18 EEE 308T ENERGY MANAGEMENT SYSTEM AND SCADA
UNIT 4
Session 1
(i). Introduction to SCADA
(ii) SCADA systems
(i). Introduction to SCADA
An Introduction to SCADA
The term SCADA stands for Supervisory Control And Data Acquisition. A SCADA
system is a common process automation system which is used to gather data from sensors and
instruments located at remote sites and to transmit and display this data at a central site for
control or monitoring purposes. The collected data is usually viewed on one or more SCADA
Host computers located at the central or master site.
A real world SCADA system can monitor and control hundreds to hundreds of thousands
of I/O points.
Common analog signals that SCADA systems monitor and control are levels,
temperatures, pressures, flow rate and motor speed. Typical digital signals to monitor and control
are level switches, pressure switches, generator status, relays & motors.
There is typically another layer of equipment between the remote sensors and instruments
and the central computer. This intermediate equipment exists on the remote side and connects to
the sensors and field instruments. Sensors typically have digital or analog I/O and these signals
are not in a form that can be easily communicated over long distances. The intermediate
equipment is used to digitize then packetize the sensor signals so that they can be digitally
transmitted via an industrial communications protocol over long distances to the central site.
There are five essential composing parts of a SCADA system:
● Human Machine Interface (HMI)
● supervisory system
● Remote Terminal Units (RTUs)
● Programmable Logic Controllers (PLCs)
● communication infrastructures
Field Devices for SCADA – RTU, PLC, IEDs, and Smartdevices
Typical equipment that handles this function are PLC’s (Programmable Logic
Controllers) and RTU’s (Remote Terminal Units). These devices employ de- facto standard
industrial data communication protocols such as Modbus, AB-DF1, and DNP3.0 to transmit the
sensor data. Typical physical interface standards are Bell 202 modem, RS-485 & RS-232.
The SCADA Host is usually an industrial PC running sophisticated SCADA MMI (Man
Machine Interface) or HMI (Human Machine Interface) software. This software is used to poll
the remote sites and store the collected data in its centralized SQL or Oracle database. Logic can
be configured in the SCADA Host software which then monitors and controls plant or
equipment. The control may be automatic, or initiated by operator commands.
Data acquisition is accomplished firstly by the RTU’s or PLC’s scanning the field inputs
connected to the RTU / PLC. This data is usually collected at a polling rate configured by the
operator. The polling rate is determined by the number of sites, the amount of data at each site,
the maximum bandwidth of the communication channel and the minimum required display and
control time.
Once the data has been acquired and sent to the SCADA Host, the MMI software will
scan the acquired data (usually at a slower rate.) The data is then processed to detect
present alarm conditions, and if an alarm is present, an alarm message will flash on the operator
screen and added to an alarm list. The operator must then acknowledge this alarm. There are 3
common types of data collected:
● Analog – used for trending
● Digital (on/off) – used for alarming
● Pulse (i.e. revolutions of some kind of meter) – accumulated /counted
Graphics Mimics
The primary operator interface is a set of graphical screens which show a representation
of the equipment being monitored. Real-time data is displayed numerically or graphically as
changing bars, circles, lines or other shapes over a static background.
As the acquired data changes in real-time, the bar, circle, line or other representative
shape is updated. For instance, an analog level increase may be displayed as a lengthening of the
representative vertical bar or a valve graphic may look open to represent that it is open. A typical
MMI will have a nested tree structure of many such screens, usually with the many overview
screen on the first page with the most relevant data displayed. There are then links that go to
other pages. Users can easily configure the type of I/O point, communication protocol driver,
polling rate, alarm thresholds and notifications, trend process data as well as configure the User
and Operator screens.
Next generation SCADA MMI software such as NetSCADA include all these functions
in one convenient easy to use and cost effective package and also have seamless internet
integration enabling many clients to securely view the collected data anywhere on the internet. A
flexible SCADA Host can easily expand to handle additional future remote sites and I/O points.
SCADA Communications
SCADA communications can employ a diverse range of both wired (lease line, dial-up
line, fiber, ADSL, cable) and wireless media (licensed radio, spread spectrum, cellular,
WLAN or satellite). The choice depends on a number of factors that characterize the clients
existing communication infrastructure.
