Automation Report

 

 

 

SEMINAR  ON

 

   

SCADA

SUBMITTED BY: DIKSHA VAID

 

ABSTRACT Automation has been of high priority for the manufacturing sector, from Ford's first set of Model-T Assembly lines in the early 1920s to the modern factory floor. With appropriate automation, the aim was to rationalize the  production and keep the process under control. Instrumentation for measur mea suring ing pro proces cesss var variab iables les ass assume umed d a sig signif nifica icant nt rol rolee in mee meetin ting g suc such h goals. The development of new sensors and instruments took place in stages concur conc urren rentt wi with th ad adva vanc ncem emen ents ts in sc scie ienc ncee an and d te tech chno nolo logy gy.. Th This is pa pape perr comprehensively reviews the evolution of industrial automation. Essentially, it reviews the milestones in the industrial automation and control systems, the emergence of Distributed Control Systems (DCSs), the advanced control architecture, the non-conventional technologies for the future and finally the  benefits from the networked system.

 

An in indu dust stria riall SC SCAD ADA A syst system em wi will ll be used used for for th thee de deve velo lopm pmen entt of th thee controls of LHC experiments. Here we describe the SCADA systems in termss of the term their ir arc archit hitect ecture ure,, the their ir int interfa erface ce to the pro proces cesss har hardwa dware, re, the functionality and the application development facilities they provide. Some attention is also aid to industrial standards to which they abide, their planned evolution as well as the benefits of their use.

AUTOMATION – HISTORY

Ideas for ways of automating tasks have been in existence since the time of th thee anci ancien entt Gr Gree eeks ks.. Th Thee Gr Gree eek k inve invent ntor or He Hero ro (fl. (fl. ab abou outt A. A.D. D. 50 50), ), for for example, is credited with having developed an automated system that would open a temple door when a priest lit a fire on the temple altar. The real impetu imp etuss for the dev develo elopme pment nt of aut automa omatio tion n cam came, e, how howeve ever, r, dur during ing the Industrial Revolution of Revolution of the early eighteenth century. Many of the steam powered devices built by James Watt, Richard Trevithick, Richard Arkwright, Thomas Savery, Thomas Newcomen, and their contemporaries were simple examples of machines capable of taking over the work of huma hu mans ns.. On Onee of the the mo most st elab elabor orat atee ex exam ampl ples es of au auto toma mate ted d ma mach chin inery ery developed during this period was the drawloom designed by the French inventor Basile Bouchon in 1725. The instructions for the operation of the

 

Bouchon loom were recorded on sheets of paper  of paper   in in the form of holes. The needles that carried thread through the loom to make cloth were guided by the presence or absence of those holes. The manual process of weaving a  pattern into a piece of cloth through the work of an individual individual   was trans tra nsfo forme rmed d by the the Bo Bouc ucho hon n proc proces esss into into an op oper erat atio ion n th that at coul could d be  performed mindlessly by merely stepping on a pedal.

INTRODUCTION

a. what is automation  b. types of automation c. role of computers in automation

 

a. What is Automation

Delegation of human control function to technical equipments a. to in incre creas asee pro produ duct ctio ion n  b. to reduce cost c. to re redu duce ce manp manpow ower  er  d. to improve improve ssafety afety worki working ng cond condition itionss e. to reduce reduce pow power er ccons onsump umptio tion n f. to impr improv ovee q qua uali lity ty

 

b. Types of Automation

Automated machines can be subdivided into two large categories—openloop and closed-loop machines, which can then be subdivided into even smaller categories. Open-loop machines are devices that, once started, go thro throug ugh h a cy cycl clee an and d then then stop stop.. A co comm mmon on ex exam ampl plee is th thee au auto toma mati ticc dishwashing machine. Once dishes are loaded into the machine and a button  pushed, the machine goes through a predetermined cycle of operations: prerinse rin se,, wa wash sh,, rin rinse se,, an and d dry, dry, for for ex exam ampl ple. e. A hu huma man n op oper erat ator or ma may y ha have ve choices as to which sequence the machine should follow—heavy wash, light wash, warm and cold, and so on—but each of these operations is alike in that the machine simply does the task and then stops. Many of the most familiar appliances in homes today operate on this basis. A microwave oven, a coffee maker, and a CD player are examples. Larger, more complex industrial operations also use open-cycle operations. Forr ex Fo exaamp mple le,, in the produ roducctio tion of a car, car, a sin singl glee ma mach chiine ma may y be  programmed to place a side panel in place on the car and then weld it in a dozen or more locations. Each of the steps involved in this process—from  placing the door properly to each of the different welds—takes place according to instructions programmed into the machine. Other category in which automation is divided is: a. Scientific Automation

 

(used by scientists)  b. Industrial Automation (building management system) c. Office Automation (used by non technical staff)

c. Role of computers in automation

Since the 1960s, the nature of automation has undergone dramatic changes as a result of the availability of computers. For many years, automated machines were limited by the amount of feedback data they could collect and interpret. Thus, their operation was limited to a relatively small number of alternatives. When an automated machine is placed under the control of a computer, however, that disadvantage disappears. The computer can analyze a vast number of sensory inputs from a system and decide which of many responses it should make.

 

LAYOUT OF INDUSTRIAL AUTOMATION

 

 

AUTOMATION- APPLICATION

Manufacturing companies in virtually every industry are achieving rapid increases in productivity by taking advantage of automation technologies. When one thinks of automation in manufacturing, robots usually come to

 

mind. The automotive industry was the early adopter of robotics robotics,, using these automa aut omated ted mac machin hines es for mat materi erial al han handli dling, ng, pro proces cessin sing g ope operat ration ions, s, and assemb ass embly ly and ins inspec pectio tion. n. Don Donald ald A. Vin Vincen cent, t, exe execut cutive ive vic vicee pre presid sident ent,, Robotic Industries Association, predicts a greater use of robots for f or assembly,  paint systems, final trim, and parts transfer will will be seen in the near futu future. re. Vinc Vi ncen entt expe expect ctss othe otherr indu indust stri ries es to he heav avil ily y in inve vest st in robot robotic icss as we well ll.. Industries such as the electronics  electronics  ind indus ustr try, y, wit ith h its ne neeed for for ma mass ss customization of electronic goods, the miniaturization of electronics goods and an d

thei theirr

inte intern rnal al co comp mpon onen ents ts,,

and the

re-s re-sttan and dard ardiz izaati tion on of

the

semico sem icondu nducto ctorr ind indust ustry, ry, whi which, ch, he say says, s, wil willl com comple pletel tely y ret retool ool it itsel selff by 2004. Robotics will continue to expand into the food and beverage industry where they will perform such tasks as packaging, palletizing, and filling; as well as the aerospace, appliance, and non-manufacturing markets. Onee ca On can n brea break k do down wn au auto toma mati tion on in prod produc ucti tion on in into to ba basi sica call lly y th thre reee catego cat egorie ries: s: fix fixed ed aut automa omatio tion, n, pro progra grammab mmable le aut automa omatio tion, n, and fle flexib xible le automation. The automotive industry primarily uses fixed automation. Also known as "hard automation," this refers to an automated production facility in which the sequence of processing operations is fixed by the equipment layout. A good example of this would be an automated production line where a series of workstations are connected by a transfer system to move  parts between the stations. What starts as a piece of sheet metal metal   in the  beginning of the process, becomes becomes a car at the end. Programmable automation is a form of automation for producing products in  batches. The products are made in batch quantities ranging from several dozen to several thousand units at a time. For each new batch, the production

