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Automation of Lift Irrigation Schemes Network Management
© ABB Group May 22, 2012 | Slide 1
Overview of Today’s Presentation
Water Automation projects with ABB India Lift Irrigation projects under execution Overview of SCADA system in Lift Irrigation projects Product overview Operation & Maintenance
© ABB Group May 22, 2012 | Slide 2
Your Partner in turnkey solution for:
Motor Motor Pump Pump
Irrigation Substation & pumping station automation. Water Transport and Supply Water / Wastewater Treatment Seawater Desalination
Motor Motor Pump Pump Motor Pump Motor Pump Motor Pump Motor Pump Motor Pump
Motor Pump Motor Pump Motor Pump Motor Pump
© ABB Group May 22, 2012 | Slide 3
One stop shop solutions from ABB
Energy supply Energy distribution
Motors and Drives Instrumentation
SCADA and Automation Actuators
© ABB Group May 22, 2012 | Slide 4
Networks and controls
Network Management System
© ABB Group May 22, 2012 | Slide 5
SCADA Defined What is SCADA ? SCADA stands for Supervisory Control and Data Acquisition SCADA is a type of application Not an off. 2012 | Slide 6 .the-shelf product or technology Used in a wide range of industrial processes Provide monitoring and control of remote equipment and facilities Primary functions of SCADA system: Data acquisition Data communication Data presentation Control © ABB Group May 22.
00 Slave Protocol IEC 60870-5-101 Master/Slave Protocol IEC 60870-5-103 Master Protocol IEC 60870-5-104 Master/slave Protocol Modbus Master/slave Protocol OPC DA client for PLC communication © ABB Group May 22.Various protocols supported by SCADA IEC 61850 Master Protocol for relay communicatios LONWORKS Devices DNP V3. 2012 | Slide 7 .00 Master Protocol DNP V3.
.SCADA Features Data Acquisition Redundant Data Processing Calculations Supervisory Control Tagging Flexible Operator Authority Map board / Video Wall Alarm Handling & Presentation Historical and Planning data handling One-line and Tabular Presentation Trend Presentation Load Shed and Restore On-line Context Sensitive Help Disturbance Data handling Control System Supervision Full graphic HMI Network Topology Hot / standby redundant support Colour Setting tools Zooming. panning and de-cluttering Data storage into open databases like Ms-SQL server. Oracle etc. © ABB Group May 22. 2012 | Slide 8 .
2012 | Slide 9 .SCADA User Benefits User Benefits Always up-to-date and reliable information about network state Secure operation of the network Manual dressing of network operational state Sorting of essential information at disturbances Easy to define calculations and reports © ABB Group May 22.
2012 | Slide 10 .Graphical User Interface Operator Station based on Microsoft Component Features On-line Configurable Menus and Toolbars Microsoft Excel for Report presentation Trend and instantaneous curves based on ActiveX components Support for large screen display walls Support for Remote Workstations on many medias WEB based system Intuitive usage – less risk for operational errors Reduced operator training costs Advanced integration possibilities with minimal costs “Future proof” .easy adaptation to new requirements User Benefits © ABB Group May 22.
2012 | Slide 11 (220KV/132KV/66/11 KV) .SCADA Architecture for Master Control Center GPS Antenna Workstation -1 Workstation -2 Workstation -3 Engineering W/S HOPF LAN A (Main) LAN B (Hot SB) Ethernet Switch Router Ethernet Switch A4 B/W Laser Printer A4 Colour Printer To Backup Control Centre Main and Redundant SCADA/DMS Server Redundant FEP For RTU’s & FRTU’s Main and Redundant HIS(UDW) Server Router/Firewall Fiber Optic Network For GIS services Substation RTU’s Pumping station PLCs © ABB Group May 22.
2012 | Slide 12 .Water Automation projects with ABB India © ABB Group May 22.
Rajiv Sagar Lift irrigation Project . Bhima Lift Irrigation Project . Dhummagudem Lift Irrigation Project Pkg-1 & Pkg-4. Indra Sagar Lift Irrigation Project. © ABB Group May 22. HNSS Lift Irrigation Project. 2012 | Slide 13 . Pranahita Chevalla LIS Pkg-5. PADA Lift Irrigation Project.Water Projects with ABB India Kerala Water Distribution System. Pkg-7 and Pkg-12 Thotapalli Lift Irrigation Project. Kalwakurty Lift Irrigation Project. Sripada Sagar Lift Irrigation Project .
