Professional Documents
Culture Documents
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
measuring process variables assumed a significant role in meeting such
goals. The development of new sensors and instruments took place in stages
concurrent with advancements in science and technology. This paper
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.
AUTOMATION HISTORY
Ideas for ways of automating tasks have been in existence since the time of
the ancient Greeks. The Greek inventor Hero (fl. about A.D. 50), 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
impetus for the development of automation came, however, during the
Industrial Revolution of the early eighteenth century. Many of the steampowered 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
humans. One of the most elaborate examples of automated machinery
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 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 was
transformed by the Bouchon process into an operation that could 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 increase production
b. to reduce cost
c. to reduce manpower
d. to improve safety working conditions
e. to reduce power consumption
f. to improve quality
b. Types of Automation
Automated machines can be subdivided into two large categoriesopenloop and closed-loop machines, which can then be subdivided into even
smaller categories. Open-loop machines are devices that, once started, go
through a cycle and then stop. A common example is the automatic
dishwashing machine. Once dishes are loaded into the machine and a button
pushed, the machine goes through a predetermined cycle of operations: prerinse, wash, rinse, and dry, for example. A human operator may have
choices as to which sequence the machine should followheavy wash, light
wash, warm and cold, and so onbut 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.
For example, in the production of a car, a single machine may 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 processfrom
placing the door properly to each of the different weldstakes 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)
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.
AUTOMATION- APPLICATION
mind. The automotive industry was the early adopter of robotics, using these
automated machines for material handling, processing operations, and
assembly and inspection. Donald A. Vincent, executive vice president,
Robotic Industries Association, predicts a greater use of robots for assembly,
paint systems, final trim, and parts transfer will be seen in the near future.
Vincent expects other industries to heavily invest in robotics as well.
Industries such as the electronics industry, with its need for mass
customization of electronic goods, the miniaturization of electronics goods
and their internal components, and the re-standardization of the
semiconductor industry, which, he says, will completely retool itself 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.
One can break down automation in production into basically three
categories: fixed automation, programmable automation, and flexible
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 in the
beginning of the process, 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
AUTOMATION- ADVANTAGES
3. Making tasks that are 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. Economy improvement- sometimes some kinds of automation imply
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
WHAT IS A SCADA?
SCADA stands for Supervisory Control And Data Acquisition. 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
Facility processes occur both in public facilities and private ones, including
buildings, airports, ships, and space stations. They monitor and control
energy consumption.
field inputs connected to the RTU (RTUs 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.
These systems are used not only in industrial processes. For example,
Manufacturing, steel making, power generation both in conventional,
nuclear and its distribution, chemistry, but also in some experimental
facilities such as laboratories research, testing and evaluation centers,
nuclear fusion. The size of such plants can range from as few as 10 to
several 10 thousands input/output (I/O) channels. However, SCADA
systems evolve rapidly and are now penetrating the market of plants with a
number of I/O channels of several 100K.
The primary interface to the operator is a graphical display (mimic)
usually via a PC Screen which shows a representation of the plant or
equipment in graphical form. Live data is shown as graphical shapes
(foreground) over a static background. 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
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. PLCs, 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.
Communication
Internal Communication:
Server-client and server-server communication is in general 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
server application and only changes to that parameter 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 recommended are, both Profibus and Worldfip are supported but
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 provision of OPC client functionality for SCADA to access
devices in an open and standard manner is developing. There still seems to
be a lack of devices/controllers, which provide OPC server software, but this
improves rapidly as most of the producers of controllers are actively
involved in the development of this standard.
The products also provide
Database
SCADA AS A SYSTEM
A SCADA System usually consists of the following subsystems:
systems to be used for everyday processes. This results in cost savings 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.
HARDWARE SOLUTIONS
System components
customer that
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
analysis and analysis associated with particular industry requirements.
Safety requirements are now being applied to the systems as a whole and
even master station software must meet stringent safety standards 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
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 performed automatically by remote terminal units ("RTUs") or by
programmable logic 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 systems typically implement a distributed database, commonly
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
results from logic and math operations applied to other points. (Most
implementations conceptually remove the distinction by making every
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
value and the timestamp 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 process parameters in the system and often also to specific
product functionality.
MMI
The products support
multiple
screens,
which
can
contain
combinations of synoptic diagrams and text. They also support the concept
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. Most of the SCADA products that were evaluated decompose 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 provided: zooming, re-sizing, scrolling... On-line configuration and
customization of the MMI is possible for users with the appropriate
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:
Alarm Handling
Alarm handling is based on limit and status checking and performed
in the data servers. More complicated expressions (using arithmetic 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). Furthermore, it is possible to suppress alarms either individually 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
straightforward manner. E-mails can be generated or predefined actions
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 is long-term storage of data either 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
frequency, or only initiated if the value changes or when a specific
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 was already mentioned, most of the SCADA products that were
evaluated decompose the process in "atomic" parameters to which a Tagname is associated. This is impractical in the case of very large processes
when very large sets of Tags need to be configured. As the industrial
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:
FEATURES OF SCADA
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. Again what will happen to the bricks of the reactor? So the
production mangers 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, its 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
acknowledged. An alarm occurs when something goes wrong. It can signal
that a device or process has ceased operating within acceptable, predefined
limits or it can indicate breakdown, wear or process malfunction.
have access to changing the application. The engineers should have access to
changing the application developed.
USEFULNESS OF SCADA
Production Dept.
Real time production status: manufacturing status is updated 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.
Data integrity and quality control is improved by using a common
interface
It is an open platform for statistical analysis
Consolidation of manufacturing and lab data
Maintenance Dept.
Improved troubleshooting and de-bugging: direct connection to wide
variety
of
devices,
diagnostic/debugging time
displays
improves
troubleshooting
reduces
Plant can be viewed remotely. Notification can include pagers, e-mails and
phones.
Co-ordination
between
maintenance
and
management
reduces
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
Common configuration platform offers flexibility for constant
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
Makes operations easier and more repeatable with its real time
functionality
Secured real time operation are maintained with windows
GENERAL TERMINOLOGY
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- used to make an object rotate based on the value 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.
SECURITY ISSUES
the mistaken belief that SCADA systems have the benefit of security
through obscurity through the use of specialized protocols and
proprietary interfaces
the mistaken belief that SCADA networks are secure because they are
purportedly physically secured
the mistaken belief that SCADA networks are secure because they are
supposedly disconnected from the Internet
WHAT IS INTOUCH
These display windows can be connected to industrial I/O systems and other
Microsoft Windows application.
WindowViewer is the runtime environment used to display graphic
windows created in WindowMaker. WindowViewer executes InTouch
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.
Key Benefits
Key Capabilities
SCADA AS AN ASSET
systems with
WONDERWARE
Intouch
ALLEN BRADLEY
R.S View
SIEMENS
Wincc
MODICON
Moriecon
G E FANUC
Cimplicity
INTELLUSION
I Fix
KPIT
Ashtra
CONCLUSION
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
Integration technology, Prolific is envisioning herself to grow from 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
Advantages
SCADA management
CONCLUSION
REFERENCES
INTRODUCTION
a. What is SCADA
b. What is Data
c. Why or where we use SCADA