I&C Solutions…

A.ABUNAYYAN TRADING CORP.

I & C Solutions …
Instrumentation & Control Solutions …
 AGENDA

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• SCADA SYSTEMS DEFINITION

• INTRODUCTION TO I&C SOLUTIONS

• SUMMARY

• OPEN DISCUSSION
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SCADA SYSTEMS
DEFINITION
 What is Supervisory Control And Data Acquisition
(SCADA)??
- System that allows an operator to monitor and control processes that
are distributed among various remote sites.
- SCADA provides an economic advantage. As the distance and
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inaccessibility to remote sites increases, SCADA becomes a
better alternative than an operator visiting the site for
adjustments and inspections.
- Distance and accessibility are two major factors for
implementing SCADA systems.
- SCADA systems allow remote sites to communicate with a
control facility and provide the necessary data to control and
monitor processes
Communication
Cloud
Front End Processor (Radio, Dial-up,
fiber-Optic, Satellite,
Microwave, Internet,
etc..)

Central Control Station

Remote Terminal Units
 What Are SCADA Systems Components
1- Field Devices: Instruments Like Flow, Pressure, Level, etc…
2- Field Analytical Measurements Like PH, EC, TDS, etc…
3- Field Equipment Like Pumps, Valves, Breakers etc…
4- Field Controllers for Local & Remote Operation: Programmable Logic
Controller (PLC’s ) , Remote Terminal Units (RTU’s).
I&C Solutions… 5- Communication Backbone like radio, fiber-optic, leased line, dial-up
modems, etc…
6- Communication Protocol to ensure proper Data transfer Flow
Meter
7- Central Software: Human Machine Interface (HMI).
8- Central Hardware: Computers, Printers, etc…
Pressure
Sensor
Remote Terminal Unit
(Fiber Optic)
SCADA Central Workstations
Water
Quality ,
Level
Sensor

Relays
Remote Terminal Unit &
(Radio) Devices

Front End Processor Remote Terminal Unit Pumping Station

(Leased Line)
 The following will be discussed in this chapter:
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• What is PLC’s ?

• Evolution of PLC’s.

• Principle of operation.

• PLC application.

• Number systems and codes used in PLCs.

 What is Programmable Logic Controller (PLC’s)

• A solid state device that controls output devices for a

process or machine based on input status and a user
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developed program.
• Originally developed to directly replace relays used for
discrete control.

Machine
Machine
ororProcess
Process

Measure Control

Programmable
ProgrammableController
Controller
Field Inputs Field Outputs
 Inside A PLC
Communications
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Output circuits
Central

Input circuits
Processor

c
r

Memory
High High
Voltage Program Data Voltage

Isolation
Isolation Barrier
Low Voltage
Barrier

AC Power supply
External DC
85-264VAC,
Power Supply
50/60 Hz
 Chassis/ Backplane / Rack
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• A housing for all the PLC modules and the power
supply is called as the Chassis or Backplane or Rack
• The chassis comes in a various sizes. Sizes are 4, 6, 10
and 13.
• The slot is the dedicated space needed to put one
module into it.
 Power Supply

Each chassis require a power supply to provide power to

the processor and each I/O slot, Communication device.
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Power Supplies have different sizing:

1- Low power when PLC is used for stand-alone

2- High power when PLC needs summable power, or redundancy,
or communication

Different Voltage Inputs:

-AC 110, 220 VAC

-DC 12, 24, 48 VDC
 Central Processor Unit (CPU)
CPUs Come in a Variety of Sizes:
The CPU is the Brain of any PLC or RTU and it contains the PLC
I&C Solutions… configuration, PLC application program and it provides the
Communication interface to the communication devices.
..CPU Components: CPU Selection:

-Processor (e.g. Intel or AMD) - Selection of CPU depends on:

- Co- Processor (depending on + I/O Capacity.
applications) + Programming Memory
- Flash Memory (Supporting Firmware) + System Performance (e.g. Redundancy)
- SRAM Memory (Supporting + Communication requirement.
Application Program) - Programming Language:
- Lithium Battery (To protect programs)
- Interface ports (RS, USB, Ethernet..)
- Communication ports (to connect to
modems)
- LED’s (For diagnostics and Status)
 Inputs & Outputs (I/O) Modules

• The interface of the Field devices and Instruments to the PLC is

through the I/O modules
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• The I/O modules come in a wide variety of densities including 4,
8, 16 , 32 and 64 point modules. Or as Remote Inputs and Outputs
(RIO).
• The I/O modules support
+ Digital Inputs. (Free-Volt, Voltage AC, DC, Fast Counters). Capacities:
8,16,32,64, 96.
+ Digital Outputs. (Relay , Free-Volt, Voltage AC, DC). Capacities:
8,16,32,96
+ Analog Inputs. (0-20mA, 4-20mA, 0-5 VDC, 0-10 VDC, RTD..).
Capacities: 4,8,16.
+ Analog Outputs. (4-20mA, 0-5 VDC..). Capacities: 2, 4,8.
+ Motion and Power Modules.
 Communication Interface

- To setup communication between PLCs And

Central Human Machine Interface or other PLCs and
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RTUs in the Field.