Lift Irrigation Projects Under Execution HNSS Lift Irrigation Project –12 pumping stations. 2012 | Slide 14 . Indra Sagar Lift Irrigation Project – 3 pumping stations PADA Lift Irrigation Project Bhima Lift Irrigation Project Kalwakurty Lift Irrigation Project Kerala Water Distribution System. – 5 pumping stations – 2 pumping stations – 1 pumping station © ABB Group May 22.
2012 | Slide 15 .Overview of SCADA system in Lift Irrigation projects © ABB Group May 22.
SCADA In Lift Irrigation Schemes Functionalities Requirements Remote operation and management Operation on Unmanned location Data collection. storage. 2012 | Slide 16 . retrieval and archive Alarm and events management Reports generating Process monitoring and control © ABB Group May 22.
etc © ABB Group May 22. 2012 | Slide 17 .Lift Irrigation Scheme Requirement The details of four levels of automation such as Local equipment panel (Level 1) Local PLC control (Level 2) Regional Control through network and Local PC (Level 3) Central Control through PCs and network of entire system (Level 4) Benefits in terms of Extent of control Performance Reliability Reduction in manpower.
Automation in Pumping Station Programmable Logic Controller Field Instrumentation : Pressure Measuring Instruments Flow Measuring Instruments Level Measuring Instruments Temperature Measuring Instruments Vibration Monitoring System SCADA Equipments Communication Equipments © ABB Group May 22. 2012 | Slide 18 .
process and store data from RTU ( substation automation) and PLC ( pumping system automation). Regulate the controlled system Distribute data to other systems © ABB Group May 22.Components of SCADA System Larger computers( Servers & workstations) running various software Provide Human-machine Interface( HMI) for operators Accept. 2012 | Slide 19 .
2012 | Slide 20 .Components of SCADA System Communication Network Connect Central Control Station and RTU/RPU/PLC Types of Networks Direct connection (Fiber Optic Backbone) Telephone (leased or dial-up line) Radio Satellite (GPRS/CDMA) VSAT © ABB Group May 22.
Technology Innovation and Future Trends Integration of SCADA with corporate IT system Integration of SCADA with GIS Integration of advanced process control technologies Standardization More open system and interoperability Wider use of wireless network © ABB Group May 22. 2012 | Slide 21 .
2012 | Slide 22 .Application Example Remote Access and Control Provide continued operational control of the facilities in the event of a facility evacuation from any other facility. Provide view-only access to process monitoring system for external end-users. Provide support staff with remote access to process control system for troubleshooting and maintenance. © ABB Group May 22.
Overview Of HNSS Pumping Stations & Master Control Centre SCADA Workstation Operator Workstation Main Server Standby Server Operating Workstations SCADA Workstation Operator Workstation Ethernet Switch Ethernet Switch Ethernet Switch Radio Equipment PLC Controller Radio Equipment PLC Controller PLC Controller Radio Equipment PS-1 Operator Workstation PS-12 SCADA Workstation Operator Workstation SCADA Workstation PS-4 (Main Control Center) Ethernet Switch Ethernet Switch Radio Equipment PLC Controller Radio Equipment PLC Controller PS-2 SCADA Workstation Operator Workstation SCADA Workstation Operation Workstation SCAD Workstation Operator Workstation SCADA Workstation Operator Workstation SCADA Workstation Operator Workstation PS-11 SCADA Workstation Operator Workstation Ethernet Switch Ethernet Switch Ethernet Switch Ethernet Switch Ethernet Switch Radio Equipment PLC Controller Radio Equipment PLC Controller PLC Controller Radio Equipment PLC Controllerv Radio Equipment PLC Controller Radio Equipment PLC Controller Radio Equipment PS-5 PS-6 Radio Link PS-7 PS-8 PS-9 PS-10 © ABB Group May 22. 2012 | Slide 23 Note:- .
AI & AO Unit Control Board. DO. DO.SCADA Architecture for Pump House in Kalwakurity LIS Main Server Standby Server Workstation -1 Workstation -2 Workstation -3 Workstation -4 Workstation -5 Ethernet Switch-1 Ethernet Switch2 PLC Controller PRINT SERVER Dot Matrix printer Dot Matrix printer Laser Jet printer DI. 2012 | Slide 24 . Synchronizing Equipment Hardwires signals from field instruments DI. AI & AO Field Instruments 11KV Switchyard © ABB Group May 22.
2012 | Slide 25 .KWA : Reservoir Monitoring Through SCADA © ABB Group May 22.
KWA Process Layout © ABB Group May 22. 2012 | Slide 26 .
2012 | Slide 27 .KWA : Overview of Control Center © ABB Group May 22.
Maintenance System Training © ABB Group May 22. Consultancy Spares Modernization.Service Trouble Shooting Service Contracts Experts. 2012 | Slide 28 . Extension Remote service.