Factors such as existing communications infrastructure, available communications at the
remote sites, data rates and polling frequency, remoteness of site, installation budget and ability
to accommodate future needs all impact the final decision. In complex SCADA architectures,
there can be a variety of both wired and wireless media and protocols involved to get data back
to the central monitoring site.
SCADA systems differ from DCS’s (Distributed Control Systems) which are generally
found in plant sites. While DCS’s cover the plantsite, SCADA systems cover much larger
geographic areas. Often SCADA Systems are required to interface to a plantsite DCS if there are
remote sensors, instruments or motors and pumps that must be controlled/monitored by the
plantsite DCS.
Wireless
Certain types of applications like those in Oil & Gas, Electrical & Water Utilities, Water
& Wastewater and Environmental Monitoring inherently require SCADA communications
because of the remoteness of the assets (i.e. Oil wells, water wells, generator stations).
Furthermore, due to the remoteness many of these often require the use of wireless
communications. In these cases, the traditional solution is to add a radio modem stage to the
standard SCADA architecture shown above.
Next generation Wireless SCADA equipment such as Bentek
Systems RIO900 or UNICON IP offers another level of integration by placing the wireless
communications and RTU functionality together in the same package.
In addition to this higher level of integration, next-generation SCADA equipment such as
the IP100 also support TCP/IP, UDP or other IP based communications protocols as well as
strictly industrial protocols such as Modbus TCP, Modbus over TCP or Modbus over UDP all
working over private radio, cellular or satellite networks. The IP100 can act as an Ethernet Serial
gateway to enable older legacy serial equipment to connect to TCP/IP networks. Coupled with
Host software such as NETSCADA, this enables implementation of powerful IP based SCADA
networks over mixed cellular, satellite systems and land line systems.
Session 2
(i). Evalution of SCADA
(ii) Objectives of SCADA
(i). Evalution of SCADA
Evolution of SCADA
● 1890’s Remote Control and Remote Indication
● 1920’s Tele-command and control
● 1930’s Check Before Operate (CEO)Systems, Based on Electro Mechanical Technology
● 1960’s Supervisory Control Systems (Remote Control & Status Indication)
● 1960’s Data Acquisitions gaming Popularity (DAS) SCADA came into being.
● 1980’s Load Dispatch Centre and Control
● 1990’s Energy Control Centre
● 2000’s Energy Management Systems
Objectives of SCADA
The important objectives of SCADA are to listed below:
1. Monitoring : Continuous monitoring of the parameters of voltage , current, etc..
2. Measurement: Measurement of variables for processing.
3. Data Acquisition: Frequent acquisition of data from RTUs and Data Loggers / Phasor
data Concentrators (PDC).
4. Data Communication: Transmission andreceiving of large amounts of data from field to
control centre’s.
5. Control: Online real time control for closed loop and open loop processes.
6. Automation:: Automatic tasks of switching of transmission lines, CBs, etc.
Session 3
(i). Benefits of SCADA
(ii) SCADA in process control
(i). Benefits of SCADA
Benefits of SCADA
The important benefits can be addresses as the following functions:
1. Continuous monitoring of process.
2. Real time control.
3. Automation and Protection.
4. Remote control and operation.
Functions of SCADA
The important functions of an SCADA are listed below.
1. Data Acquisition
2. Information Display
3. Supervisory Control
4. Alarm Processing
5. Information Storage and Reports
6. Sequence of Event Acquisition
7. Data Calculation
8. Special RTU Processing/Control
SCADA use cases and industry examples
SCADA is used to assist in automating and managing industrial processes that have
become too complex or cumbersome for human monitoring and control. SCADA is particularly
useful for processes that can be monitored and controlled remotely, especially in cases where it is
possible to reduce waste and improve efficiency.
Some common industry examples of SCADA industrial automation are the following:
● electricity generation and distribution;
● oil and gas refining operations;
● telecommunications infrastructure;
● transportation and shipping infrastructure;
● fabrication and other industrial processing;
● food and beverage processing;
● chemical manufacturing; and
● utilities infrastructure, including water and waste control.
With SCADA, these processes can be monitored closely and tweaked to improve performance
over time.
