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com

PRINCIPLES &
PRACTICAL DESIGN of
SCADA SYSTEM
Presented by ControlManuals.com

Concept and Architecture of SCADA - Controlmanuals.com 1

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Overview of
SCADA Systems

Presented by ControlManuals.com

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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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Terms & Terminology

Field Instrumentation

Data Acquisition

Control Loop

Supervisory Control

Remote Terminal Unit (RTU)

Master Terminal Unit (MTU)

SCADA Server

Communications Equipment

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Historical Background (1)

1960s:
• Radio Telemetry : weather
monitoring using unmanned
balloon/rocket
• Hardwired Remote Monitoring :
oil & gas and processing
industries

1970s :
• Two-way radio telemetry
• Mini-computer
• Distributed Process Control
System (DCS)
• Programmable Logic Controller
(PLC)
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Historical Background (2)

1980s :
• Low cost microcomputer (PC)
• Satellite Communications
• Cellular Telephone

1990s :
• Local Area Network (LAN)
• High Speed Communication Devices
• Internet

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Data Acquisition
Device Status

PROCESS
valve status (open/close)
switch position (on/off)
pump (start/stop)

FIELD- INTERFACE
Variables
pressures
flow rates
temperatures
tank levels

Alarms
Low Tank Level Alarm
High Tank Level Alarm
Fire Alarm

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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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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

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Control Loop

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

Actuator Sensor

input output

PROCESS
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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

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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 Set Point 1 Set Point 2 Set Point 3

• etc
CONTROLLER

CONTROLLER
Actuator Sensor

CONTROLLER
Actuator Sensor
PROCESS
LOOP #1 Actuator Sensor
PROCESS
LOOP #2
PROCESS
LOOP #3
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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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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

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SCADA System Architecture

RTU
01 transducers/
transm itters

Enterprise Network Modem

RTU
02 transducers/
transm itters

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

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

Modem transducers/
transm itters

Radio

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Data Communications

One MTU can exchange
Two-way communications
data with one or more RTUs (half or full duplex)

Data exchange within MTU
serial transmission
and RTUs follows a pre- (asynchronous/synchronous)
defined set of rules called
Leased or non-leased line
communication protocol
Guided or wireless medium :

Data is encoded as binary • radio link (UHF, VHF,
signal (series of ones and microwave, satellite)
zeros) • cable link (telephone,

This binary signal is twisted pair, coaxial, power
modulated before it line carrier)
propagates through • fiber optic
communication medium • etc

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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

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Communications
W indows 3.1
W indows-95
W indows N T B usiness M anagem ent
Client Applications

W indows N T
O perator C onsole
RT /History D ata
Server

W indow s NT W indow s N T P lant H ighw ay

O perator C onsole R T/H istory Data
Server

P lant H ighw ay

P rocess M anagem ent

C ontroller

Fieldbus

Fis her
PD M eters Analytical
M easurem ent C om m on Head -Sim ple -Analog I/O H andheld
C oriolis C onfiguration and
-Pressure -C om plex -D iscrete I/O PD A
Valves -TC /RT D M aintenance
-Tem p
Positioners
-Flow
-Level Field M anagem ent

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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)

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Plant Network

RTU to Sub-MTU to MTU
connection

Medium
• guided : cable, telephone,
ISDN, optical fiber, etc.
• wireless : broadcast radio,
microwave, satellite

Protocol
• DH, DH+, DH-485,
ControlNet
• Modbus, ModbusPlus,
ModbusTCP
• Hostlink
• DNP

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Corporate/Enterprise Network

Ethernet

TCP/IP

Corporate Applications
• Real time asset management
• Business support
• Marketing & sales
• Procurement
• Manufacturing
• Distribution
• Data warehouse

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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
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Man Machine Interface (MMI)

Provides human access to field automation system
• 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

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Man Machine Interface

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.

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User Applications

Development tools is provided by SCADA system supplier
(scripting tools)

Examples :
• Meter gross/net computation
• Pipeline terminal display
• Pipeline inventory
• Transient modeling systems
• Dynamic leak detection
• Pipeline simulator
• Compressor optimization
• Automatic well testing
• Well revenue calculation
• etc.

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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

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Industrial Automation Server

OPC

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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)

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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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.

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Dynamic Data Exchange (DDE)

An application protocol that allows data exchange on real-time
basis on Windows/WindowsNT platforms

NetDDE = Dynamic Data Exchange over network

I/O Devices

Driver

Tag Database
DDE Link

Windows DDE Windows DDE Other

Application Application Applications
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Sample of System linked to Excel

DDE
Conversation Excel Based
Operating Panel

MMI Software

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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

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Web Based Monitoring Example

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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

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