modeling systems
• Dynamic leak detection
• Pipeline simulator
• Compressor optimization
• Automatic well testing
• Well revenue calculation
• etc.

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 System Database
 Store historical process information
for engineering, production,
Business maintenance, and business
Applications
Statistical purposes
Process
Control  Features :
• Engineering units conversion
Process • Analog value filtering
Visualization
• Value limit checking
Realtime
 Standardized Data Structure
Database
• Analog point structure
• Status point structure
Engineering • Accumulator point structure
Workstation
• Container points
• User defined structure
 Each point in the database has a
Batch number of associated parameters,
Process
Asset
Management
Management all of which can be referenced
relative to a single tag name

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 Industrial Automation Server

OPC

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 OLE for Process Control (OPC)
 Object Linking and Embedding (OLE) for Process Control
 A standard for process automation (SCADA) communications
 A standard software mechanism for sharing data between
process automation (SCADA) of different manufacturers
 OPC is based on Microsoft OLE (Object Linking and
Embedding) and DCOM (Distributed Component Object Model)
 OPC advantage :
• Simple to implement
• Flexible to accommodate multiple vendor needs
• Provide a high level of functionality
• Allow for efficient operation

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 Plant-Office Data Integration
 Networking has been successfully
implemented from field device
level up to management level.

Office
Business
 Data can easily be interchanged Applications
Statistical
Process
between applications in the same Control

computer or different computers Asset

Management
over a network.
Realtime Dynamic Data Exchange
 SCADA system can give an OLE for Process Control
Database
immediate response needed from
field device to management

Plant
system. Engineering
Workstation
 Real-time plant information can be
transferred to office application.
Batch
 Corporate information system Process
Visualization
Process
Management

must be designed to meet its

business process.

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 Dynamic Data Exchange (DDE)
 An application protocol that allows data exchange on real-time
basis on Windows/WindowsNT platforms
 NetDDE = Dynamic Data Exchange over network

I/O Devices

Driver

Tag Database
DDE Link

Windows DDE Windows DDE Other

Application Application Applications
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 Sample of System linked to Excel

DDE
Conversation Excel Based
Operating Panel

MMI Software

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 Web-based Process Monitoring
 Internet browser as an acceptable MMI standard will minimizes
operator/user training by providing a familiar operating
environment
 Many visualization techniques are available (JavaScript, Java,
Shockwave/Flash, etc)
 Extra development effort is not needed since SCADA supplier
software usually provide integrated web-based and application
specific MMI development
 Allows the users (e.g. : supervisor/manager) to monitors
process operation, documents and reports either in the Intranet
or Internet
 Secured network design is a must to avoid cyber risk such as
hacking attempts and virus

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 Web Based Monitoring Example

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 Summary
 SCADA is a two-way system : remote monitoring &
controlling
 Applicable to widely distributed processes
 Two way communication system is required
 Basic Elements of SCADA :
• Master Terminal Unit (MTU)
• Remote Terminal Unit (RTU)
• Communications Equipment

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