 

equipment must be reprogrammed and changed over to accommodate the new product style. Flexible automation is an extension of programmable automation. Here, the variety of products is sufficiently limited so that the changeover of the equipment can be done very quickly and automatically. The reprogramming of th thee eq equi uipm pmen entt in flex flexib ible le au auto toma mati tion on is do done ne off-l off-lin ine; e; th that at is, is, th thee  programming is accomplished at a computer terminal without using the  production equipment itself. itself. Computer Compu ter numeri numerical cal control (CNC) is a form of prog programmabl rammablee auto automation mation in which a machine is controlled by numbers (and other symbols) that have  been coded into a computer. The program is actuated from the computer's memory. The machine tool industry was the first to use numerical control to cont co ntro roll th thee po posi siti tion on of a cu cutt ttin ing g tool tool rela relati tive ve to th thee wo work rk pa part rt be bein ing g mach ma chin ined ed.. Th Thee CN CNC C pa part rt prog progra ram m re repr pres esen ents ts th thee set set of ma mach chin inin ing g inst instru ruct ctio ions ns for for the the pa part rtic icul ular ar pa part rt,, wh whil ilee th thee co code ded d nu numb mber erss in th thee sequenced program specifies x-y-z coordinates in a Cartesian axis system, defining the various positions of the cutting tool in relation r elation to the work part.

AUTOMATION- ADVANTAGES

1. Replacing human operator in tedious task.

2. Replacing humans in tasks that should be done in dangerous environment.

 

3. Making tasks that are ar e beyond human capabilities such as handle too heavy loads, too large objects, too hot or cold substances or the requirement to make things too fast or too slow.

4. Eco Econom nomy y imp improv roveme ementnt- som someti etimes mes som somee kin kinds ds of aut automa omatio tion n imp imply ly improves in economy of enterprises, society or most of the humankind.

DISADVANTAGES 1. Technology limits- nowadays technology is not able to automatize all desired task.

2. Initial costs are relative high.

SCADA- HISTORY

ON 20TH  SEPT. 2000 2000,, the Fina Finance nce Comm Committee ittee ap approve proved d the prop proposal osal to nego ne goti tiat atee wi with th ET ETM M A. A.G. G. for for the the su supp pply ly of PV PVSS SS-E -ETM TM’s ’s SC SCAD ADA A developing the control systems of ALICE, ATLAS, CMS and LHCb. In accordance SCADA Working Group, that was set up by the CREN Controls

 

Board, re PVSS as one of the SCADA products for the development of future control CREN.

These decisions are the accomplishment of around thirteen person- years FTE- spanning over more than three years- to identify and evaluate a proper control system that copies with the extreme requirements of high energy  particle experiments such as those of of LHC.

Widely used in industry for Supervisory Control and Data Acquisition of  processes, SCADA systems are now also penetrating the experiments laboratories for the controls of ancillary systems such as cooling, ventilation distribution etc. More recently they were also applied for the controls of small sma ll pa part rtic icle le de dete tect ctor orss such such as the the L3 mu muon on de dete tect ctor or an and d th thee NA NA48 48 experiment, to two examples as CREN.

SCADA systems have made substantial progress over the recent years in functionality, scalability, performance and openness.

WHAT IS A SCADA? SCADA stands for Superv Supervisory isory Control And Data Acquisi Acquisition. tion. SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data. SCADA focuses on gathering and

 

circulating the right amount of system information to the right person or computer within the right amount of time so that creative solutions are made  possible.

The keyword supervisory indicates that decisions are not directly made by the system. Instead, the system executes control decisions based on control  parameters entered by the agency staff. The system monitors the health of the process and generates alarm notifications when conditions are out of tolerance. It is also tasked with placing the process in a safe mode. It waits for user inputs to correct problems. The supervisory mode is designed to operatee the syste operat system m in a manne mannerr that avoid avoidss out of tolera tolerance nce condit conditions. ions. In a water / wastewater process, pumps are started and stopped by the system according to limits assigned by operations. As long as the system responds correctly to the control commands, the system remains in control. It gene genera rall lly y refer referss to an indu indust stria riall co cont ntro roll syst system: em: a co comp mput uter er syst system em moni mo nito torin ring g an and d co cont ntro roll llin ing g a proc proces ess. s. Th Thee proc proces esss ca can n be in indu dust stri rial al,, infrastructure or facility based as described below:

  ●Industrial processes processes   incl includ udee thos thosee of manufacturing manufacturing,,  production  production,,  power   generation,, fabrication generation fabrication,, aan nd refining refining,, and may run in continuous, batch, repetitive, or discrete modes. ●Infra ●In frast struc ructu ture re proc proces esses ses ma may y be pu publ blic ic or priv privat ate, e, an and d in incl clud udee water   treatment and treatment  and distribution, wastewater collection and treatment treatment,, oil and gas  pipelines, electrical power transmission and distribution, civil defense siren siren   systems, and large communication systems.

 

●Facility processes occur both in public facilities and private ones, including  buildings, airports, ships, and space stations. They monitor and control energy consumption.

WHAT IS DATA ACQUISITION? Data acquisition is the process of retrieving control information from the equipment which is out of order or may lead to some problem or when decisions are need to be taken according to the situation in the equipment. So this acquisition is done by continuous monitoring of the equipment to which it is employed. The data accessed are then forwarded onto a telemetry system ready for transfer to the different sites. They can be analog and digital information gathered by sensors, such as flow meter, ammeter, etc. It can also be data to control equipment such as actuators, relays, valves, motors, etc.

WHY WH Y OR OR WHE WHERE RE WE USE US E SCA SCADA DA?

