CHAPTER 2 COMMUNICATION PROTOCOL
OPEN
Type
Advantages
PROPRIETY
Single Communication
Own Protocol
Compatible
Features
Capabilities
Specific
Interoperability
DNP
Two - wire multi drop
Four - wire point to point
Two - wire point to point
Four - wire point to point
Dial modems
Weakness
Advantange
Maintenance by Company
Flexibility
Universal
Interoperability
Introduction to SCADA PART 2
The basic variable related with the network/power/station
The Hierarchical Level on control include
National Load Control Center
Regional Load Control Center
Power Station Control Center
Substation Control Room
Distribution Control Room
Load End Control Room
Integration of control and Protection for HT AC Transmission and Distribution
Conventional protection functions were segregated from control functions.
Data logging were perform manually by operators
It is because protection relays are electromechanical relay and hard wire relays connections
Impossible to integrated between protection and control functions
Sensing faults
Giving alarms
Tripping circuit Breaker
Auto-reclosing of circuit breaker
Introduction SCADA Chapter 1 Prt1
Category
Network SCADA
Network SCADA
Basic SCADA
RTU/PLC
MTU
eg : car manufacturing robot room, temperature control water level
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Have more than One MTU
eg : Power System and Communication System
Using LAN, WAN & Internet
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LAN, WAN & Internet
eg : Water system, Subways System, Security System
PLC/RTU
Element
Remote Terminal Unit (RTU)
Communication
operator
Human Machine Interface (HMI)
Master Terminal Unit (MTU)
Wireless
Wire Network
Switched Public Telephone Network
Internet
Gather data from the distant site & transmits control signal to the site
Present through the HMI
Control signal to device control
Transmits data to the MTU
Graphics > Schematic > Pull down menu > Touch screen Window
Generation of SCADA
1st - Monolithic
2nd - Distributed
Poor Security
3rd - Network
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General centre on mainframe systems
No connection to other system because of limited network
Used WAN network
Connect to difference RTU so that the master computer could send and receive data.
Produced by RTU vendors, and limited to being compatible with their own master machines.
Used LAN network
LAN connections allow multiple stations to share information in real time.
E.g
Device Net (Allen Bradley)
Profibus (SIEMENS)
Less expensive than first generation
Distribute Station
Communications processors
communicate with RTU Operator interfaces human machine
interface with system operator, etc
Related with 2nd generation SCADA
Current
volatge
Frequency
uses an open system design rather than a proprietary environment that is controlled by a company.
Power Factor
Reactive power, Active power, Apparent power
Temperature, Vibration and process variable
Systems from various networks that share master station functionalities
It would be a significant improvement to deploy SCADA functionality across a WAN rather than simply a LAN.
Hierarchies
The master station(s)
Field level instrumentation and control devices
The commercial data processing department computer system
Communications system
Marshalling terminals and RTUs
With development of Programmable Microprocessor are combine
SCADA software
User interface
Graphics displays
Alarms
Trends
RTU (and PLC) interface
Scalability
Access to data
Database
protection
Control & Automation
Networking
Fault tolerance and redundancy
Data Aqu.Meas Transmission
Monitoring
Client/server distributed processing
Comparison between Conventional Relay system and SCADA system for power System Protection
CONVENTIONAL RELAY SYSTEM
SCADA SYSTEM
Self-diagnostics and easily maintained
Expensive system
Less space
Less consume power and less generate heat
Capability of arithematic functions implementation
Easy to program and reprogram
Easy to troubleshoot
Size of RTU
Difficult to troubleshoot and dignose
Average cost
More Space
Consume more power and generating more heat
Relays are used only for on/off control
Any change in the control program needs rewiring of the relays
Medium size
Small size
No human interface feature
Large size more
10 until 20 analog and digital signals
100 digital and 30 until 40 analog inputs
more than 100 digital and more than 40 analog inputs
Benefits of SCADA (In General)
Improve operation of plant or process
Increase productivity of the personnel
Improve the reliability of the process, equipment and part due to better information and control
Improve protection to the plant equipment
Safeguard to the environment from failure to the system
Improve energy saving due to optimization of the process handling
Benefits of SCADA (Power System Operation)
SCADA Chapter 3
Cost of providing and maintaining operator attended the failure and any switching event
Delay operation may lengthen an outage and deteriorate customer service
Comparize
Operator attendance of remote stations are uneconomically
LAN
WLAN
Easy to trace the failure
All personnel able to receive the real time information
