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A TECHNICAL PAPER

ON

“SCADA” TECHNOLOGY

M.Lakshmi Prasanna A.Gayatri


Sri Sai Institute of Technology and Sri Sai Institute of Technology
Science and Science
Rayachoty Rayachoty
Kadapa Kadapa
lakshmi_jayamdevi@yahoo.co.in pydirama_ece@yahoo.co.in
ABSTRACT:
SCADA is a computer system for gathering and analyzing “real time
data”.SCADA system are used to monitor and control a plant or equipment in industries.
Introduction of SCADA –SCADA systems have made sustainable progress over the
recent years in terms of functionality, performance.
Evolution –Created sensaphone SCADA 3000 a Y2K-complaint hardware and software
system designed to accommodate in small to mid-sized companies.
The architecture of SCADA – hardware architecture and software architecture.
Functionality – alarm and event monitoring, data acquisition, operator interface, non real
time control, Data bases and data logging, use of MMI, logging/archiving, report
generation, automation.
Development with the help of SCADA –Rapid expansion in communication systems
and increase processing power available at site.
Operation – operation of SCADA with remote telemetry unit.
Applications of SCADA –waste water control and monitoring petroleum and
hydrocarbon processing, power generation, food processing, steel manufacturing,
Remote tele-communication and plant machinery maintenance.
Case study –Updating SCADA system at power plant for increased capability and
reliability.
Advantages and disadvantages – The advantages and disadvantages in using “SCADA”
technology.
Developments in SCADA –Tecnomatix technology, Schneider electric’s new
telemecanique brand.
Conclusion –purpose of using SCADA systems which reduce down time; increase
throughput; limit the frequency of accidents; improve record etc;
SCADA –SUPERVISORY CONTROL AND DATA ACQUISITION:
SCADA stands for Supervisory Control and Data Acquisition. As the name
indicates it is not a full control system, but rather focuses on the supervisory level. As
such, it is purely software package that is positioned on top of hardware to which it is
interfaced, in general via Programmable Logic Controllers (PLC’S), or other commercial
hardware modules. Contemporary SCADA systems exhibit predominantly open-loop
control characteristics and utilize predominantly long distance communications, although
some elements or closed-loop control and/or short distance communications may also be
present. It is process control software that remotely gathers “real time data” used in
manufacturing to acquire measurements of process variables and machine states, and for
performing regulatory or machine control. SCADA is used by the energy industry,
telecommunication industry, transport industry, and water and waste control industry.
SCADA –is also called supervisory control and data acquisition system or
supervisory control and data acquisition software.

INDRODUCTION
Widely used in industry for Supervisory Control and Data Acquisition of
industrial processes, SCADA systems are now also penetrating the experimental physics
laboratories for the controls of ancillary systems such as cooling, ventilation, power
distribution, etc. More recently they were also applied for the controls of smaller size
particle detectors such as the L3 muon detector and the NA48.
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.

EVOLUTION:
Phonetics created the SENSAPHONE SCADA 3000, a Y2K-complaint hardware
and software system design to accommodate small to mid-size companies seeking
SCADA control. The system main unit uses two microprocessors to perform all control
and communication functions. In terms of hard ware, the standard SENASAPHONE
SCADA 3000 is equipped with 16 universal inputs, eight relay outputs, two RS-232 ports
for local programming and radio communications, and a four line by 20-characters LCD.

WHAT DOES SCADA MEAN?


SCADA stands for Supervisory Control and Data Acquisition, it is a computer
system for gathering and analyzing “real time data” SCADA systems are used to monitor
and control a plant or equipment in industries.
SCADA systems are used not only in industrial processes: e.g. steel making,
power generation (conventional and nuclear) and distribution, chemistry, but also in some
experimental facilities such as nuclear fusion. The size of a plant ranges from few 1000 to
several thousand to 10 thousand input/output (I/O) channels. 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:
1. Hardware Architecture:
One distinguishes two basic layers in a SCADA system: the “client layer” which
caters for 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 which are connected to data servers.

Figure 1: TYPICAL HARDWARE ARCHITECTURE


2. Software Architecture
The products are multi-tasking and are based upon a real-time database (RTDB)
located in one or more servers. Servers are responsible for data acquisition and handling
(e.g. polling controllers, alarm checking, calculations, logging and archiving) on a set of
parameters, typically those they are connected to.

figure2: GENERIC SOFTWARE ARCHITECTURE

FUNCTIONALITY:
1. Alarms and Event Monitoring:
A SCADA system must be able to detect, display, and log alarms and events. When
there are problems the SCADA system must notify the operators to take corrective action.
Alarms and event must be recorded so that engineers and programmers can review the
alarms to determine what caused the alarm and prevent them happening again. More
complicated 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, and multiple alarm
priority levels are supported.