SCADA can be used to monitor and control plant or equipment. The control may be automa automatic, tic, or initi initiated ated by opera operator tor commands. The data acquis acquisition ition is accomplished firstly by the RTU's (remote Terminal Units) scanning the

 

field inputs connected to the RTU (RTU’s may also be called a PLC  programmable logic controller). This is usually at a fast rate. The central host will scan the RTU's (usually at a slower rate.) The data is processed to detect alarm conditions, and if an alarm is present, it will be displayed on special alarm lists. Data can be of three main types. Analogue data (i.e. real numbers) will be trended (i.e. placed in graphs). Digital data (on/off) may have alarms attached to one state or the other. Pulse data (e.g. counting revolutions of a meter) is normally accumulated or counted. Thes Th esee syst system emss are us used ed no nott on only ly in indu indust stri rial al proc proces esse ses. s. Fo Forr ex exam ampl ple, e, Manufa Man ufactu cturin ring, g, ste steel el mak making ing,, pow power er gen genera eratio tion n bot both h in con conven ventio tional nal,, nucl nu clea earr an and d its its dist distrib ribut utio ion, n, ch chemi emist stry ry,, bu butt al also so in some some ex expe peri rime ment ntal al facilities facilit ies suc such h as lab labora orator tories ies res resear earch, ch, tes testin ting g and eva evalua luatio tion n cen center ters, s, nuclear fusion. The size of such plants can range from as few as 10 to se seve veral ral 10 thou thousa sand ndss inpu input/ t/ou outp tput ut (I/ (I/O) O) ch chan anne nels ls.. Ho Howe weve ver, r, SC SCAD ADA A systems syste ms evolv evolvee rapidl rapidly y and are now penetra penetrating ting the market of plant plantss with a number of I/O channels of several 100K. The primary interface to the operator is a graphical display (mimic) us usua uall lly y via via a PC Sc Scre reen en wh whic ich h show showss a repr repres esen enta tati tion on of th thee pl plan antt or equi eq uipm pmen entt in grap graphi hica call form. form. Li Live ve da data ta is show shown n as grap graphi hica call shap shapes es (foreground (foregr ound)) over a stati staticc backgroun background. d. As the data changes in the field, the foreground is updated. E.g. a valve may be shown as open or closed. Analog data can be shown either as a number, or graphically. The system may have many such displays, and the operator can select from the relevant ones at any time. SCADA systems were first used in the 1960s.SCADA systems have made substantial progress over the recent years in terms of functionality, scalability, performance and openness such that they are an alternative to in

 

house development even for very demanding and complex control systems as those of physics experiments. SCADA systems used to run on DOS, VMS and UNIX; in recent years all SCADA vendors have moved to NT and some also to Linux.

ARCHITECTURE

In this section we are going to details which describe the common architecture required for the SCADA products.

 

Hardware Architecture The basic hardware of the SCADA system is distinguished into two  basic layers: the "client layer" which caters for the man machine interaction and the "data server layer" which handles most of the process data control activities. The data servers communicate with devices in the field through  process controllers. Process controllers, e.g. PLC’s, are connected to the data servers either directly or via networks or fieldbuses that are proprietary (e.g. Siemens H1), or non-proprietary (e.g. Profibus). Data servers are connected to each other and to client stations via an Ethernet LAN. Fig.1. shows typical hardware architecture.

 

Figure 1: Typical Hardware Architecture

Communication

 

Internal Communication: ServerServ er-cli client ent and ser server ver-ser -server ver com commun munica icatio tion n is in gen genera erall on a  publish-subscribe and event-driven basis and uses a TCP/IP protocol, i.e., a client application subscribes to a parameter which is owned by a particular serve rver application and only changes to that parame rametter are then communicated to the client application. Access to Devices: The data servers poll the controllers at a user defined polling rate. The  polling rate may be different for different parameters. The controllers pass the requested parameters to the data servers. Time stamping of the process  parameters is typically performed in the controllers and this time-stamp is taken over by the data server. If the controller and communication protocol used support unsolicited data transfer then the products will support this too. The products provide communication drivers for most of the common PLCs and widely used field-buses, e.g., Modbus. Of the three fieldbuses that are re reco comm mmen ende ded d are, are, bo both th Pro Profi fibu buss an and d Wo Worl rldf dfip ip are supp suppor orte ted d bu butt CANbus often not. Some of the drivers are based on third party products (e.g., Applicom cards) and therefore have additional cost associated with them. VME on the other hand is generally not supported. A single data server can support multiple communications protocols; it can generally support as many such protocols as it has slots for interface cards. The effort required to develop new drivers is typically in the range of 2-6 weeks depending on the complexity and similarity with existing drivers, and a driver development tool kit is provided for this.

 

Interfacing Application Interfaces / Openness The pro provis vision ion of OPC cli client ent fun functi ctiona onalit lity y for SCA SCADA DA to acc access ess devices devic es in an open and standard manner is deve developin loping. g. There still seems to  be a lack of devices/controllers, which provide OPC server software, but this impro imp rove vess rap rapid idly ly as mo most st of the the prod produc ucer erss of co cont ntrol rolle lers rs are acti active vely ly involved in the development of this standard. The products also provide •

an Open Data Base Connectivity (ODBC) interface to the data in the archive/logs, but not to the configuration database,

•

an ASCII import/export facility for configuration data,

•

a library of APIs supporting C, C++, and Visual Basic (VB) to access data in the RTDB, logs and archive. The API often does not provide ac acce cess ss to the the prod produc uct' t'ss inte intern rnal al feat feature uress such such as al alar arm m hand handli ling ng,, reporting, trending, etc. The PC produ products cts provide support for the Micro Microsoft soft standard standardss such as

Dyna Dy nami micc Da Data ta Ex Exch chan ange ge (D (DDE DE)) wh whic ich h al allo lows ws e. e.g. g. to vi visu sual aliz izee da data ta dynamically in an EXCEL spreadsheet, Dynamic Link Library (DLL) and Object Linking and Embedding (OLE).

Database

 

Thee co Th conf nfig igura urati tion on da data ta are are stor stored ed in a da data taba base se th that at is lo logi gica call lly y centralized but physically distributed and that is generally of a proprietary format. For performance reasons, the RTDB resides in the memory of the servers and is also of proprietary format. The archive and logging format is usuall usu ally y als also o pro propri prieta etary ry for per perfor forman mance ce rea reason sons, s, but som somee pro produc ducts ts do support logging to a Relational Data Base Management System (RDBMS) at a slower rate either directly or via an ODBC interface. Scalability Scalab Sca labili ility ty is und unders erstoo tood d as the pos possib sibili ility ty to ext extend end the SCA SCADA DA  based control system by adding more process variables, more specialized servers serv ers (e.g. (e.g. for ala alarm rm han handli dling) ng) or mor moree cli client ents. s. The pro produc ducts ts ach achiev ievee scalability by having multiple data servers connected to multiple controllers. Each Eac h dat dataa serv server er has its own confi configur gurati ation on dat databa abase se and RTDB and is re resp spon onsi sibl blee for for the han andl dlin ing g of a su sub b-se -set of th thee proc proces esss va vari riab able less (acquisition, alarm handling, archiving).

 

SCADA AS A SYSTEM A SCADA System usually consists of the following subsystems: •

A Hum Human-M an-Machi achine ne Inter Interface face   or HM HMII is th thee ap appa para ratu tuss wh whic ich h  presents process data to a human operator, and through this, the human hum an ope operat rator or mon monito itors rs and con contro trols ls the pro proces cess. s. A sup superv erviso isory ry (compu (co mputer ter)) sys system tem,, gat gather hering ing (ac (acqui quirin ring) g) dat dataa on the pro proces cesss and sending commands (control) to the process.



  Remote Terminal Units (RTUs) connecting to sensors in the process, converting sensor signals to digital data and data and sending digital data to the supervisory system.

 

•

Programm Prog rammable able Logi Logicc Con Controll troller er  (PLC (PLCs) s) us used ed as fie field ld de devi vice cess

 because

they

are

more

economical,

versatile,

flexible,

and

configurable than special-purpose RTUs.