Local area network
Connect both wired and wireless connection
CONSIDERATION OF SCADA
Connected together with communication/network element
Technologist must consider list when put Scada in the system
Overall control requirement
Free external attacks
Sequence Logic
Analog Loop Control
Type of display requirement (HMI)
LAN is secure
Lost popularity due to the latest wireless network
Historical Archiving Requirement
Speed of communication or update time
System redundancy
Need physical access for switch or router
Expansion capability
Connected locally with Ethernet cable
Mobility Limited
Maintenance scope
Reliability of SCADA
not vary with external factor
Less expensive
Wireless local area network
Connected complete wireless
Small area covered
Large area covered
Use public communication links
Usually a low speed
Uses WIFI and Ethernet cables
Suitable for DCS system
Connected together wirelessly communication/network element
vulnerable to external attack
WLAN is not secure
Use public communication links
Popular
Usually a fast speed
Uses Fibre optic wires, microwave and satellite
Connecting wireless to switch and router
Suitable for SCADA system
Cable is not necessary
Outstanding mobility
Due to external factor environment and quality cable
More expensive
Wide Range
Any Type of device
Any equipment vendor
Eg: Computer connected in college
Eg : Laptop, cellphone, tablet connect to wireless router/hotspot
DISADVANTAGES
High License Fee
Upgrade
Update
Support & Maintenance
Specific only vendor
MODBUS
Serial
RTM
ACSII
TCP/IP
Introduction to SCADA CHAPTER 1 PART 3
1.1 INTRODUCTION
1.11 PROCESS CONTROL
1.12 PROCESS DIAGRAM
1.13 PIPING & INTRUMENTATION DIAGRAM (P& ID)
1.14 PROCESS EQUIPMENT SYMBOL AND NUMBERING
1.15 PROCESS CONTROL VARIETY
Valve in industry
Pump, compressor, fan & blower
ISA Symbology
Process Flow Diagram (PFD)
Process & Instrumentation Diagram (P&ID)
Definition
process to maintain at the desired operation conditions, safely and efficiently, while satisfying environmental and product quality requirements.
Controlled Terminology
i) Controlled Variables (CVs)
ii) Manipulated Variables (MVs)
Disturbance Variables (DVs)
quantify the performance or quality of the final product,
which are also called output variables (Set point)
These input variables are adjusted dynamically to keep the controlled
variables at their set-points.
also called as load variables
It represent input variables that can cause the controlled variables to deviate
from their respective set points (cannot be manipulated).
Specific Objective of Process
- Increase product throughput
- Increase yield (hasil) of higher valued products
- Decrease energy consumption
- Decrease pollution
- Decrease off-spec product
- Increase Safety
- Extended life of equipment
- Improve Operability
- Decrease production labo
Piping and Intrunmentation Diagram (P&ID)
Process equipment symbol and numbering
i) Process Flow Daigram (PFD)
iv) Sensors
v) Transmitter
iii) Close Loop Diagram
ii) Block Flow Diagram (BFD)
vi) Controller
vii) Final Control Element
device that measures a physical quantity and converts it into a signal which
can be read by an observer or by an instrument.
a transducer that responds to a measurement variable and converts that
input into a standardizedtransmissionsignal.
a device which monitors and affects the operational conditions of a
given dynamical system.
operational conditions are typically referred to as output variables of the system which
can be affected by adjusting certain input variables.
device that directly controls the value of manipulated
variable of control loop
eg, control valves, pumps, heaters,
Instrunmentation Symbology
click to edit
Instrunmentation Abbreviation
Instrumenatation signal line symbol
Type of Process Control Loop
- Feedback Control
- Feedforward Control
- Feedforward-plus- Feedback
- Ratio Control
- Split Range Control
- Cascade Control
- Differential Control
measures a process variable and sends the measurement to a
controller for comparison to set point
used in case where the controlled variable
has the potential of being a major load disturbance on the process variable ultimately being controlled.
to ensure that two or more flows are kept at the same ratio even if the
flows are changing.
uses the output of the primary controller to manipulate the set point of
the secondary controller as if it were the final controlelement.
A very common control scheme is split range control in which the output of a controller is split to two or more control valve
e often combined with feedback systems.
CHAPTER 4 HUMAN MACHINE INTERFACE (HMI)
4.1 Ergonomic factor
4.2 HMI Organization
4.3 HMI Screen Design
4.4 Integration HMI and SCADA
4.0 Introduction
user interface or dashboard
that connects a person to a machine,system, or device.
include Man-Machine Interface (MMI),Operator Interface Terminal (OIT), Local Operator Interface (LOI), or
in SCADA also known as Master Terminal Unit (MTU)
application of psychological and physiological
principles to the engineering to design of products, processes, and systems.