-Communication Interfaces variety:

+ RS-232, RS485
+ Fiber-Optic
+ Wire-line (2 or 4 Wires).
+ Leased Line
+ Dial-up
+ GSM, GPRS
+ Radio: VHF, UHF, Trunking, Spread-Spectrum
+ Microwave
+ Satellite
+ Ethernet ,Modbus, Modbus +,Profibus , DH+
 For understanding PLC operation we should define the
following:
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• Input devices

• Output devices

• Data, memory and Addressing

• Operation cycle
 Inputs

I&C Solutions… - All field switches, push-buttons, Level switches,

Sensors , Transmitters, are considered as input
devices.
 Outputs

I&C Solutions… - All field devices such as valves, Pumps , Motors ,

solenoids, lights and horns are considered as Output
devices.
 Memory, Data and Addressing

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- Memory is a physical space allocated in
controller.

- Data is the information stored in that space, data

are stored in binary digits.

- Data is grouped as 16 bits and called word.

- Each word of data has specific, physical location

in the CPU is called “address”.
 PLC Operating Cycle

- Operating cycle consists of 4 operations performed

sequentially as shown below.
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I&C Solutions… • Programming Languages.

• Ladder Logic instructions.

• Program Execution.
 Programming Languages

- A program is a set of commands or

instructions.
I&C Solutions… - There are rules for each programming
language for combining the
instructions and produce the desired
action.
- Programming Languages include:

• IEC-61131-3
-SFC: Sequential Function Chart.
-FBD: Function Block Diagram
-Ladder Diagram
-Structured Text
-Instruction List
 Ladder Logic Instructions

-Ladder Logic is the programming Software

-Instruction are classified in groups, following is the
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most commonly used instructions.
• Relay Logic Instruction
• Timers
• Counters
• Math
• Boolean
• Comparison
• Data handling
• Application specific instructions
• Program Flow
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 Program Execution

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- The PLC solves each rung sequentially, from the
top to the bottom.

- for the output of one rung to effect an instruction

in another rung in the same scan, it must have
lower rung number.

- Rung order does not necessarily dictate the

sequence of operation.
 What is Remote Terminal Unit (RTU’s)
Remote Terminal Unit (RTU’s) :

I&C Solutions… • Electronic equipment installed at the Remote Site to monitor or

measure the sensors or devices installed at the remote site.

• The RTU converts the measured status or signal to a form of data that can
be transmitted over the Communication Media. It also converts the data
received from the central to a form of command, that can control the
function at The device.

A. Mother Board B. Power Supply

C. I/O Bus D. Battery
E. Enclosure F. I/O Modules as required
G. CPU -Processor Module H. Communications Interface

RTU’s= PLC + Communication Interface + Enclosure

 Remote Terminal Unit Components
Communication Device
(F.O., Wire-Line, Radio, Etc…)

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UPS Batteries
Power Supply
Input/Output Modules
(AI, DI, DO, AO)
C.P.U. Module
Enclosure

Generator
•Generator Running .
Ultrasonic Sensor •Generator Trip
•Tank Level Reading Flow Meter Pressure Transmitter Flow Control Valve Pumps
•Flow Meter Reading •Pressure Reading •Valve H-OFF-A SSW. •Pump H-OFF-A SSW.
•Flow Totalizer •Valve Open/Close Command •Pump Start /Stop Command
•Valve Open /Close Statues •Pump Run /Trip Statues
•Valve Opening Percentage •Pump Temp High
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 Local Human Machine Interface
(HMI) OR (MMI)

I&C Solutions… -Local Human Machine Interface provides GUI local

capabilities using Industrial Display Units showing
graphics and Alpha-numeric values.
-There different types and sizes of HMI, 5.7,8,10.4,14
Inches, color o B&W, Button or Touch Operated.
 SCADA or Central HMI Software

-SCADA or Central HMI Allow Visualization of field Process and

applications. To be displayed as Graphic displays.
I&C Solutions… -Central HMI, provides Monitoring, Control, Interlocks, Alarms,
Trending, Database, Reports.
-HMI can be structured as Stand-Alone, Client Server, Redundant,
Remote Access.
-SCADA Web Enabled
-Remote Alarms, using Paging, Mobile, SMS….
 Tag Definition

- A tag represents a variable in a device such as

PLC or in local memory, for example, a tag can
I&C Solutions… represent a process variable in programmable
controller.
-In tag database you configure the PLC data
HMI should monitor or control.
- Each entry in the database is called a tag,
 Alarms & Events

-Alarms are respective to Tag definition where a

Tag can be represented as an Alarm upon Tag
I&C Solutions… Activation.
-Alarms can be prioritize and Displayed in
different structure, Color coded depending on the
alarm priority or alarm status.
-Events are also respective to Tag definition
where a Tag can be presented as a change of State
and hence as an event happening on site.
 Trending

-Trending is displaying Variables values against time.

