Department of Engineering Physics ITB 11 April 2003

PRINCIPLES &
PRACTICAL DESIGN of
SCADA SYSTEM
Department of Engineering Physics
Institut Teknologi Bandung
11 April 2003

Concept and Architecture of SCADA Systems 1-1

 Department of Engineering Physics ITB 11 April 2003

Overview of
SCADA Systems

Department of Engineering Physics

Institut Teknologi Bandung
11 April 2003

Concept and Architecture of SCADA Systems 1-2

 Department of Engineering Physics ITB 11 April 2003

SCADA Terminology
 SCADA is an acronym for Supervisory Control and
Data Acquisition
 Data Acquisition :
Gathers information from widely distributed
processes
 Supervisory Control :
Calculate and give limited control instructions to
distant process facilities

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 Department of Engineering Physics ITB 11 April 2003

Terms & Terminology

 Field Instrumentation
 Data Acquisition
 Control Loop
 Supervisory Control
 Remote Terminal Unit (RTU)
 Master Terminal Unit (MTU)
 Communications Equipment

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 Department of Engineering Physics ITB 11 April 2003

Data Acquisition
Device Status

PROCESS
valve status (open/close)
sw itch position (on/of f)
pump (start/stop)

FIELD- INTERFACE
Variables
pressures
f low rates
temperatures
tank levels

Alarms
Low Tank Level Alarm
High Tank Level Alarm
Fire Alarm

Concept and Architecture of SCADA Systems 1-5

 Department of Engineering Physics ITB 11 April 2003

Data Acquisition on an ESP System

Load
Current (A)

ESP Compensator
Pressure (Mpa)
Line
Frequency (A)
Intake
Pressure

Intake
Vibration (Hz) Temperature (oC)

Current
Leakage (A)
Motor Winding
Temperature (oC)

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 Department of Engineering Physics ITB 11 April 2003

Types of Field Devices

 Conventional  Fieldbus based
• 4-20 mA analog signal • Microprocessor and
• Discrete status (0/1) embedded system
• Point-to-point configuration technology
• Dedicated wiring for each • Digital signal
devices • Point-to-point or point-to-
multipoint
• Simplified wiring, drawings,
and control engineering
Conventional 4-20 mA Fieldbus • Embedded control algorithm
I/O
Modules
Bridge • example :
 Foundation Fieldbus
Transmitter
 Profibus Transmitter
 HART transmitter

Concept and Architecture of SCADA Systems 1-7

 Department of Engineering Physics ITB 11 April 2003

Control Loop

P&ID
ON-OFF
Sequential
Fuzzy Logic
Neural Netw ork
Set Point
Process
Manipulated Variable
 Temperature
Variable  Pressure
 Flow rate CONTROLLER  Level
 Heat in  Flow rate

Actuator Sensor

PROCESS
input output

Concept and Architecture of SCADA Systems 1-8

 Department of Engineering Physics ITB 11 April 2003

Example : Flow Control Loop

 Objective :
• maintain flow rate at a desired value (set point)
 Control elements :
• Sensor : Flow Transmitter
• Controller : PLC (PID)
• Actuator : Control Valve

Concept and Architecture of SCADA Systems 1-9

 Department of Engineering Physics ITB 11 April 2003

Supervisory Control
 Set point management for several control loops
 Optimization to achieve “the best operating point”
 Use advanced control algorithm
• cascade controller
• ratio controller Supervisory Control

• override control Se t Point 1 Se t Point 2 Se t Point 3

• etc
CONTROLLER

Actuator CONTROLLER
Sensor

CONTROLLER
PROCESS
Actuator Sensor

LOOP #1
PROCESS
Actuator Sensor

LOOP #2
PROCESS
LOOP #3
Concept and Architecture of SCADA Systems 1-10
 Department of Engineering Physics ITB 11 April 2003

Goals to Achieve
 Technical :
• Safety
• Increased productivity
• Equipment protection and maintenance
• Operational optimization
• Energy saving
• Immediate access to inventories, receipts, deliveries, etc.
 Economical :
• Plant-wide optimization
• Optimization of personnel utilization

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 Department of Engineering Physics ITB 11 April 2003

Applicable Processes
 Widely distributed processes; spreading over large
areas
 Require frequent, regular, or immediate intervention
 High cost of routine visits to monitor facility operation
 Examples :
• Oil and gas production facilities
• Pipelines for gas, oil, chemical, or water
• Electric power transmission system
• Railroad traffic
• Feed water purification plant
• Building automation

Concept and Architecture of SCADA Systems 1-12

 Department of Engineering Physics ITB 11 April 2003

SCADA System Architecture

RTU
01 transducers/
transmitters

Enterprise Network Modem

RTU
02 transducers/
transmitters

Modem
Plant Level Network
Engineer (Supervisory)
Station Modem
RTU
03
Modem

Modem transducers/
Manager transmitters
Station
MASTER TERMINAL Radio
Radio
UNIT (MTU) Field Device Network
RTU
Database 04
Server

