SCADA

SCADA (supervisory control and data acquisition) is a system operating

with coded signals over communication channels so as to provide
control of remote equipment. The control system may be combined with
a data acquisition system by adding the use of coded signals over
communication channels to acquire information about the status of the
remote equipment for display or for recording functions. It is a type of
industrial control system (ICS). Industrial control systems are computer-
based systems that monitor and control industrial processes that exist in
the physical world. SCADA systems historically distinguish themselves
from other ICS systems by being large-scale processes that can include
multiple sites, and large distances.

These processes include industrial, infrastructure, and facility-based

processes, as described below:

Industrial processes include those of manufacturing, production,

power generation, fabrication, and refining, and may run in
continuous, batch, repetitive, or discrete modes.
Infrastructure processes may be public or private, and include
water treatment and distribution, wastewater collection and
treatment, oil and gas pipelines, electrical power transmission and
distribution, wind farms, civil defense 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 heating, ventilation, and air conditioning
systems (HVAC), access, and energy consumption.
A SCADA system usually consists of the following subsystems:
Remote terminal units (RTUs) connect to sensors in the process
and convert sensor signals to digital data. They have telemetry
hardware capable of sending digital data to the supervisory system,
as well as receiving digital commands from the supervisory
system.
 Programmable logic controller (PLCs) connect to sensors in the
process and converting sensor signals to digital data. PLCs have more
sophisticated embedded control capabilities, typically one or more
programming languages, than RTUs.

PLCs do not have telemetry hardware, although this functionality is

typically installed alongside them. PLCs are sometimes used in place of
RTUs as field devices because they are more economical, versatile,
flexible, and configurable.

A telemetry system is typically used to connect PLCs and RTUs with

control centers, data warehouses, and the enterprise. Examples of wired
telemetry media used in SCADA systems include leased telephone lines
and WAN circuits. Examples of wireless telemetry media used in
SCADA systems include satellite (VSAT), licensed and unlicensed
radio, cellular and microwave.

Systems concepts

The term SCADA usually refers to centralized systems which monitor

and control entire sites, or complexes of systems spread out over large
areas (anything from an industrial plant to a nation).

Most control actions are performed automatically by RTUs or by 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 over all performance of the loop.
SCADA Applications

Supervisory Control and Data Acquisition (SCADA) Systems are

frequently used in Water and Waste Water Systems to monitor and
control tank levels, remote well pumps, lift station pumps, high service
pumps, valves, and chemical pumps.

SCADA Systems monitor a variety of plant data including flows, motor

currents, temperatures, water levels, voltages, and pressures. Alarms at
central or remote sites triggered by any abnormal conditions are
propagated to the HMI computer for operator's attention. In addition to
alarms, important plant information such as, levels, flows, pressure will
be logged in the HMI computer database for reports and trends.

We have thousands of active remote telemetry sites monitoring and

controlling equipment via radio, telephone, and cellular systems. We
manufacture a complete line of RTU's, CTU's, and control components.
We handle the complete system: from the central computer and software
to the pump controls and treatment plants.
Following are the SCADA Applications:
Water Distribution
Water Treatment
Waste Water Treatment
Pump Stations
Elevated Storage Tank automation
Water Well
Alarm Screen
Programming and HMI Software
System Reports
Trends
Water Distribution

The SCADA Communication network is spread throughout the water

distribution system to monitor parameters such as tank levels and system
pressure. Workstations, which are typically PC-based and located in a
control or operations room at a treatment plant, allow operators to view
the entire process and perform control actions.

With in the plant, process controllers or programmable logic controllers

(PLC's) supervise unit processes, such as chemical treatment,
sedimentation, and filtration. A local area network (LAN), such as
Ethernet, links the controllers to the workstations as well as to one
another.

Water Treatment
Based on the type of water treatment plant, surface water treatment vs. a
well system, the automation process can get quite involved. Control
Systems has done countless jobs of both types.

Our systems are far superior to others. We have done surface water
treatment plants that involve drawing water from river, filter the raw
water using bar screens, then enters sedimentation where water is mixed
with various chemicals to get the dirt out of the water then the settled
water is fed through the filters and to the clear wells. Various chemicals
are mixed at various stages of the process.

Our systems provide the operator with the luxury of backwashing the
filters automatically based on the hours it is in service or based on the
amount flow that has been through the filter.