(ii) SCADA in process control
Supervisory control and data Acquisition (SCADA), or Distributed Control system
(DCS) are controlling production plants such as power, Oil & Gas, water and waste management,
etc. SCADA systems are also used by Process Industries including cement, paper and pulp,
petrochemicals, fertilizers, steel industries, and aluminium plants. Supervisory control and data
acquisition system is a system in which messages or commands are sent for the purposes of
operation and control of processes.
An example for process control by SCADA
A plant consists of three production units i.e. unit1, unit2, unit3. These three units’
operation is controlled by SCADA according to the product demand.
When the site’s temperature decrease the product demand may also decrease and so
system activate low demand alarm and turn off the respective plant.
When the temperature of all the sites is less, then the set point temperature or any one
of the single site temperature is greater than or equal to set point temperature. This is the
requisite. At this condition the SCADA will turn ON unit1 and turn off both the other Units
and system; the the low demand alarm will also be on.
When the any two sites temperature is greater than the set point temperature, then unit1
and Unit 2 will be turn ON automatically and Unit 3 will remain OFF; the system now will
activate the normal demand alarm.
When the all three sites temperature is greater than the set point temperature, then all the
units i.e. unit1, Unit 2 and unit3 will be turn ON automatically and system activate the over
demand alarm.
For this practical requisite SCADA program will be set. This process control will thus be
obtained by SCADA automatically without any human interface.
Like this, there are numerous processes and the SCADA can be suitably programmed to
perform each.
Session 4
(i).Usage of SCADA
(ii) Real time monitoring and control by SCADA
Real time monitoring and control by SCADA
Real-time monitoring is a technique that allows you to determine the current state of
queues and channels. The information returned is accurate at the moment the command was
issued.
A number of commands are available that when issued return real-time information about
queues and channels. Information can be returned for one or more queues or channels and can
vary in quantity. Real-time monitoring can be used in the following tasks:
● Helping system administrators understand the steady state of their system. This helps
with problem diagnosis if a problem occurs in the system.
● Determining the condition of the system at any moment, even if no specific event or
problem has been detected.
● Assisting with determining the cause of a problem in your system.
● With real-time monitoring, information can be returned for either queues or channels.
● You monitor a channel by issuing commands to ensure that the channel is running
properly. Before you can use some of the channel attributes, you must enable them for
real-time monitoring.
What are the benefits of real-time monitoring?
1. Network security
Real-time monitoring can help you or your IT department identify and resolve security problems
as soon as they arise. These issues can include unusual or suspicious traffic, unauthorized
requests or devices, cyberthreats, or any other potentially harmful behavior on your network.
2. Network performance
a. Bandwidth usage: If you are sending or receiving more data than you planned for, your
network pipe could get overloaded, which can impact overall performance.
b. Latency: This is the time between a request and response of data. Latency is more
important in some situations than others; for example, it’s very relevant when you’re playing
a real-time game.
c. Network availability/uptime: Knowing the actual uptime on your network allows you to
confidently advertise your service-level agreement.
d. Speed: The speed of your network will vary at any given point. Visibility into the speed
you are receiving versus the expected speed is important to maintaining good network
performance.
3. Incident response time
It is important for businesses to resolve incidents as soon as they arise, however big or
small they appear to be. For example, it may seem obvious to resolve a cyberattack or data
breach immediately, but even something as seemingly inconsequential as a slow-loading website
or an abundance of 404 webpages can severely impact your business. Monitoring your network
in real time can help you catch these incidents as soon as they occur and respond immediately.
“Faster incident response means faster mitigation, which means less loss to the company,”
VanIperen added.
4. Employee productivity
Monitoring your network can increase employee productivity. For example, using
real-time monitoring to optimize your network performance can enable your team to send
company emails, work on projects and collaborate with colleagues more efficiently. You can also
use real-time monitoring to track employee data transfer and protect any sensitive information
they may be working with.
5. Cost savings
Up-to-date knowledge on how your network is being used can ultimately save you
money. Instead of overspending on advanced software or unnecessary site speeds, you can gain a
bird’s-eye view of the exact technology and support you need. An optimized network can also
help you make money, primarily if you work in e-commerce.
Session 5
(i).Functions of SCADA
(ii) SCADA applications
Self Study. Earlier 4 sessions dealt with these two topics in depth.
Session 6
(i). SCADA hardware
(ii). SCADA hardware functions
SCADA hardware functions
1.