Modem transducers/
transmitters

Radio

Concept and Architecture of SCADA Systems 1-13

 Department of Engineering Physics ITB 11 April 2003

Remote Terminal Unit (RTU)

 Placed at remote plant location
 Integrated with instrumentation and
control systems (PLC or DCS)
 Functions :
• Gathers information from the field
• Send the information to MTU
• Process the supervisory control
instruction from MTU

Concept and Architecture of SCADA Systems 1-14

 Department of Engineering Physics ITB 11 April 2003

Communications
Windows 3.1
Windows-95
Windows NT Business Management
Client Applications

Windows NT
Operator Console
RT/History Data
Server

Windows NT Windows NT Plant Highway

Operator Console RT/History Data
Server

Plant Highway

Process Management
Controller

Fieldbus

Fisher
PD Meters Analytical
Measurement Common Head -Simple -Analog I/O Handheld
Coriolis Configuration and
-Pressure -Complex -Discrete I/O PDA
Valves -TC/RTD Maintenance
-Temp
Positioners
-Flow
-Level Field Management

Concept and Architecture of SCADA Systems 1-15

 Department of Engineering Physics ITB 11 April 2003

Actuator/Sensor Level Device Network

 Analog signals of the Field Level
conventional sensors and  Intelligent field devices are
actuators are transmitted via configured in multidrop/bus
two-wire cable topology
 One dedicated two-wire cable is  Single or multi-master mode is
required for each supported
sensor/actuator
 The numbers of field devices in
 Analog-to-digital and digital-to- a field level network is limited
analog converters are required
to enable interfacing  Interoperability issue
and communications
with other
intelligent devices
(programmable
controllers,
smart transmitter,
fieldbus devices)

Concept and Architecture of SCADA Systems 1-16

 Department of Engineering Physics ITB 11 April 2003

Corporate/Enterprise Network
 Ethernet
 TCP/IP
 Corporate Applications
• Real time asset management
• Business support
• Marketing & sales
• Procurement
• Manufacturing
• Distribution
• Data warehouse

Concept and Architecture of SCADA Systems 1-17

 Department of Engineering Physics ITB 11 April 2003

Master Terminal Unit (MTU)

 Customized configuration for each applications
 Connected to Local Area Network (LAN)
 Equipped with auxiliary devices (data storage,
console, pointing devices, etc)
 Functions :
• Collect process information from RTUs and share the
information on the LAN
• Online operator interface (MMI)
• Send supervisory control instruction to RTUs
• Alarm management
• Report generation
• System security
• Central data processing
Concept and Architecture of SCADA Systems 1-18
 Department of Engineering Physics ITB 11 April 2003

Man Machine Interface (1)

In the beginning…

 The plant floor was simple,  Control information was not

unsophisticated available

 The customers were patient

Concept and Architecture of SCADA Systems 1-19

 Department of Engineering Physics ITB 11 April 2003

Man Machine Interface (2)

Quick…fast forward to 2000

 Companies and the world are  Customers are Internet savvy

linked by computers and want faster service, better
quality

 Businesses must make changes to

remain competitive

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 Department of Engineering Physics ITB 11 April 2003

Man Machine Interface (3)

What is your plant doing?
Is your equipment running? Is it down? Why?
How long does it take to MONITOR critical values on
the production line?
Can you easily ANALYZE information about your
process?
Can you CUSTOMIZE your application to provide you
with the exact information you want?
Do your operators have CONTROL over the plant
floor?

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 Department of Engineering Physics ITB 11 April 2003

Man Machine Interface (4)

Visualization…

Concept and Architecture of SCADA Systems 1-22

 Department of Engineering Physics ITB 11 April 2003

Man Machine Interface (5)

 Provides human access to field automation system
(Process Visualization)
• Operational
• Maintenance & troubleshooting
• Development
 Function :
• Communicates with field I/O from Programmable Logic
Controllers (PLCs), Remote Terminal Units (RTUs), and
other devices.
• Gives up-to-date plant information to the operator using
graphical user interface
• Translates operator instruction into the machine
• Engineering development station
• Operator station

Concept and Architecture of SCADA Systems 1-23

 Department of Engineering Physics ITB 11 April 2003

Man Machine Interface (6)

In the beginning…

 The plant floor was simple,  Control information was not

unsophisticated available

 The customers were patient

Concept and Architecture of SCADA Systems 1-24

 Department of Engineering Physics ITB 11 April 2003

Man Machine Interface (7)

 Plant information :  Presentation Method :
• Process Variables • Graphics Trending
• Device status • Charts
• Alarms • Reports
• Control Loops • Animation
• etc • etc
 Equipment :
• Keyboard
• Mouse or other pointing
devices
• Touchscreen or CRT
• etc.