2. Data Acquisition:
SCADA must be able to read data from PLCs and other hardware and then to
analyze and graphically present that data to the user. SCADA systems must be able to
read and write multiple sources of data.
3. Operator Interface:
A SCADA system collects all of the information about a process. The SCADA
systems then need to display this data to the operator so that they can comprehend what is
going on with the process.

4. Non Real Time Control:


For simple control requirements, the SCADA system should be able to control instead
of a PLC. For anything other than simplistic control we prefer a PLC to do the real time
control with SCADA doing the non real time control. The SCADA system is the medium
between the operator and the real time controller.
5. Data Bases And Data Logging:
Most applications require recipes, data logging, and other means of reading and
writing databases. SCADA systems can log incredible amounts of data to disk for later
review. This is helpful for solving problems as well as providing information to improve
the process.
6. Use Of MMI:
SCADA uses MMI to present the data acquire from the process to allow the process
operation to be supervised e.g. start/stop or changing set points. SCADA provides MMI
functions such as: Mimics-a graphical representation of the process with dynamically up
dated values; Trends-graphs of variables against selected time periods; Reports-allows
process variables to be summarized on a period basis; Alarms-they also support the
concept of a “generic” graphical object with links to process variable’s.
7. Logging/Archiving:
Logging is the medium term storage of data on the disk, where as archiving is the
long term storage of data on disk or any other permanent storage medium. Logging of
data can be performed at a set frequency, or only initiated if the value changes or when a
specific predefined event occurs. The logged data is time stamped and can be filtered
when viewed by the user.

8. Report Generation:
One can produce reports using SQL type queries to the archive, RTDB or logs.
Although it is sometimes possible to embed EXCEL charts in the report. Facilities exist to
be automatically generated, print and archive reports.
9. Automation:
The majority of the products allow actions to be automatically triggered by events.
Scripting languages provided by the SCADA products allow these actions to be defined.
The concepts of receipts is supported, whereby a particular system configuration can be
saved to a file and then re-loaded at a latter date. Sequencing is also supported; it is
possible to execute a more complex sequence of actions on one or more devices.
Sequences may also react to external events.

DEVELOPMENT WITH THE HELP OF SCADA:


SCADA system were developed for gathering data from far and wide using poor
quality comms and providing and providing high levels of reliability and operability.
Given the rapid expansion of communication systems,(satellite, cellular, fiber, microwave
etc)and the increasing processing power available at site.
When the data gathering, integrity and validations requirements of SCADA can be
met by commonly used for IT systems, then there will be even further convergence.
SCADA system can be justified cost, but the really big payoff is to reduce the
capital investment. In many cases the applications that run at that level are becoming
more important than the user stuff. However applications like batch tracking and leak
detection are SCADA advantages.

OPERATION OF SCADA:
Supervisory control and data acquisition (SCADA) technology collects real-time
data from virtually any environment where there is a need to monitor machinery or
processes, make adjustments based on measurable conditions, measure down time, or
regulate processes to avoid costly problems. The computer-based technology was
designed to do all the things with little human involvement.
From a central reading location, a SCADA system can monitor a number of
remote sites equipped with RTUs. The RTUs measures various conditions and
parameters, including tank levels, temperature, voltage, current, volume, and flow. The
unit reports the data back to the CPU, carrying out the necessary analysis and cost
functions.
Additionally, SCADA technology personal of current or potential alarm
situations, allowing an operator to and fine tune a process. Control can be automatic or
initiated by operator commands, based on the sophistication of the individual system. The
technology is widely accepted as a reliable and efficient control system within numerous
industrial markets.

APPLICATION OF SCADA:
A typical SCADA application requires several low cost distributed RTUs,
controlled by a central station/master.
Common applications for SCADA systems typically include water and waste
treatment, petroleum and hydro carbon processing, power generation, food processing,
steel manufacturing, remote telecommunications and plant machinery maintenance.
Unlike in plant process control systems, SCADA systems typically include a
remote telecommunication link. Real-time measurements and controls at remote stations
are transferred to a CPU through the communication link. Large systems can monitor and
control 10-2000 remote sites, with each site containing as many as 2000 I/O points.
A SCADA system for small applications:
SCADA is not a new technology by any means, but innovations and significant
improvements have been made since its introduction. Until recently, SCADA technology
was often viewed as a luxury item by small industrial companies. The technology was
deemed unobtainable because of high association with that systems could not be fully
used because of their massive I/O capacities.

CASE STUDY:
UPDATING SCADA SYSTEMS AT POWER PLANTS FOR INCREASED
CAPACITY, RELIABILITY.
Companies have long monitored and controlled electric power generating
operations using computer-based Supervisory Control and Data Acquisition systems.