SCADA is an acronym that stands for Supervisory Control and Data Acquisition. It refers
to a system that collects data from various sensors at a factory, plant or in other remote locations
and then sends it to a central computer, which manages and controls the data. Figure 1 shows
typical hardware architecture A SCADA system includes signal hardware (input and output),
controllers, networks, user interface (HMI), communications equipment and software. The
SCADA provides real-time control and optimizes exploitation management systems.
2. RTU (REMOTE TERMINAL UNIT)
The RTU is installed at a remote location and collects data from PLCs, acting as data
concentrator. The SCADA Server request data from the RTU, which codes the data into a format
that is transmittable and then the RTU, transmits data to SCADA Server.
The RTU also collects information from the SCADA Server and implements processes
that are directed by the SCADA Server. The RTU is also equipped with input channels for
sensing or metering, output channels for control, indication or alarms and a communications
port.
3. CONNECTING MULTIPLE RTU
In order to connect multiple RTU or other instruments to the SCADA Server trough serial
port, a new BUS is needed. A RS 485 serial line allows multiple devices connection. The
SCADA Server has only RS-232 interface, so a serial data converter RS-232/RS-485 is required.
Figure 3 shows a typical hardware architecture using multiple RTU.
4. REDUNDANCY
For increasing the integrity of the system, multiple servers are occasionally configured in
hot-standby or dual-redundant formation, providing monitoring and continuous control during
server failure. For increasing integrity of field bus, dual RTU in master slave configuration and
redundant field bus is used. If the plant processes are critical, or the downtime costs are high,
redundancy must be incorporated into the system to eliminate failures caused by equipment
failure. Figure 4 shows a typical hardware architecture using dual redundant server and dual
RTU in master slave configuration.
5. MULTI DROPPING
In many cases, the RTU and other instruments are RS-232 interface equipped. In this
case, each of them has to be connected through RS-232/RS-484 serial data converter in order to
connect all devices in the same bus. Finally, even the SCADA Server has to be connected
through serial data converter R-S484/RS232. Instead of using many serial data converters, using
a multi-dropping system is a better solution. The multi-dropping system allows more than one
devices to share a RS-232 common serial (see Figure 5)
Session 7
(i). RTU standards
(ii). Difference between RTU and PLC
(i). RTU standards
RTUs are primarily stand-alone data acquisition and control units. A typical RTU
configuration is shown in Figure below, which includes the hardware modules such as
control microprocessor and associated memory, analog inputs, analog outputs, counter inputs,
digital inputs, digital outputs, communication and I/O interfaces, power supply, together with an
RTU rack and enclosure. Small RTUs generally have fewer than 10 to 20 analog and digital
signal inputs; medium-sized RTUs have 100 digital and 30 to 40 analog signal inputs. Any RTU
with more signal inputs than this is referred to as large.
RTUs are used to convert electronic signals received from (or required by) field
instrumentation into (or from) the communication protocol that is used to transmit the data over a
network. RTUs appear in the field as a box in a switchboard with electrical signal wires running
to field instrumentation and a cable linked to a communication channel interface, such as a
telephone cable, a field bus, or a radio.
The instructions for the automation of field data interface devices are usually stored
locally since the limited bandwidth typical of communication links to the SCADA central host
makes central storage impractical. Such instructions are traditionally held within local electronic
devices known as programmable logic controllers (PLCs), which have in the past been physically
separate from RTUs. PLCs connect directly to field instruments and incorporate programmed
intelligence in the form of logical procedures that will be executed in the event of certain field
conditions. More recent systems have no PLCs and local control logic is held within the RTUs,
or in relay logic in the local switchboard.
Modern RTU is modular architecture with advanced capabilities to support data
processing functions. Modern RTU modules include expandable analog input/output, digital
input/output points, accumulated input units, and communication cards with power supply. The
SCADA for substation automation has the option of installing one RTU in one cabinet with
connections to the substation and number of slave RTUs at different locations within the
substation and connected to the master RTU with fiber-optic communications.
The modern RTU can accept AC inputs from a variety of measurement (digital meter)
and protection devices (digital relays) through a serial port. The RTU can take the measurements
as hardwired from CT, potential or VT, station service transformers, and transducers.