In a well based water treatment plant, we provide the operator with a

host control matrix system that allows him to designate a tank as a
controlling tank and all the wells should run or stop based on the level in
that tank. Wells can be grouped and a group of wells can be started and
stopped from the HMI computer by the operator with the click of a
button or by the selected tank. Well groups can be alternated based on
first-on-first-off or all stop algorithms. Our graphics are very easy to
understand by the operator with minimal computer skills and knowledge
of the water treatment process.
Waste Water Treatment

Control Systems has done quite a number of waste water treatment

plants including sequential batch reactor based, traditional lagoon based,
and clarifier based. We have done it all. We measure all the parameters
at each step of the way, process the parameters based on the set criteria
by the operators, and control the process 24x7. We generate alarms
appropriately and inform the operator of any abnormal conditions in the
system via a dialer or on the HMI system.

Lift Station

Control Systems Duplex Controller DC201B combines duplex controls

with a built-in Lift-Station Analyzer, Remote Telemetry Unit and
optional data logging capability. The controller normally operates on
120 VAC but can also operate on +12 VDC. The controller is panel
mounted with a separate backplate mounted terminal board for field
contacts. Automatic motor alternation is provided along with
Manual/Off/Auto switches for each motor and a Lead-Pump selector
switch. Variable time delays are provided for motor failures. Alarm
indicators and outputs are provided for motor failure, seal failure, high
level and auxiliary alarms. All inputs are optically isolated and operate
on +15 VDC. Integral RTU functions and optional Float Test (FT201)
and Alarm Telemetry boards (DCAT-E) make this a very versatile
system.

Remote Telemetry features include industry standard communications

protocols, user-selectable unit number and baud rate, and RS232 and
RS485 serial ports for interfacing to System Control and Data
Acquisition (SCADA) systems via telephone or radio modems. A Dallas
Semiconductor 1-wire communications option board may be added for
communications to I-button security badges. An optional LCD operator
interface can also be used for stand-alone units or for temporarily
viewing statistics locally. Four (4-20ma dc) analog inputs are standard
for RTU transmission: one for tank level and three others for any desired
input to the SCADA system.

This multifunctional unit also includes CSIs Lift-Station Analyzer

algorithms which track vital duplex lift-station statistics including
influent flow rate estimation and totalized flow, water level, pump
runtimes and capacities, which are calculated on each fill and draw
down cycle.

Pump Stations
Graphical display screens indicating status of pump stations. A pump
station screen typically show the instantaneous station flow, wet well
level for waste water pump stations, pump run times, pump starts, pump
status such as running, failed, off, forced on and forced off, pump start
position, power status, generator status etc.

For Variable Frequency Drive (VFD) pumps, the screen also shows
VFD speed and other VFD setpoints.

Elevated Storage Tank Automation

An elevated storage tank automation typically involves taking the water

tank level via 4-20 ma analog input using submersible level transducer
and controlling well pump(s) to fill the tank as needed. The operator can
enter well start and stop setpoint via a locally installed operator interface
(OIT) or remotely from the SCADA computer.

He can also enter tank low water level alarm and tank high water level
alarm setpoints. The RTU at the tank site reads inputs and controls the
outputs by calling the well pumps based on the set setpoints. If the water
level in the tank crosses the alarm conditions then an alarm is generated
appropriately and operator will be informed via a dialer, If one is
available or on a SCADA System.

In a multiple well system, operator can enter lead well start and stop
setpoint and lag well start and stop setpoint. When the level drops below
lead well start setpoint, the tank controller calls for the lead well pump
to run. If the level reaches stop setpoint, lead well will be stopped. On
the other hand, upon calling the lead well, if the level continue to drop
and reaches below lag well start setpoint, lag well will be called to run.
Both well pumps continue to run until the tank level reaches stop
setpoint, at which both well pumps will be turned off.

Water Well

A well automation involves reading the inputs such as flow, pressure,

motor current and optional chemical residuals, well switch status, Hand-
Off-Automatic, calculating statistics such as pump starts, runtimes,
controlling outputs to run the well pump, optional chemical pumps. Each
well RTU has setpoints to for generating high and low alarms for high
flow, low flow, high pressure, low pressure, high current, and low
current alarms. It also generates pump failure alarm if the pump failed to
run in a set period of time after being told to run.

In the event of a communication failure with the tank, our RTU runs a
smart internal algorithm that turns on and off the well pump to prevent
the tank from running empty. If interested, call us for more on this.

In addition to its local operation, the RTU is responsible for

communicating its state to the SCADA system computer, if available.