•

Communication  infrastructure Communication infrastructure connecting the supervisory system to

the Remote Terminal Units

 

  TYPICAL SCADA SYSTEM

EXAMPLE OF SCADA SYSTEM

SCAD SC ADA A (Supe (Superv rvis isor ory y Co Cont ntro roll an and d Da Data ta Ac Acqu quis isit itio ion) n) + HM HMII (H (Hum uman an Machine Interface) = CCC (Control, Cost reduction and Confidence)  CCC systems use real-time data acquisition and trending to allow you to see what is happening with your business, as it happens. Any process can be automated and monitored by these systems. Pioneered in the chemical and  petrochemical industries, new hardware and software now allow these

 

systems syste ms to be used for every everyday day process processes. es. This result resultss in cost savin savings gs that  pay for a system in a few months. A quick example is the automation of a dosing system using day tanks and large holding tanks used to fill the day tanks.

A SCADA system could be programmed to: •

monitor high and low levels in the day tanks,

•

fill them when a certain level is reached,

•

calculated and store the volume used,

•

monitor the level in the main feed f eed tank,

 

•

Alarm when a certain level is reached to notify purchasing (or send an e-mail),

•

Plot the usage of chemicals vs time, process, or any other parameter.

HUMAN MACHINE INTERFACE

A Human-Machine Interface Interface or  or HMI is the apparatus which presents process data to a human operator, and through which the human operator controls the process.  HMI's are an easy way to standardize the facilitation of monitoring multiple RTU's or PLC's (programm (programmable able logic controlle controllers). rs). Usually RTU's or PLC's willl ru wi run n a pre progr rograamm mmed ed proc roces ess, s, bu butt mo mon nit ito ori ring ng each ach of th them em individually can be difficult, usually because they are spread out over the system. syste m. Becau Because se RTU's and PLC's historic historically ally had no standardi standardized zed method to display or present data to an operator, the SCADA system communicates with PLC's throughout the system network and processes information that is easily disseminated by the HMI. HMI's can also be linked to a database, which can use data gathered from PLC's or RTU's to provide graphs on trends, logistic info, schematics for a specific sensor or machine or even make troubleshooting guides accessible.

 

An important part of most SCADA implementations are alarms. An alarm is a digital status point that has either the value NORMAL or ALARM. Alarms can be created in such a way that when their requirements are met, they are activated. An example of an alarm is the "fuel tank empty" light in a car. The SCADA operator's attention is drawn to the part of the system requiring attention by the alarm. Emails and text messages are often sent along with an alarm activation alerting managers along with the SCADA operator.

HARDWARE SOLUTIONS

SCADA solution often has Distributed Control Systems components. Use of smart RTUs or PLCs, which are capable of autonomously executing simple logic processes without involving the master computer, is increasing. A functional block programming language, IEC 61131-3, is frequently used to create programs which run on these RTUs and PLCs. Unlike a procedural language such as the C programming language or FORTAN,IEC 61131-1 has minimal training requirements by virtue of resembling historic physical control arrays. This allows SCADA system engineers to perform both design and implementation of a program to be executed on a TRU or PLC.

System components

 

The three components of SCADA system are: 1. Multiple Remote Terminal Units 2. Central Control Room with Host Computer  3. Communication Infrastructure

REMOTE TERMINAL UNIT The RTU RTU connects  connects to physical equipment. Typically, an RTU converts the el elec ectr tric ical al si sign gnal alss fro from the the eq equi uipm pmen entt to di digi gita tall va valu lues es such such as th thee open op en/c /clo lose sed d stat status us from from a switch switch   or a valve valve,, or me meas asure ureme ment ntss such such as  pressure, flow, voltage or current. By converting and sending these electrical signals out to equipment the RTU can RTU can control equipment, such as opening or closing a switch switch or  or a valve valve,, or setting the speed of aa pump  pump.. The RTU can read digital status data or analogue measurement data, and send out digital commands or analogue setpoints. An important part of most SCADA implementation arealarms. An alarm is a digital status point that has either the value NORMAL or ALARM. Alarms can be created in such a way that when their requirements are met, they are activated. An example of an alarm is the “fuel tank empty” light in a car. The SCADA operator’s attention is drawn to the part of the system requiring attention by the alarm. Emails and the text messages are often sent along with an alarm activation alerting managers along with the SCADA operator.

 

CENTRAL CONTROL ROOM COMPUTER  The SCADA usually presents the information in the form of mimic. This means that a operator can see a representation of the plant being controlled. For example a picture of a pump connected to a pipe can show the operator that the pump is running and how much fluid it is pumping through the pipe at the moment. The operator can then switch the pump off. The SCADA will show the flow rate of the fluid in the pipe decrease in relay time. The HMI  package for the SCADA system includes a drawing program that the oper op erat ator or or syst system em pe perso rsonn nnel el us usee to ch chan ange ge th thee wa way y th thes esee po poin ints ts are are represented represe nted in the interfac interface. e. These repres representat entation ion can be as simpl simplee as an on screen traffic light, which represents the state of an actual traffic light in the field or as complex as a multi-projector display representing the position of all the elevators in a skyscraper or all the trains on a railway. The interface is usually 2D and is displayed using the X11 protocol, although some vendors  provide immersive 3D interfaces and support for other display APIs such as Win 32 GDI/DirectDraw. Scada master computers typically run on top of a third party operating system. Nearly all SCADA products run on either a UNIX variant or HP Open VMS, although many vendors are beginning to  provide Microsoft Windows as a host operating system option. Initially more ‘open’ platforms such as Linux were no as widely used due to highly dynamic dynam ic dev developme elopment nt env environm ironment ent an and d beca because use a SC SCADA ADA

custo customer mer tha thatt

was able to afford the field hardware and devices to be controlled could usually also purchase UNIX or open VMS licenses.

 

OPERATIONAL PHILOSOPHY Instead of relying on operator intervention, or master station automation, RTUs may now be required to operate on their own to control tunnel fires or  perform other safety related tasks. The master station software is required to do more analysis of data before presenting it to operators including historical analys ana lysis is and ana analys lysis is ass associ ociate ated d wit with h par partic ticula ularr ind indust ustry ry req requir uireme ements nts.. Safety requirements are now being applied to the systems as a whole and even master station software must meet stringen stringentt safet safety y stand standards ards for some markets. For some installations, the cost that would result from the control system failing is extremely high possibly even lives could be lost. Hardware for SCADA systems is generally ruggedized to withstand temperature, vibration and voltage extremes but in these installations reliability is enhanced by having redundant hardware and communications channels. A failing part can  be quickly identified and its functionality automatically taken over by  backup hardware. A filed part can often be replaced without interrupting the process. The reliability of such systems can be calculated statistically and is stated as the mean time to failure, which is a variant of mean time  between failures. The calculated mean time to failure of such high reliability systems can be in the centuries.

COMMUNICATION METHODS

INFRASTRUCTURE

AND

 

SCADA systems have traditionally used combinations of radio and direct serial or modem connections to meet communication requirements, although Ethernet and IP over SONET is also frequently used at large sites such as railways and power stations. This has also come under threat with some customer want in SCADA S CADA data to travel over their pre-established corporate networks or to share the network with other applications. The legacy of the early low bandwidth protocols remains, though, SCADA protocols are designed to be very compact and many are designed to send information to the master station only when the master station polls the RTU.