Poor Ergonomic can cause
Increase levels of mental strain and stress
- Human Error
- Occupational Accident
Improve health and safety by
- User Central Design
- Instruction Manual
- Usability Engineering
Advantages
- Ease to keep track of processes under normal conditions
- Abnormalities can be handled entirely from within the HMI
2.Effectively monitors and informs of abnormal conditions
- In event of abnormality HMI operator is not distracted
- During abnormality HMI only prompts relate to problem
resolution
- Holistic adherence to High Performance HMI “good practices”regarding graphics, navigation, workstation, environmental, and alarm management factors
- Less space require
- Good ergonomics for operator.
not different from creating Word Document or
Power Point Slide
Flowchart HMI Screen Design
- HMI Style Guide
- Gather and Review data
- Create First Draft
- Refine and Approve
Client must approve the HMI design after test and
commissioning done.
markup of existing displays, a
Microsoft Visio or CAD drawing, or paper sketch.
o Data sources are:
i. P&IDs or Process Flow Chart diagram
ii. Existing displays
iii. Procedures (interlock and standard operating
procedure)
iv. Incident or near-miss analyses
v. . Operator interviews.
Determine the Colour of Background, line type and thickness,
Text size and Fontstyle, ISA object(Tanks, Pumps, Valves etc).
CHAPTER 5 INTRODUCTION TO INTERNET OF THINGS (IoT)
The Internet of Things or IoT is the network of physical devices, vehicles, home appliances and other items embedded with electronics, software, sensors, actuators and connectivity which enables these objects to connect and exchange data.
Examples: SMART HOME
MQTT - is a lightweight protocol and utilize publish subscribe network protocol. It ideal for connecting remote devices with a small code footprint and minimal bandwidth.
Industry Internet of things (IoT) is the internet of things that utilize in industry such as manufacturing, power system, water treatment and utility
IR 4.0 is a new phase of the Industrial Revolution that focuses heavily on interconnectivity, automation, machine learning and real time data
ADVANTAGES
Lightweight and efficient
Bi-directional communication
Able to connect million IoT devices
Support for unreliable networks (cellular network etc)
MQTT structured by 3 Entities which are:
MQTT Publisher is a sender that send the data. It also known as client to MQTT broker.
MQTT Subscriber is a consumer that receives the data. It also known as client to MQTT broker.
MQTT Broker is third component acts like postmen, dorecting messages from the Publisher to any end points acting as Subscribers
Publisher and Subscriber do not know anything about each other and never in direct contact with each other.
An IoT cloud is a massive network that supports IoT devices and applications
IoT devicess can be connected to the cloud via several methods
Wi-Fi
LPWAN (Low Power Wide Area NEtworks)
Cellular
Satellite
Ethernet
Benefits of IoT Cloud
Do not have to install hardware or manage large networks and infrastructure
Realtime data on your phone or connected devices
Remotely create or change setpoints
History and event trends for the life of the installation
Alarms and callouts configurable to any data point sent dorect to email, phone, or text
Configure wells and assign personnel access by routs or regions
Weakness of IoT Cloud
Security-Targeted from the hacker because of variety and data in store in cloud
Performance- Latency problem can result in inconsistent reaction times with local HMI screen and confuse boardman and operator
Reliability- Data backup are depend on cloud service. No control over where it store and how long it store.
Comparison between SCADA and IoT
SCADA
Purpose- Close Loop System
Architecture- Centralized
Approach-Polling
Security-High
Usage-Mission Critical, Real-Time
IoT
M2M
Decentralized
Publish / Subscribe
Low to High- Depending on Implementation
Diagnostics, Monitoring,PM
IoT offers several benefits to SCADA system
Monitor their overall system processes
Improve the customer experience (CX)
Enhance staff productivity and save money
Make better decisions making
IoT will give challenges to be implement for SCADA
High Investment cost
Loss of many job to automatic processes and IT-controlled processes, especially for blue collar workers
Rely on the machine to decide cause loss of human skills, cognitive and hands on
Still unclear with legal issues and data security
Lack of adequate skill-sets to expedite the transition towards a IR 4.0
Low top management commitment
Insufficient qualification of employees
A working cyber-security strategy to protect your SCADA
securing the perimeter
Patching all known vulnerabilities
Restricting logical and physical access
Installing antivirus software
use file integrity checking software
Ensure redundancy