-Trending Could be displayed as Real-time
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-Trending could be displayed as historical.
-Trending could be in different forms, Graphs, Bars,
Lines, Etc..
 Graphic User Interface

-HMI allows you to generate Graphics base on site

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-Inserting Maps, Icons, Shapes….
-Displaying Statuses, Values, Variables….
-DO controls, Safety Sequences, Set points…
 Control Rooms View

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 Control Rooms View

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 Where to Apply SCADA Systems

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Water Distribution Water Transmission

Networks Systems
- Network Management - Pipe Line Management
- Pump Stations Control & Monitoring - City Feeders Management
- Valve Stations Control - Pump Stations Control & Monitoring
- Network Simulation - Valve Stations Control
- Leak Detection - Off-Line & On-Line Simulation
- Water Quality Management - Leak Detection
- Automatic Metering - Hydraulic Profile Monitoring
 Where to Apply SCADA Systems

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Sewage Lifting Water Wells &

Stations Pumping Stations
- Pumps Control & Monitoring - Pumps Control & Monitoring
- Pump Fault Alarms - Pump Fault Alarms
- Pumps Flow, Pressure - Pumps Flow, Pressure
- Wet Well Levels - Tanks Levels
- Pumps Voltage, Current, PF - Pumps Voltage, Current, PF
- H2S Monitoring - TDS, Chlorine, EC, PH Monitoring
- Odor System Control & Monitoring - Dosing System Control & Monitoring
- Dosing System Control & Monitoring
 Where to Apply SCADA Systems

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Sewage Treatment Plant

- Plant Auto or Semi-Auto Control
- Monitoring, Flow, Pressure
- Monitoring DO, H2S
- Pre-treatment, Secondary & Tertiary
- Aeration, Contact and Settling Tanks
- Dosing System, Odor Control
- Grit & Grease Removal
 Where to Apply SCADA Systems

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Water Treatment Plant

RO, Filtration, Desalination
- Plant Auto
- Monitoring, Flow, Pressure, Level
- Monitoring PH, EC, TDS , Conductivity
- Pre-treatment Control & Monitoring
- Chemical Control & Mentoring
-Power Systems Control & Monitoring
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SAMPLES OF SCADA
SYSTEM LAYOUTS
 SYSTEM LAYOUT 1

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 SYSTEM LAYOUT 2

I&C Solutions… UPS UPS

UPS UPS
UPS

UPS

UPS

UPS UPS UPS UPS UPS UPS

 SYSTEM LAYOUT 3

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 SYSTEM LAYOUT 4

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 SYSTEM LAYOUT 5

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Summary
 SYSTEM LAYOUT 6

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Summary
 SYSTEM LAYOUT 7

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Summary
 Key requirements for any modern SCADA
Solution
Flexibility
– Open Software, not locked into a single vendor SCADA solution
I&C Solutions… – Add to, don’t replace, your existing automation investment
Reporting
– Easy to create
– Uses off the shelf tools (Microsoft)
– Web based for easy sharing with information consumers
Integration
– Easily shares and/or integrates information with databases, ERP or any business system
– Connectivity to any system, PLC or device
Security
– Protected at every access point, data-level system security
Robustness
– Cost effective, built-in redundancy with auto failover
Development
– Very productive development and change management capabilities
– Multiple developer environment with complete audit trail of all changes
– Automatic configuration and maintenance of historical data
Maintenance
– Remote software deployment
– Centralized system and application diagnostics
Mobility
– Mobile solutions for site-wide, medium and long range communications
– Event notification via cell phone, pager, PA System, e-mail, etc.
 Criteria To Select SCADA Systems & SCADA Vendor

1- To have Field Proven References.

I&C Solutions… 2- To have Field Proven Experience.
3- To have Proven Communication Capabilities.
4- To have Knowledge in Application.
5- To have Integration Skills and Engineering
Capabilities
6- To Be Open Architecture and Compatibility.
7- To have Design, After Sale services Capabilities
8- To have, Distributed Reporting, Alarms and
Database
9- To adopt Distributed Intelligence Structure.
10-To use Solid & Robust Communication Protocol.
 SCADA Systems Benefits

1- Remote Auto or Manual Operation from One Location.

I&C Solutions… 2- Discover Faults as they Occur on Site
3- Foresee Issues in Operation Before they Happen
4- Allows to take immediate actions.
5- Provides Excellent Database, and Reports on Consumptions,
Faults.
6- Allows Staff & Time Management.
7- Could be Integrated On-Line with Maintenance Management
Systems.
8- Allows to have Proper Spare Parts management.
9- An Excellent tool to manage and monitor Performance of O&M
Contractors or Staff.
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