 

SYSTEM CONCEPT

The term SCADA usually refers to centralized systems which monitor and control entire sites, or complexes of systems spread out over large areas (anything between an industrial plant and a country). Most control actions are pe perfo rforme rmed d au auto toma mati tica call lly y by rem remote ote ter termin minal al uni units ts   ("R ("RTU TUs" s")) or by  programmable logic controllers ("PLCs"). controllers ("PLCs"). Host control functions are usually restricted to basic overriding or supervisory level intervention. For example, a PLC may control the flow of cooling water through part of an industrial  process, but the SCADA system may allow operators to change the set  points for the flow and enable alarm conditions, such as loss of flow and high temperature, to be displayed and recorded. The feedback control loop  passes through the RTU or PLC, while the SCADA system monitors the overall performance of the loop. 

 

Data acquisition begins at the RTU or PLC level and includes meter readings and equipment status reports that are communicated to SCADA as required. Data is then compiled and formatted in such a way that a control room operator using the HMI can make supervisory decisions to adjust or override normal RTU (PLC) controls. SCADA SCA DA sys system temss typ typica ically lly imp implem lement ent a dis distri tribut buted ed dat databa abase, se, com common monly ly referred to as a tag database, which contains data elements called tags or  points. A point represents a single input or output value monitored or controlled by the system. Points can be either "hard" or "soft". A hard point represents an actual input or output within the system, while a soft point

 

resul res ults ts from from logi logicc an and d ma math th op oper erat atio ions ns ap appl plie ied d to ot othe herr po poin ints ts.. (M (Mos ostt implem imp lement entati ations ons con concep ceptua tually lly remo remove ve the dis distin tincti ction on by mak making ing eve every ry  property a "soft" point expression, which may, in the simplest case, equal a single hard point.) Points are normally stored as value-timestamp pairs: a valu va luee an and d th thee timestamp timestamp when  when it was recorded or calculated. A series of value-timestamp pairs gives the history of that point. It's also common to store additional metadata with tags, such as the path to a field device or PLC register, design time comments, and alarm information.

 

FUNCTIONALITY

Access Control Users are allocated to groups, which have defined read/write access  privileges to the pr process ocess parameters in the system and often also to specific  product functionality. MMI Thee Th

prod roduc ucts ts

su sup ppo port rt

mu mult ltiiple ple

scre screeens ns,,

whi hich ch

can can

co cont ntaain

combination combin ationss of synoptic diagrams and text. They also supp support ort the conce concept pt of a "generic" graphical object with links to process variables. These objects can be "dragged and dropped" from a library and included into a synoptic diagram. diagra m. Most of the SCADA produ products cts that were evaluat evaluated ed deco decompose mpose the  process in "atomic" parameters (e.g. a power supply current, its maximum value, its on/off status, etc.) to which a Tag-name is associated. The Tagnames used to link graphical objects to devices can be edited as required. The products include a library of standard graphical symbols, many of which would however not be applicable to the type of applications encountered in the experimental physics community. Standard windows editing facilities are pro provid vided: ed: zoo zoomin ming, g, rere-siz sizing ing,, scr scroll olling ing... ... On On-li -line ne con config figura uratio tion n and cust cu stom omiz izat atio ion n of the the MM MMII is po poss ssib ible le for for us users ers wi with th th thee ap appro propr pria iate te  privileges. Links can be created between display pages to navigate from one view to another.

 

Trending The products all provide trending facilities and one can summarize the common capabilities as follows: •

the parameters to be trended in a specific chart can be predefined or defined on-line

•

a chart may contain more than 8 trended parameters or pens and an unlimited number of charts can be displayed (restricted only by the readability)

•

real-time and historical trending are possible, although generally not in the same chart

•

historical trending is possible for any archived parameter

•

zooming and scrolling functions are provided

•

 parameter values at the cursor position position can be displayed The trending feature is either provided as a separate module or as a

graphical object (ActiveX), which can then be embedded into a synoptic display. XY and other statistical analysis plots are generally not provided.

 

Alarm Handling Alarm handling is based on limit and status checking and performed in the dat dataa serv servers ers.. Mor Moree com compli plicat cated ed exp express ression ionss (us (using ing ari arithm thmeti eticc or logical expressions) can be developed by creating derived parameters on which status or limit checking is then performed. The alarms are logically handled centrally, i.e., the information only exists in one place and all users see the same status (e.g., the acknowledgement), and multiple alarm priority levels (in general many more than 3 such levels) are supported. It is generally possible to group alarms and to handle these as an entity (typically filtering on group or acknowledgement of all alarms in a group). group ). Furthe Furthermore, rmore, it is possible to supp suppress ress alarm alarmss eithe eitherr indi individua vidually lly or as a complete group. The filtering of alarms seen on the alarm page or when viewing the alarm log is also possible at least on priority, time and group. However, relationships between alarms cannot generally be defined in a straigh stra ightfo tforwa rward rd man manner ner.. E-m E-mail ailss can be gen genera erated ted or pre predef define ined d act action ionss automatically executed in response to alarm conditions. Logging/Archiving The terms logging and archiving are often used to describe the same facility. However, logging can be thought of as medium-term storage of data on disk, whereas archiving archiving is long long-term -term storage of data eithe eitherr on disk or on another permanent storage medium. Logging is typically performed on a cyclic basis, i.e., once a certain file size, time period or number of points is reached the data is overwritten. Logging of data can be performed at a set freq freque uenc ncy, y, or on only ly init initia iate ted d if the the va valu luee ch chan ange gess or wh when en a sp spec ecif ific ic

 

 predefined event occurs. Logged data can be transferred to an archive once the log is full. The logged data is time-stamped and can be filtered when viewed by a user. The logging of user actions is in general performed together with either a user ID or station ID. There is often also a VCR facility to play back archived data. Report Generation Onee can On can prod produc ucee rep repor orts ts usin using g SQ SQL L ty type pe qu queri eries es to th thee arch archiv ive, e, RTDB or logs. Although it is sometimes possible to embed EXCEL charts in the report, a "cut and paste" capabili capability ty is in general not provided provided.. Facilities exist to be able to automatically generate, print and archive reports. Automation Thee ma Th majo jori rity ty of the the pro produ duct ctss allo allow w acti action onss to be au auto toma mati tica call lly y triggered by events. A scripting language provided by the SCADA products allows these actions to be defined. In general, one can load a particular display, send an Email, run a user defined application or script and write to the RTDB. The con concep ceptt of rec recipe ipess is sup suppor ported ted,, whe whereb reby y a par partic ticula ularr sys system tem configuration can be saved to a file and then re-loaded at a later date. Sequencing is also supported whereby, as the name indicates, it is possible to execute a more complex sequence of actions on one or more devices. Seque Seq uenc nces es may may also also reac reactt to ex exte tern rnal al ev even ents ts.. So Some me of th thee prod produc ucts ts do support an expert system but none has the concept of a Finite State Machine (FSM).

