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The document provides a comprehensive overview of SCADA (Supervisory Control and Data Acquisition) systems, detailing their architecture, components, functionalities, and historical development. It highlights the importance of SCADA in various industries, emphasizing its efficiency, cost-effectiveness, and ability to facilitate real-time monitoring and control. Additionally, the document outlines the different generations of SCADA systems and their applications across sectors like energy, transportation, and manufacturing.

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SCADA SCADA Architecture Architecture 1 1 SCADA SCADA Architecture Architecture
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Contents Contents  architecture of architecture of SCADA SCADA 4 4
Introduction Introduction SCADA (Supervisory Control and Data Acquisition) SCADA (Supervisory Control and Data Acquisition) System System  Why Why SCADA? SCADA?   Definition of SCADA Definition of SCADA 5 5   Definition of SCADA Definition of SCADA
 The architecture of SCADA consists of The architecture of SCADA consists of programmable logic controllers (PLC) or remote programmable logic controllers (PLC) or remote terminal units (RTU). Both act as a communicator with terminal units (RTU). Both act as a communicator with HMIs (Human HMIs (Human- -Machine Interfaces), machines, Machine Interfaces), machines, terminals, and sensors. terminals, and sensors. Architecture of SCADA Architecture of SCADA 6 6 terminals, and sensors. terminals, and sensors.  The SCADA software will then route the data to the The SCADA software will then route the data to the computer and start processing, analyzing, and computer and start processing, analyzing, and displaying the data. Hence, staff and operators can displaying the data. Hence, staff and operators can analyze information and make decisions. analyze information and make decisions.
History History   Egyptian supervisory Egyptian supervisory   First half of the 20 First half of the 20th th century century   Development from telemetry system Development from telemetry system Weather predictions Weather predictions 7 7   Weather predictions Weather predictions   Rail road tracks Rail road tracks   Two way system Two way system   1960s idea for supervisory 1960s idea for supervisory   1970s radio system 1970s radio system
Why SCADA? Why SCADA?   Saves Time and Money Saves Time and Money   Less traveling for workers (e.g. helicopter ride) Less traveling for workers (e.g. helicopter ride)   Reduces man Reduces man- -power needs power needs   Increases production efficiency of a company Increases production efficiency of a company 8 8   Increases production efficiency of a company Increases production efficiency of a company   Cost effective for power systems Cost effective for power systems   Saves energy Saves energy   Reliable Reliable   Supervisory control over a particular system Supervisory control over a particular system
What is SCADA? What is SCADA?   Supervisory Control and Data Acquisition Supervisory Control and Data Acquisition   Supervisory Supervisory   Operator/s, engineer/s, supervisor/s, etc Operator/s, engineer/s, supervisor/s, etc   Control Control   Monitoring Monitoring   Limited Limited 9 9   Limited Limited   Telemetry Telemetry   Remote/Local Remote/Local   Data acquisition Data acquisition   Access and acquire information or data from the Access and acquire information or data from the equipment equipment   Sends it to different sites through telemetry Sends it to different sites through telemetry   Analog / Digital Analog / Digital
HMI SCADA HMI SCADA systems are divided into 4 distinct systems are divided into 4 distinct generations based on their architecture generations based on their architecture 1) The initial stage of SCADA (Supervisory Control & Data 1) The initial stage of SCADA (Supervisory Control & Data Acquisition) systems was known as 'monolithic SCADA' which Acquisition) systems was known as 'monolithic SCADA' which marked the beginning of its use. marked the beginning of its use. 2) 2nd generation distributed Supervisory Control and Data 2) 2nd generation distributed Supervisory Control and Data Acquisition (SCADA) systems are being widely used to effectively Acquisition (SCADA) systems are being widely used to effectively manage and monitor large scale industrial processes. manage and monitor large scale industrial processes. 10 10 manage and monitor large scale industrial processes. manage and monitor large scale industrial processes. 3) The third generation of SCADA systems are connected through 3) The third generation of SCADA systems are connected through networks, enabling the sharing of data among multiple users and networks, enabling the sharing of data among multiple users and devices. devices. 4) Fourth generation SCADA, also known as the "Internet of Things" 4) Fourth generation SCADA, also known as the "Internet of Things" technology, is becoming more prominent in industries due to its technology, is becoming more prominent in industries due to its capabilities. It allows for improved sensing and control with enhanced capabilities. It allows for improved sensing and control with enhanced communication & integration of systems. communication & integration of systems.