Concept and Architecture of SCADA Systems 1-25

 Department of Engineering Physics ITB 11 April 2003

System Database
 Store historical process information
for engineering, production,
Business maintenance, and business
Applications
Statistical purposes
Process
Control  Features :
• Engineering units conversion
Process • Analog value filtering
Visualization
• Value limit checking
Realtime
 Standardized Data Structure
Database
• Analog point structure
• Status point structure
Engineering • Accumulator point structure
Workstation
• Container points
• User defined structure
 Each point in the database has a
Batch number of associated parameters,
Process
Asset
Management
Management all of which can be referenced
relative to a single tag name

Concept and Architecture of SCADA Systems 1-26

 Department of Engineering Physics ITB 11 April 2003

Industrial Automation & Integration

OPC

Concept and Architecture of SCADA Systems 1-27

 Department of Engineering Physics ITB 11 April 2003

OLE for Process Control (OPC)

 Object Linking and Embedding (OLE) for Process
Control
 A standard for process automation (SCADA)
communications
 A standard software mechanism for sharing data
between process automation (SCADA) of different
manufacturers
 OPC is based on Microsoft OLE (Object Linking and
Embedding) and DCOM (Distributed Component
Object Model)

Concept and Architecture of SCADA Systems 1-28

 Department of Engineering Physics ITB 11 April 2003

The Goal of OPC Design

 Provides a standard mechanism for communicating
to numerous data sources
 The data source could be either devices on the
factory floor (field devices), or a database in a control
room
 OPC advantage :
• Simple to implement
• Flexible to accommodate multiple vendor needs
• Provide a high level of functionality
• Allow for efficient operation

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 Department of Engineering Physics ITB 11 April 2003

System Configuration Before OPC

Display Trend Report

Application Application Application

Software Software Software Software

Driver Driver Driver Driver

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 Department of Engineering Physics ITB 11 April 2003

System Configuration Using OPC

Display Trend Report

Application Application Application
OPC OPC OPC

OPC OPC OPC OPC

Software Software Software Software
Driver Driver Driver Driver

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 Department of Engineering Physics ITB 11 April 2003

Before and After OPC

Concept and Architecture of SCADA Systems 1-32

 Department of Engineering Physics ITB 11 April 2003

Vendor Benefits
 Past:
Client application vendors had to develop a different
driver for each control device.

 Now:
The OPC standard provides the greatest benefit to
client vendors in that they only have to develop one
driver to access data from a process control device

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 Department of Engineering Physics ITB 11 April 2003

End-User Benefits (1)

 Enables to choose the application that best meets
their needs.
 Any OPC compliant client application can interface to
a control device.
 User gets the best solution for a particular task.
 Lower integration costs and risks.

Concept and Architecture of SCADA Systems 1-34

 Department of Engineering Physics ITB 11 April 2003

End User Benefits (2)

 More spending time on the final integration goal and
less time developing custom drivers.
 Since the solution is based on standard OPC
components rather than custom drivers, the project
risk is lower.
 This interface to Visual Basic and VBA provides
access to process data for those who are skilled in
these tools.
 Spreadsheet report generation is easily
accomplished through the use of a VBA macro

Concept and Architecture of SCADA Systems 1-35

 Department of Engineering Physics ITB 11 April 2003

Plant-Office Data Integration

 Networking has been successfully
implemented from field device
level up to management level.

Office
Business
 Data can easily be interchanged Applications
Statistical
Process
between applications in the same Control

computer or different computers Asset

Management
over a network.
Realtime Dynamic Data Exchange
 SCADA system can give an OLE for Process Control
Database
immediate response needed from
field device to management

Plant
system. Engineering
Workstation
 Real-time plant information can be
transferred to office application.
Batch
 Corporate information system Process
Visualization
Process
Management

must be designed to meet its

business process.

Concept and Architecture of SCADA Systems 1-36

 Department of Engineering Physics ITB 11 April 2003

Web-based Process Monitoring

 Internet browser as an acceptable MMI standard will minimizes
operator/user training by providing a familiar operating
environment
 Many visualization techniques are available (JavaScript, Java,
Shockwave/Flash, etc)
 Extra development effort is not needed since SCADA supplier
software usually provide integrated web-based and application
specific MMI development
 Allows the users (e.g. : supervisor/manager) to monitors process
operation, documents and reports either in the Intranet or
Internet
 Secured network design is a must to avoid cyber risk such as
hacking attempts and virus

Concept and Architecture of SCADA Systems 1-37

 Department of Engineering Physics ITB 11 April 2003

Web Based Monitoring Example

Concept and Architecture of SCADA Systems 1-38

 Department of Engineering Physics ITB 11 April 2003

Summary
 SCADA is a two-way system : remote monitoring &
controlling
 Applicable to widely distributed processes
 Two way communication system is required
 Basic Elements of SCADA :
• Master Terminal Unit (MTU)
• Remote Terminal Unit (RTU)
• Communications Equipment

Concept and Architecture of SCADA Systems 1-39