 

EVOLUTION

SCADA vendors release one major version and one to two additional minor versions once per year. These products evolve thus very rapidly so as to take advantage of new market opportunities, to meet new requirements of their customers and to take advantage of new technologies. As wa wass al alre read ady y me ment ntio ione ned, d, mo most st of the the SC SCAD ADA A prod produc ucts ts th that at we were re evaluated decompose the process in "atomic" parameters to which a Tagname is associated. This is impractical in the case of very large processes when wh en ve very ry la larg rgee se sets ts of Ta Tags gs ne need ed to be co conf nfig igur ured ed.. As th thee in indu dust stria riall applications are increasing in size, new SCADA versions are now being designed to handle devices and even entire systems as full entities (classes) that encapsulate all their specific attributes and functionality. In addition, they will also support multi-team development. As far as new technologies are concerned, the SCADA products are now adopting: •

Web technology, ActiveX, Java, etc.

•

OPC as a means for communicating internally between the client and server modules. It should thus be possible to connect OPC compliant third party modules to that SCADA product.

 

FEATURES OF SCADA

DYNAMIC PROCESS GRAPHIC mimics developed in SCADA software

should resemble the process mimic. SCADA should have good library of symbols so that you can develop the mimic as per requirement. Once the operator sees the screen he should know what is going on in the plant.

REAL TIME AND HISTORICAL TREND  the trend play very important

role in the process operation. If your batch fails or the plant trips, you can simply go to the historical trend data and do the analysis. You can have  better look of the parameters through the trend. Ex. We commission a SCADA system for Acid Regeneration plant where the plant has to be operated on 850-deg temperature. If the operator operates the plant at 900 deg you can imagine how much additional LPG he is putting into the reactor react or.. Ag Agai ain n wh what at wi will ll ha happ ppen en to the the bric bricks ks of th thee reac reacto tor? r? So th thee  production manger’s first job will be to go through the trends how the operators are operating the plant. Even when the plant trips there are more than 25 probable reasons for the sample but if you go through the history trends, it’s very easy to identify the problem.

 

ALARMS  have a very critical role in automation. Generally you have alarm

states for each inputs/outputs like your temperature should not cross 80 deg or lever should be less than 60. So if the parameters go in alarm state the operator should be intimated with alarm. Most of the SCADA software support four types of alarms like LOLO,LO,HI and HIHI. Deadband the value of deadband defines the range after which a high low alarm condition returns to normal. Alarms are the most important part of the plant control applications because the operator must know instantly when something goes wrong. It is often equally important to have a record of alarms and whether an alarm was acknowled ackno wledged. ged. An alarm occurs when something goes wron wrong. g. It can signal that a device or process has ceased operating within acceptable, predefined limits or it can indicate breakdown, wear or process malfunction.

RECIPE RECIP E MANA MANAGEME GEMENT NT  is an ad addi diti tion onal al fe feat atur ure. e. So Some me SC SCAD ADA A

software support it, some do not. Most of the plants are manufacturing multi  products. When you have different products to manufacture, you just have to load the recipe of the particular product.

SECURITY  is on fac facili ility ty peo people ple gener generall ally y loo look k for. You can alloc allocate ate

certain facilities or features to the operator, process people, engineering dept and an d ma main inte tena nanc ncee de dept pt.. for for ex examp ample le op opera erato tors rs shou should ld on only ly op opera erate te th thee system, he should not be able change the application. The engineers should

 

have access to changing the application. The engineers should have access to changing the application developed.

DEVICE DEVIC E CONN CONNECTI ECTIVITY VITY  you will find there are hundreds of

automation hardware manufacturer like Modicon, Siemens, Allen Bradly, ABB. Everybody has there own way of communication or we can say they havee the hav there re own com commun munica icatio tion n pro protoc tocol. ol. SCA SCADA DA soft softwar waree sho should uld hav havee connectivity to the different hardware used in automation. It should not happen that for Modicon I am buying one software and for Siemens another one. The softw software are like Aspi Aspicc or Wonderwar Wonderwaree has connect connectivity ivity to almost all hardware used in automation.

DATABASE DATA BASE CONN CONNECTIV ECTIVITY ITY  now now a da days ys in info form rmat atio ion n pl play ayss ve very ry

important role in any business. Most manufacturing units go for Enterprise Resource Planning or Management Information System.

 

USEFULNESS OF SCADA

Production Dept.

● Real time producti production on status: manufactu manufacturing ring status is updat updated ed in real time in direct communication to operator and control device ● Production schedules: production schedules can be viewed and updated directly ● Production information management: production specific information is distributed to all Quality Dept.

● Da Data ta in inte tegri grity ty an and d qu qual alit ity y co cont ntro roll is im impr prov oved ed by usin using g a co commo mmon n interface ● It is an open platform for statistical analysis ● Consolidation of manufacturing and lab data Maintenance Dept.

● Imp Improv roved ed tro troubl ublesh eshoot ooting ing and dede-bug buggin ging: g: dir direct ect con connec nectio tion n to wid widee variety

of

devices,

diagnostic/debugging diagnostic/debuggin g time

displays

imp mpro rov v es

trou roubleshooting

reduces

 

● Plant can be viewed remotely. Notification can include pagers, e-mails and  phones. ●

Co Co-o -ord rdin inaation tion

be bettwe weeen

ma main inte ten nan ancce

an and d

ma mana nag gem emen entt

red reduc ucees

unscheduled downtime. Enterprise Information

● Corporate information and real time production data can be gathered and viewed from anywhere within operations ● User specific information ensures better informed decisions ● Data exchange with standard databases and enterprise systems provides integrated information solutions Engineering Dept.

● Integrated automation solutions reduce design and configuration time ●

Com ommo mon n

co conf nfiigu gura rati tio on

pla platform form

offe offers rs

fl flex exiibi bili lity ty

for for

co cons nsttan antt

configuration in all areas ● Capable of connecting to wide variety of systems. Reduces start up time and system training with industry proven open interfaces Manufacturing Dept.

● Unscheduled down time is reduced due to swift alarm detection and event driven information

 

● Mak akes es op oper eraatio tions ea eassier ier an and d mo more re rep repeat eatab ablle with its rea real ti time me functionality ● Secured real time operation are maintained with windows

 

GENERAL TERMINOLOGY

What is a Tag- a tag is a logical name for a variable in a device or local

memory (RAM). Tags that receive data from some external devices such as  programmable logic controllers or servers are refereed to as I/O tags. Tags that receive receive data internally from software are call called ed memory tags. Analog Tags- store a range of values. EX temp, flow, density etc Discrete tags- to store values such as 0 or 1. EX on/off status of a pump,

valves, switches etc. System tags- store information generated while the software is running

including alarm info and system time and date. String tags- are used to store ASCII strings a series of characters or whole

word. The max string length is 131 characters. Touch links- allow the operator to input data into the system. EX. Operator

may turn the value on or off, enter a new alarm set point, run a complex logic script etc. Touch push buttons-are used to create object link that immediately perform

an operation when clicked with the mouse or touched. These operations can  be discrete value changes, action script executions and show or hide window commands.