2012 | Slide 29 .Product Overview © ABB Group May 22.
Automation Hardware & Software Hardware Remote Terminal Unit – RTU 560. ( for substation automation) Programmable Logic Controller – AC800. RTU211. AC31 ( pumping station automation) Software SCADA – Network Manager. AC500. © ABB Group May 22. Micro SCADA Pro. 2012 | Slide 30 . 800xa GIS – Facilplus.
Market Requirements for Modern RTUs Commands NCC Monitoring Direction Process + serial interfacing of IEDs Station HMI Integrated HMI PLC functions Data archives © ABB Group May 22. 2012 | Slide 31 .
2012 | Slide 32 .Maintenance © ABB Group May 22.
which has to be looked in for better performance. © ABB Group May 22. an operator can extend its Plant Life by at least 25 %.Maintenance Overview Maintenance. Maintenance of equipment is of primary importance for every plant. Maintenance procedures should be given a high priority in the daily work schedule. because making sure that the plant equipment functions properly is an important factor in achieving the proper water quality discharge. 2012 | Slide 33 . which has been a non-core area for a pumping Stations. is an integral area. By proper Maintaining the Plant Equipment.
2012 | Slide 34 . Electrical Systems Mechanical Equipments Automation Equipments Instrumentation © ABB Group May 22.Maintenance in LIS Proper Maintenance is required for all the systems in the Pumping Stations.
© ABB Group May 22. Predictive Maintenance. Breakdown maintenance.Maintenance Overview Types of Maintenance: Preventive Maintenance. 2012 | Slide 35 .
Preventive Maintenance is the form of Inspection and tests that are performed every day. © ABB Group May 22. 2012 | Slide 36 . Routine Maintenance: Routine maintenance is best described as the daily general Inspections and test including regular lubrication. that are performed as a part of regular operation of the Plant.Preventive Maintenance It should be considered as a part of your normal daily work routine and something that is necessary to keep the plant operation at full capacity. Types of Preventive Maintenance Planned Maintenance: Planned Maintenance is defined as the periodic scheduled removal of equipment from service for the disassembly and inspection of Internal working parts.
operating efficiency. © ABB Group May 22. 2012 | Slide 37 . and other indicators of the operating Condition of process systems will provide the data required to ensure the maximum interval between repairs and minimize the number and cost of unscheduled outages created by failures.Predictive Maintenance Predictive Maintenance is regular monitoring of the actual mechanical condition.
Improper Functioning of Instruments. SCADA Value is not matching with the Field Values.Key points for Predictive Maintenance: Based on the Criticality of the Process Value & Instruments Value the Checking and Calibration should be done. 2012 | Slide 38 . Based on the Alarm Generated. © ABB Group May 22.
and the ratio of fixed costs to product output is negatively affected. and this can be overcome by proper Preventive and Predictive maintenance.Breakdown Maintenance During the Shut Down Operation Breakdown Maintenance should be done. © ABB Group May 22. labor is no longer optimized. Breakdowns in industrial manufacturing systems can have significant impact on the profitability of a business. 2012 | Slide 39 . Expensive production equipment is idled. Rapid repair of down equipment is critical to business success.
During Shut down Clean all the Instruments and Equipments by dismantling.Key Points for Breakdown Maintenance: Before shutdown Collect the required data for preparing shutdown procedures. 2012 | Slide 40 . Critical Instruments can be Calibrated during this Time. © ABB Group May 22.
Check whether the A/C temperature Check whether the cable is properly connected from the field devices in to the TB. Periodically back up of PLC configuration. 2012 | Slide 41 . Check for the Error Status Led and based on that fault can be identified.. © ABB Group May 22. Check for proper functioning of UPS supply and battery connected to the PLC.Programmable Logic Circuits: Protect the PLC from dust free environment by cleaning the room using blowers. etc.
Cost Effective Maintenance Self-diagnostics Hot swap maintenance On-line changes of application program and configuration Compact Flash memory for storage of application and data Search & Navigation Comprehensive maintenance features reduce down-time © ABB Group May 22. 2012 | Slide 42 .
etc. Check for the A/C temperature. Periodically back up of SCADA configuration. 2012 | Slide 43 . Update with recent Antivirus developed.SCADA Equipments : Protect the systems from dust free environment by cleaning the room using blowers. Check whether the communication cable are properly protected and connected. © ABB Group May 22..
2012 | Slide 44 .Steps to Deploy SCADA System Analyze process requirements System design Hardware selection and procurement Control system programming HMI development Installation Testing Startup system © ABB Group May 22.