The RTUs shall be designed in accordance with applicable International Electro-
technical Commission (IEC), Institute of Electrical and Electronics Engineer (IEEE), American
National Standards Institute (ANSI), and National Equipment Manufacturers association
(NEMA) standards, unless otherwise specified in this Technical specification. In all cases the
provisions of the latest edition or revision of the applicable standards in effect shall apply.
(ii). Difference between RTU and PLC
Comparison Table Between PLC and RTU
Parameters of Comparison PLC RTU
Full-Form Programmable Logic Controller Remote Terminal Units
Suitable For Local control Wider geographical telemetry
Cost Cheaper More expensive
Tools Used IEC 61131-3 Alternate proprietary tools
Processing Local processing Little to no processing
“RTU” stands for “Remote Terminal Units.” It is also referred to as “Remote Telemetry
Unit”; “PLC” stands for “programmable logic controller.”
RTUs are considered more suitable for wider geographical telemetry, the reason being that
RTUs use wireless communication; PLCs are more suitable for local control, for example, for
assembly lines in factories, light fixtures, amusement rides, etc. PLCs are specially designed for
output arrangements and multiple inputs. They have electrical noise immunity, vibration and
impact resistance, varied temperature ranges, etc.
Ruggedness
RTU is far more rugged and resistant to harsh environmental conditions and attacks than a PLC.
RTU is specifically designed for remote IO applications where the IO’s are distributed far in the
plant and data needs to be transferred in a wireless manner. So, it is more rough and tough to use
and has more efficiency than a PLC.
Also, since they are located in remote areas; where even power supply is distinct; they can run on
solar power or batteries many times. They even have less energy consumption than a PLC. The
geographic telemetry of RTU is widely spread than a PLC.
Communication Speed and Data Transfer
The speed of data transfer is faster in a PLC than in an RTU. Also, all the process data and
programming data will be communicated in a PLC.
But, in RTU, only requested data and changes in it will be communicated. Basically, in a PLC,
the programs are driven in a cyclic manner, and in an RTU, the programs are driven in an event
manner (trigger-based).
Operating Voltage
A PLC works on 24V DC or 230V AC, but an RTU works with any process voltage.
IO Control
RTU is generally not used for output control like valves, pumps, motors, etc.
Session 8
(i). Features of SCADA
(ii). Software of SCADA
(ii). Software of SCADA
The best SCADA software will be of lasting value to your organizsation, helping you
stay ahead of your competitors and grow. The best software should improve production quantity
and quality, reduce costs, minimizse waste and be completely reliable.
SCADA software should also deliver efficiency gains across different systems in your
organizsation, as well as improve the performance of your plant and equipment. To bring value to your
organizsation, SCADA systems need to lengthen the lifecycle of your assets and reduce your maintenance
costs.
Software solutions help protect your engineering investments, improve machine
reliability and uptime, improve operational efficiency, productivity and reliability.
● Operational Excellence
SCADA software delivers operational excellence within industrial automation and across
our full Engineering and, Operations and Performance software portfolio.
● High Performance
SCADA software is reliable, flexible and high performance, and has been helping
industries around the world for decades.
● Trusted Solutions
SCADA software is highly secure, scalable and offers real-time supervisory control. It’s
trusted to manage critical infrastructures around the world.
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HTML technology based software are also familiar for SCADA. The software collects
data, enables control functions as well as alarm detection and notifications, and displays process
charts, trend graphs, reports, and other information from various IoT gateway devices compatible
with CONPROSYS series and MQTT (Message Queueing Telemetry Transport) communication
devices on an HMI monitoring screen. This enables simplified development and operation of
monitoring and management systems for a variety of purposes.
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● Multi-device support for anytime, anywhere monitoring
o Monitoring is possible through any browser that supports HTML5, allowing users to monitor
equipment not only from PCs but also tablets and smartphones. With support for Windows,
Android/iOS, Mac, and Linux, monitoring and operation tasks are not limited to any specific OS
or hardware configuration.
● Programless system development
o All development and execution tasks involved with constructing a system can be performed over
the web. No specialized knowledge is necessary, and screen creation is as easy as dragging and
dropping using a web browser. The ability to work with onscreen data without a program, such
as when linking collected data and databases with various information, and to control equipment
makes it possible to develop systems quickly.