 

Colour links- are used to animate the line colour, fill colour or text colour of

an object. Each of these colour attributes can be made dynamic by defining a colour link for the attribute. The colour attribute may be linked to the value of a discrete expression, analogue expression, discrete alarm status or analog alarm status. Visibility- used to control visibility of an object based on the value of

discrete tag name or expression. Blink-  used to make an object blink based on the value of the discrete

tagname or expression.

Orientation- us used ed to ma make ke an obje bject rota rotate te ba bassed on th thee va valu luee of a tagname /expression. Disable- used to disable the touch functionality of objects based on the value

of a tagname of expression. Often used as a part of a security strategy. Value display links- provides the ability to use text object to display the

value of a discrete, analog or string tagname. Percent fill links- used to provide ability to vary the fill level of a filled

shape according to the value of an analog tagname or an expression that computes to an analog value. Application script- are linked to entire applications and are used to start

other applications, create process simulation, calculate variables and so on: three types of application scripts are on start up, while running, on shut down.

 

Window script- is linked to specific window. 3 types of window scripts are

on show, while showing, on hide. Key script- touch pushbutton action scripts are similar to key scripts, except

th they ey are as asso soci ciat ated ed wi with th an ob obje ject ct that that yo you u li link nk to a to touc uch h li link nk ac acti tion on  pushbutton. 3 types are on on key down, while down, on key up. Condition script- is linked to discrete tagname or expression that equates to

true or false. You can also use discrete expressions that contain analog tagnames. 4 types of scripts that you can apply to a condition are on true, on false, while true, while false.

Data change script- are linked to a tagname and/or tagname field changes  by a value greater than a dead band that you defined for the tagname in the

tagname dictionary. Applicatio Appli cation n secur security ity- to an app ppllicat icatio ion n is opt ptiion onal al.. It pro provi vid des th thee

application developer with the ability to control whether or not specific operators are allowed to perform specific functions within an application Security is based on the concept of operator logging on to the application and entering his user name and password and access level. For each operator access to any protected function is granted upon verification of his password and access level.

 

SECURITY ISSUES

The move from proprietary technologies to more standardized and open solu soluti tion onss to toge geth ther er wi with th the the incr increa ease sed d nu numb mber er of co conn nnec ecti tion onss be betw twee een n SCADA systems and office networks and the Internet Internet has  has made them more vulnerable to attacks.Consequently, the security of SCADA-based systems has come into question as they are increasingly seen as extremely vulnerable to cyberwarfare/cyberterrorism attacks. In particular, security researchers are concerned about: •

the lack of concern about security and authentication in the design, deployment and operation of existing SCADA networks

•

the mistaken belief that SCADA systems have the benefit of security security   through throu gh obsc obscurity urity   throu through gh the the us usee of spec specia iali lize zed d prot protoc ocol olss an and d  proprietary interfaces

•

the mistaken belief that SCADA networks are secure because they are  purportedly physically physically secured

•

the mistaken belief that SCADA networks are secure because they are supposedly disconnected from the Internet

SCAD SC ADA A syst system emss are used used to co cont ntro roll an and d mo moni nito torr ph phys ysic ical al proc proces esse ses, s, examples of which are transmission of electricity, transportation of gas and oil in pipelines, water distribution, traffic lights, and other systems used as

 

th thee ba basi siss of mode modern rn soci societ ety. y. Th Thee se secu curit rity y of th thes esee SC SCAD ADA A syst system emss is important because compromise or destruction of these systems would impact multiple areas of society far removed from the original compromise. For example, a blackout caused by a compromised electrical SCADA system would cause financial losses to all the customers that received electricity from from that that so sour urce ce.. Ho How w se secu curi rity ty wi will ll affe affect ct le lega gacy cy SC SCAD ADA A an and d ne new w deployments remains to be seen. There are two distinct threats to a modern SCADA system. First is the threat of unauthorized access to the control software, whether it be human access or cha change ngess ind induce uced d int intent ention ionall ally y or acc accide identa ntally lly by vir virus us inf infect ection ionss and other software threats residing on the control host machine. Second is the threat of packet access to the network segments hosting SCADA devices. In many cases, there is rudimentary or no security on the actual packet control  protocol, so anyone who can send packets to the SCADA device can control it. In many cases SCADA users assume that a VPN is sufficient protection and are unaware that physical access to SCADA-related network jacks and switches provides the ability to totally bypass all security on the control software and fully control those SCADA networks. These kinds of physical access attacks bypass firewall and VPN security and are best addressed by endpoint-to-endpoint authentication authentication and authorization such as are ar e commonly  provided in the non-SCADA world by in-device SSL or other cr cryptographic yptographic techniques. Many vendors of SCADA and control products have begun to address these risks in a basic sense by developing lines of specialized industrial firewall  firewall  and VPN VPN   sol soluti utions ons for TCP/ TCP/IP-b IP-base ased d SCA SCADA DA net networ works. ks. Add Additi itiona onally lly,, application white listing solutions are being implemented because of their

 

ability to prevent malware and unauthorized application changes without the  performance impacts of traditional antivirus scans. Also, the ISA Security Compli Com plianc ancee Ins Instit titute ute (ISC (ISCI) I) is eme emergi rging ng to form formali alize ze SCA SCADA DA sec securi urity ty testing starting as soon as 2009. ISCI is conceptually similar to private testing and certification that has been performed by vendors since 2007. Eventu Eve ntuall ally, y, sta standa ndards rds bei being ng def define ined d by ISA ISA99 99 WG4 wil willl sup supers ersede ede the initial industry consortia efforts, but probably not before 2011. The increased interest in SCADA vulnerabilities has resulted in vulnerability researchers discovering vulnerabilities in commercial SCADA software and more general offensive SCADA techniques presented to the general security community. In electric and gas utility SCADA systems, the vulnerability of the large installed base of wired and wireless serial communications links is addressed in some cases by applying bump-in-the-wire devices that employ authen aut hentic ticati ation on and Adva Advanced nced Encry Encryption ption Stand Standard ard   encryption rather than replacing all existing nodes.

 

WHAT IS INTOUCH

Wonderware InTouch provides a single integrated view of all your controls and information resources. Intouch enables engineers, supervisors, operators and managers to view to view and interact with the working of entire operation through graphical representations of their production processes.

THE INTOUCH ENVIOREMENT

InTo InTouc uch h co cons nsis istt of thre threee ma majo jorr prog progra rams. ms. Th Thee InTo InTouc uch h Ap Appl plic icat atio ion n Manage Man ager, r, Win Window dowmak maker er and Win Window dowvie viewer wer.. InT InTouc ouch h als also o inc includ ludes es the diagnostics program Window Logger. The InTouch Application Manager   orga organizes nizes the appl applicati ication on to create create.. It

is also used to configure Windowviewer as an NT service, to configure  Network Application Development for client based and server based ar arch chit itec ectu ture res, s,

to

co conf nfig igur uree

Dy Dyna nami micc

Re Reso sour urce ce

Co Conv nver ersi sion onss

an and/ d/or or

distributed alarms. WindowMaker  is the dev develo elopme pment nt env enviro ironme nment, nt, whe where re obj object ect ori orient ented ed

graphi gra phics cs are use used d to cre create ate ani animat mated, ed, touch touch sen sensit sitive ive dis displa play y win window dows. s.