Power pumped storage station:


Many power plants are brought on-line and continue to run uninterrupted until
maintenance is required. It is a pumped storage hydroelectric plant, designed specifically
to help the power plant meet peak demand. Pumped storage is the most economic method
of doing so.
The older computer system at the plant was sufficient for monitoring the plant-just
barely. It was operating at near capacity. It did not allow the collection and graphic
display of data. Therefore the company upgraded the computer system with
MODCOMP’s REAL/IX PX operating system a real time implementation of UNIX that
runs on Intel-based platforms. The power plant has more computing power and greater
flexibility to upgrade in the future because the SCADA system now uses industry
standard hardware and software systems.
Defining Goals, System Design:
Power plant began the process of upgrading its SCADA systems with a number of
broad goals. Those include:
 Migrating to standard, open systems with a long useful life.
 Maintaining existing user interfaces whenever possible.
 Permitting future expansion without performance degradation.
 Utilize the existing I/O infrastructure to contain costs.
The new system runs on two Intel-based host servers, one that is the primary system
and other is the secondary backup and the information source. In case of hardware failure,
plant operators can fail over to the secondary servers. Eight RTUs are connected to the
servers. Each of the six generators is monitored by the independent RTUs. The RTUs
communicate with the host servers over a dual-redundant fiber optic TPC/IP network.
The new system is far more responsive.

Migrating to Open Systems:


The power plant first goal for the new system was to migrate to standard open systems.

The new systems use Intel-based computers running the REAL/IX PX operating system.
The UNIX operating system platform is compactable with a number of third party
programs that power plant can integrate into its SCADA or reporting systems at the later
date.

Maintaining User Interfaces, functionality:


The important requirement was to minimize the impact of the changeover on daily
operations and the need for re-training. Existing applications software functionality was
also migrated into the new SCADA package. The original 10000-point database, with
6500 digital inputs and 3500 analog inputs, was imported into the new software.
Utilizing Existing I/O, Leaving Room to Grow:
The major challenges for SCADA systems are to keep the majority of the I/O
infrastructure and to reduce the cost of the system by interfacing the existing MODACS
interface over the new system. The important feature of the SCADA system is its
scalability. Secondly, the REAL/IX PX operating system ensures that the systems will
continue to run in real time.
New Capabilities:
As the part of the upgrade the power plant wanted to interface its real-time control and
data with a data acquisition system with a data historian, creating a historical database for
later analysis. Another new capability is remote access for maintenance. System
engineers from MODCOMP can dial in to the system, diagnose many problems remotely
and fix them. One can expect to see wide scale integration of SCADA and Geographic
Information systems (GIS). With GIS, SCADA base users can integrate with real time
data to pin point a disruption of service. It will make power companies more productive
in determining where faults are located.

ADVANTAGES AND DISADVANTAGES OF SCADA TECHNOLOGY:


Advantages of SCADA system include Wide area connective and pervasive;
routable; parallel polling; redundancy and hot stand by ; large addressing ranges;
integration of I.T to automation and monitoring net works; standardization; reduce down
time; limit the frequency of accidents; improve record; increase through put.
Disadvantages of SCADA Technology include IP performance over head; web
enabled SCADA hosts users to remotely monitor, control remote sites via a web browser;
security concerns.
DEVELOPMENTS IN SCADA:
SCADA 3000 was released to five beta sites for testing and evaluation. As a
result of testing Phonetics has added several features such a additional ladder and C
program functions.
Tenomatix technologies new product is eM-Insight, a data source neutral
tolerance management and statistical process control product that helps manufacturing
companies share and distribute parts inspection data throughout the organization.
Schneider Electric’s new Telemecanique brand Unity plat form of PLC processors
and automation software provide new tools designed to enhance productivity.
As far as new technology is 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 be possible to connect OPC complaint third party modules to
the SCADA products.

ENGINEERING:
The need for proper Engineering cannot be sufficiently emphasized to reduced
development effort and to reach a system that complies with the requirements, that is
economical in development and maintenance and i.e., reliable and robust. The
Engineering activities specific to the use of a SCADA system includes templates for
different types of panels; Instructions on how to control; a mechanism to prevent
conflicting controls; alarm levels, behavior to be adopted in case of specific alarms.
CONCLUSION:
SCADA systems are used to monitor and control a plant and equipment in
industries. The benefits one can expect from adopting a SCADA system a rich
functionality and extensive development facilities. The systems are used to mission
critical industrial processes where reliability and performance are paramount. These
systems are used to gather and analyze “real time data”.
REFERENCES:
www.marineeng.com/scada.
www.modcomp.com/scada/virgina_power.html.
www.electronics_x.com/electronic/waste water.html
www.modular-scada.co.uk/what -is-scada.html
www.electronics.com/power generation/scada.html
Under the Guidance of Chinna Subbanna.
A.Daneels, W.Salter, “technology survey summary of survey report.

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