● Quick creation of expressive monitoring screens
o The software includes an image library for drawing process charts with more than 60 different
components (including lamps, labels, trends, meters, lists, and tables), as well as a dedicated tool
for simplified editing of detailed screens. Together, these features enable “visualization” of data
without the need for programming. Take advantage of a variety of components, including alarm
summary, alarm history, historical trends, reports, data change history, operation history,
instrument monitor, and map.
● Compatibility with MQTT, a popular IoT communication protocol
o The software supports the MQTT protocol, which is becoming a popular lightweight IoT
protocol, and can also be used with IoT gateways that use MQTT communication functions. An
MQTT Broker is also included, eliminating the need for preparing a separate broker.
● Universal execution environment that can be installed anywhere
o Using a Windows Server environment as the execution environment makes it possible to use the
software in any environment, including in the cloud or an on-premise environment. Meet a
variety of customer demands without being limited by the environment, whether starting a new
cloud service or developing a new system for simple visualization of an existing factory.
● Impressive cost performance for stress-free adoption
o Licenses can be purchased according to the scale of the system (number of projects), and the
software can be downloaded and purchased directly from CONTEC’s dedicated website. A free
trial version of the software is also available. CONTEC’s demo site also allows users to see just
how convenient the development environment is.
Session 9
(i). Protocols of SCADA, DNP (Distributed Network Protocol)
(ii). Protocols of SCADA, IEC (International Electro Technical Commission)
(i). Protocols of SCADA, DNP (Distributed Network Protocol)
Distributed Network Protocol 3 (DNP3) is a set of communications protocols used
between components in process automation systems. Its main use is in utilities such as electric
and water companies. Usage in other industries is not common. It was developed for
communications between various types of data acquisition and control equipment. It plays a
crucial role in SCADA systems, where it is used by SCADA Master Stations (a.k.a. Control
Centers), Remote Terminal Units (RTUs), and Intelligent Electronic Devices (IEDs). It is
primarily used for communications between a master station and RTUs or IEDs. ICCP, the
Inter-Control Center Communications Protocol (a part of IEC 60870-6), is used for inter-master
station communications. Competing standards include the older Modbus protocol and the
newer IEC 61850 protocol.
The IEEE adopted DNP3 as IEEE Std 1815-2010 on July 23, 2010.[1] IEEE Std 1815 was
co-sponsored by the Transmission and Distribution Committee and Substations Committee of
the IEEE Power & Energy Society, with additional input from the DNP Users Group.
In April 2012, the IEEE approved Std 1815-2012 for publication. IEEE Std
1815-2010 has been deprecated. The 2012 version of the standard includes features for Secure
Authentication Version 5. The previous version of secure authentication in IEEE 1815-2010
used pre-shared keys only. The new version is capable of using Public Key Infrastructure, and it
facilitates remote key changes.
(ii). Protocols of SCADA, IEC (International Electro Technical Commission)
The International Electrotechnical Commission (IEC) is an international standards
organization that prepares and publishes international standards for all electrical, electronic and
related technologies – collectively known as "electrotechnology". IEC standards cover a vast
range of technologies from power generation, transmission and distribution to home appliances
and office equipment, semiconductors, fibre optics, batteries, solar energy, nanotechnology and
marine energy as well as many others. The IEC also manages four global conformity assessment
systems that certify whether equipment, system or components conform to its international
standards.
All electrotechnologies are covered by IEC Standards, including energy production and
distribution, electronics, magnetic
and electromagnetics, electroacoustics, multimedia, telecommunication and medical technology,
as well as associated general disciplines such as terminology and symbols, electromagnetic
compatibility, measurement and performance, dependability, design and development, safety and
the environment.
IEC Standards
IEC standards that are not jointly developed with ISO have numbers in the range
60000–79999 and their titles take a form such as IEC 60417: Graphical symbols for use on
equipment. Standards developed jointly with ISO, such as ISO/IEC 26300 (Open Document
Format for Office Applications (OpenDocument) v1.0), ISO/IEC 27001 (Information technology,
Security techniques, Information security management systems, Requirements), and ISO/IEC
17000 series, carry the acronym of both organizations.
IEC standards are also being adopted by other certifying bodies such as BSI (United
Kingdom), CSA (Canada), UL & ANSI/INCITS (USt, SABS (South Africa), Standards
Australia, SPC/GB (China) and DIN (Germany). IEC standards adopted by other certifying
bodies may have some noted differences from the original IEC standard.