2012 | Slide 45 . Regularly check whether all the connection points are fixed tightly. © ABB Group May 22.Communication Equipment : Check whether all the communication cables are away from power cables.
Calibration: Calibration is the process of establishing the relationship between a measuring device and the units of measure. This is done by comparing a device or the output of an instrument to a standard having known measurement characteristics.PT etc when a specified usage (operating hours) has elapsed.PS. 2012 | Slide 46 . For example PG. when an instrument has had a shock or Vibration which potentially may have put it out of calibration whenever observations appear questionable © ABB Group May 22. Calibration can be called for: with a new instrument when a specified time period is elapsed.
Pressure Measuring Instruments Maintenance for Pressure Measuring Instruments: Proper calibration is required for every three Months. 2012 | Slide 47 . Routine maintenance should be done every day by checking any leakage is there in isolation valve. pointer alignment and process connections. Pressure Calibrating Instruments: Dead Weight Tester Handheld Pressure Calibrator. Multi-calibrator for Transmitters © ABB Group May 22. impulse & piping line.Instrumentation.
Instrumentation. Calibration is required for a period of 6 Months.Flow Measuring Instruments Types: Flow switch Electromagnetic – Insertion type Flow Switch : Switch will be calibrated by applying certain pressure based on the flow and confirm whether NO & NC is getting changed. © ABB Group May 22. Calibration Equipment: Equipment which can generate Pressure. 2012 | Slide 48 .
Zero Setting should be done for a period of 3 Months.Flow Measuring Instruments Electromagnetic Insertion Type: Routine Maintenance should be done by checking the proper connection and proper parameter display in the SCADA System.Instrumentation. Zero setting Calibration should be done for every 6 months by changing the mode in to zero setting by ensuring no flow in the pipe line and meter should show zero in display. Calibrating Equipment: Laptop Calibration kit from manufacturer © ABB Group May 22. 2012 | Slide 49 . Normal Calibration is required whenever the instrument is not showing the proper zero value after zero setting.
Ultrasonic Level Transmitter: Calibration should be done by Configuration setting in the manual The device can be programmed with the help of a magnetic key board supplied with the Unit.: Tank Height : 7m.g. © ABB Group May 22. Ensure the Proper current output is coming during periodic checking based on the Level For e. Making sure the instrument is protected against overheating. 2012 | Slide 50 . Transmitter Output : (4-20)mA For this the Transmitter should deliver 4 mA for 0% Level and 20 mA for 100% Level. Checking should be done for a period of 3 months. Calibration should be done when the parameters are not matching.Instrumentation – Level Measuring Instruments Types Ultrasonic Level Transmitter Conductivity Type Level Switch: Ensure proper mounting of the Instrument.
© ABB Group May 22. Standard Calibration is not required.Instrumentation – Level Measuring Instruments Level Switch Type : Conductivity Type Clean the probe during the time of checking. 2012 | Slide 51 . Checking should be done by dipping the Rod in to the water and check for the chances in NO/NC when the rod touches the water. Checking should be done once in 3 months.
2012 | Slide 52 . Calibration should done once in three months.Instrumentation – Temperature Measuring Instruments Temperature Gauges Temperature Switch Temperature Scanners Temperature Gauges : Calibration is done by applying particular temperature from temperature bath and check for the changes occurred. Temperature Generating Source Temperature bath Calibration Equipment: © ABB Group May 22.
2012 | Slide 53 . Calibration should be done once in 6 months. Calibration should done once in three months.Instrumentation – Temperature Measuring Instruments Temperature Switch: Calibration is done by applying particular set point temperature from temperature bath and check for the NO/NC changes occurred. Ensure proper covering and protection is done. Temperature Generating Source Temperature bath Apply particular resistance or mV through decade resistance box or through Multi-calibrator and check for the changes occurred by comparing with the standard chart. Standard reference chart for RTD and Thermocouple Decade resistance Box or Multi-calibrator Calibration Equipment: Temperature Scanner: Calibration Equipment: © ABB Group May 22.
© ABB Group May 22. Check for the Error Status Led and based on that fault can be identified. Vibration Parameters can be checked by comparing with the Handheld Vibration Meters. Calibration Equipment: Handheld Vibration Meters.Instrumentation – Vibration Mointoring System Check for the proper alignment of the sensor. 2012 | Slide 54 . Clean the sensors periodically without shaking the Sensors.
Benefits Of Maintenance : Optimum availability Optimum Operating Conditions Maximum utilization of maintenance resources Optimum equipment life Minimum Spares inventory Ability to react quickly © ABB Group May 22. 2012 | Slide 55 .
2012 | Slide 56 .© ABB Group May 22.
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