 

These display windows can be connected to industrial I/O systems and other Microsoft Windows application. WindowViewer  is the the runt runtim imee en envi viro ronm nmen entt used used to di disp spla lay y grap graphi hicc

windowss cre window create ated d in Win Window dowMak Maker. er. Win Window dowVie Viewer wer exe execut cutes es InT InTouc ouch h QuickScript, performs historical data logging and reporting, processes alarm logging and reporting and can function as a client and a server for both DDE and Suite link communication protocol.

 

WONDERWARE SCADA SOFTWARE SOLUTIONS

SCADA solutions often impose complex demands on software architectures. Wonderware InTouch HMI Visualization, coupled with the award-winning ArchestrA-based Wonderware System Platform is uniquely positioned to meet these challenges. Solutions built on ArchestrA technology benefit from a single, open and scalable software architecture that can connect to virtually any automation system, syste m, remote terminal unit (RTU), intelli intelligent gent electron electronic ic device device (IED),  programmable logic controller (PLC), database, historian or business system in use today. The open nature of this platform enables users to expand their existing systems without having to buy new hardware or control systems. Geographically dispersed applications, from a few hundred to one million I/O and from a single node to hundreds of stations, can be rapidly and securely implemented.

Key Benefits •

Easy-to-use, easy to implement

•

Easy configuration, simplified maintenance

•

High security and availability

 

•

Virtually unlimited scalability

Key Capabilities

•

HMI visualization and geographically distributed SCADA

•

Template based development and maintenance

•

Remote application development and change management

•

Data level security built into the system

•

Easy and flexible alarm definition

•

Data collection and analysis for new and existing systems

•

Easy-to-use report generation

•

Open access to historical data

 

SCADA AS AN ASSET

TYPICAL DETERIORATION CURVE FOR INFRASTRUCTURE ASSET

 

SCADA SYSTEM MANAGEMENT

SCADA Systems Management (SSM) helps its customers to transform the opera rattional

perfo rformance

of

their

businesses

throu rough

the

use

of

Manufacturing Enterprise Solutions (MES). Our in-depth practical experience of a range of industries combines with our expertise in the award-winning GE Fanuc Proficy products to enable us to deliver insights that bring benefits. We offer offer a ran range ge of cos cost-e t-effec ffectiv tivee ser servic vices es tha thatt addres addresss the ope operat ration ional al management issues from shop floor to board room. Our pragmatic solutions are targeted at unlocking value quickly

 

SCADA A BOOM IN ENGINEERING

Whil Wh ilee

on onee

sh sho ould uld

righ rightl tly y

an antticip icipat atee

sign signiifi fica can nt

de dev vel elo opm pmen entt

an and d

maintenance savings by adopting SCADA product for the implementation of a control system, it does not mean a “no effort” operation. The need for  proper engineering can not be sufficiently emphasized to reduce dev de vel elo opm pmen entt effor ffortt and to reac reach h a sys syste tem m tha hatt com ompl plie iess wi witth th thee requirements, that is economical in development and maintenance and that is reliable and robust. Examples of engineering activities specific to the use of a SCADA system are the definition of: ● a library of objects complete with standard object behavior, graphical interface and associated scripts for animation, ● templates for different types of “panels”, eg alarms ● instructions on how to control eg. A device ● a mechanism to prevent conflicting controls

 

PRAC PR AC TICA TICAL L USE USES S OF SCAD SC ADA A

● SCADA used as a control mechanism for chemical plants, electricity genera gen eratio tion, n, ele electr ctric ic pow power er tra transm nsmiss ission ion,, ele electr ctrici icity ty dis distri tribut bution ion,, dis distri trict ct heating. ● Control mechanisms are described in Process Control. ●EPICS is an example of an open source software environment used to develop and implement SCADA system to operate devices such as particle accelerators, telescopes and other large experiments.

 

 

ADVA AD VANTA NTAGES GES OF SCADA SCADA SYSTE SYSTEM M

1. A SCADA system is "normally" significantly cheaper than a DCS.  

2. SCAD SCADA A can conti continue nue opera operating ting even when telec telecommun ommunicati ication on are temporarily lost.

3. SCADA systems allow a smaller number of operators to control a large number of individual assets.

 4. SCADA systems were designed to be used on large scale

systems with

remote assets over a very large geographical area.

5. SCADA system improves operation, maintenance and customer service and provides rapid response to emergencies.

6. It provides a high level of system reliability and availability.

 

SCADA MANUFACTURERS AND NAME OF THE SOFTWARE

  WONDERWARE

Intouch

 

ALLEN BRADLEY

R.S View

 

SIEMENS

Wincc

 

MODICON

Moriecon

 

G E FANUC

Cimplicity

 

INTELLUSION

I Fix

 

KPIT

Ashtra

 

CONCLUSION

 SCADA is a control system with

● More interfaces and efficient storage

● More record or device oriented configuration

● But system wide configuration tools are ar e needed

● Are less expensive than DCS, but offer different functionality than DCS

● And finally various applications

 

REFERENCES

www.ref.web.cern.ch/ref/CERN/CNL/2002/003/scada/ www.princeton-indiana.com/wastewater/pages/scada/scada-overview.html www.scadanews.com www.sss-mag.com/scada.html www.scada.com

 

COMPANY PROFILE

ABOUT PROLIFIC

Prolific Technology Inc., a leading IC design house and ASIC design service  provider, was founded in November 1997 by a group of highly experienced and specialized technical engineers. The Company started out by developing Smart I/O IC solutions, focusing on niche USB/IEEE 1394 bridge controller  products. The Company then also ventured in the Mixed-Mode technology development, successfully designing Brushless Motor Driver IC and Hall sensors. With the future towards 3C integration, the Company will devote more efforts in SOC development as well as integration of competitive multimedia (MPEG-4/JPEG/MP3) and GPS products. The Company will also continue to introduce new technologies for existing IC product base that will offer customers a wide range of product solutions. Through System Integ Int egra rati tion on te tech chno nolo logy gy,, Pro Proli lifi ficc is en envi visi sion onin ing g he hers rsel elff to grow grow fro from m a Professional IC Design House to a leading SOC Core Technology Pioneer.

 

CONTENTS

AUTOMATION •

History

•

Introduction

•

Layout of Industrial Automation

•

Applications

•

Advantages and Disadvantages SCADA •

History

•

Introduction

•

Architecture

•

SCADA as a system

•

Features of SCADA

•

Usefulness of SCADA

•

General terminology

•

What is Intouch

•

Intouch environment

•

Wonderware SCADA solution

 

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SCADA a boom in engineering

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Practical uses of SCADA

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Advantages

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SCADA management

CONCLUSION REFERENCES

 

INTRODUCTION

a. What is SCADA  b. What is Data c. Why or where we use SCADA