Elements of SCADA Elements of SCADA Elements of a SCADA system Elements of a SCADA system   Sensors and actuators Sensors and actuators   RTUs/PLCs RTUs/PLCs   Communication Communication   MTU MTU NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 11 11   MTU MTU   Front End Processor Front End Processor   SCADA server SCADA server   Historical/Redundant/Safety Server Historical/Redundant/Safety Server   HMI computer HMI computer   HMI software HMI software
Master Terminal Unit (MTU): Master Terminal Unit (MTU): This is mostly This is mostly considered as the heart of SCADA. considered as the heart of SCADA.  Other names of this component are central Other names of this component are central control system or central station or SCADA control system or central station or SCADA Master Terminal Unit (MTU) Master Terminal Unit (MTU) 12 12 control system or central station or SCADA control system or central station or SCADA master. master.  This component, initiates virtually all This component, initiates virtually all communication with remote sites and interface communication with remote sites and interface with an operator with an operator component. component.
The main functions of this SCADA masters are The main functions of this SCADA masters are as follows. as follows. • Interfacing with operators through monitors, • Interfacing with operators through monitors, operators console and printers. operators console and printers. MTU cont.. MTU cont.. 13 13 operators console and printers. operators console and printers. • Making communication through gathering, • Making communication through gathering, storing, and sending information to storing, and sending information to other systems other systems • Processing data to generate appropriate action • Processing data to generate appropriate action
flow diagram of Master transfer unit flow diagram of Master transfer unit 14 14
Sensors Sensors Types of sensors: Types of sensors:   Pressure sensors Pressure sensors   Temperature sensors Temperature sensors 15 15   Temperature sensors Temperature sensors   Light sensors Light sensors   Humidity sensors Humidity sensors   Wind speed sensors Wind speed sensors   Water level sensors Water level sensors   Distance sensors Distance sensors
Actuators Actuators Actuator Actuator: is a part of a device or machine that helps to : is a part of a device or machine that helps to achieve physical movement by converting energy often achieve physical movement by converting energy often electrical, air , or hydraulic in to mechanical force, torque electrical, air , or hydraulic in to mechanical force, torque etc.., etc.., 16 16 etc.., etc.., Actuator Examples Actuator Examples   Valves Valves   Pumps Pumps   Motors Motors
RTUs RTUs RTU RTU – – Remote Terminal Unit Remote Terminal Unit   Intelligent to control a process and multiple processes Intelligent to control a process and multiple processes   Data logging and alarm handling Data logging and alarm handling   Expandable Expandable 17 17   Expandable Expandable   Asks the field devices for information Asks the field devices for information   Can control IEDs (Intelligent Electronic Device) Can control IEDs (Intelligent Electronic Device)   Slave/Master device Slave/Master device
Alarms Alarms Types of alarms: Types of alarms:   Good alarms Good alarms   Critical failure alarms Critical failure alarms NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 18 18   Critical failure alarms Critical failure alarms
Safety instrumented systems Safety instrumented systems Actions: Actions:   Override the normal control system Override the normal control system   Take over the actuators Take over the actuators 19 19   Take over the actuators Take over the actuators
PLCs PLCs PLC PLC – – Programmable Logic Controller Programmable Logic Controller   Ladder logic Ladder logic   Industrial computer that replaced relays Industrial computer that replaced relays NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 20 20   Industrial computer that replaced relays Industrial computer that replaced relays   Not a protocol converter Not a protocol converter   Cannot control IEDs Cannot control IEDs   Communication compatibilities Communication compatibilities   Takes actions based on its inputs Takes actions based on its inputs
Communication Communication Communication systems: Communication systems:   Switched Telephone Network Switched Telephone Network   Leased lines Leased lines   Private Network (LAN/RS Private Network (LAN/RS- -485) 485) 21 21   Private Network (LAN/RS Private Network (LAN/RS- -485) 485)   Internet Internet   Wireless Communication systems Wireless Communication systems   Wireless LAN Wireless LAN   Global System for Mobile Communication Global System for Mobile Communication (GSM) Network (GSM) Network   Radio modems Radio modems
Communication cont. Communication cont. Protocols: Protocols:   MODBUS MODBUS   DNP 3.0 ( DNP 3.0 (Distributed Network Protocol Distributed Network Protocol ) )   Fieldbus Fieldbus NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 22 22   Fieldbus Fieldbus   Controller Area Network (CAN) Controller Area Network (CAN)   Profibus Profibus(Process Field Bus) (Process Field Bus)   DirectNet DirectNet   TCP/IP TCP/IP   Ethernet Ethernet
Front End Processor Front End Processor Front End Processor Front End Processor   Gathers all communications and converts them Gathers all communications and converts them into SCADA friendly communication into SCADA friendly communication 23 23 into SCADA friendly communication into SCADA friendly communication   Communication interface between several RTU Communication interface between several RTU channels and the host Master Station computer channels and the host Master Station computer
SCADA server SCADA server SCADA Server SCADA Server   It can be a Web server It can be a Web server   Data logging Data logging 24 24   Data logging Data logging   Analyzing data Analyzing data   Serve the clients through a firewall Serve the clients through a firewall   Clients connected in the corporation or connected Clients connected in the corporation or connected outside through internet outside through internet   Real Real- -time decision maker time decision maker   Asks RTU for information Asks RTU for information
Historical server Historical server Historical/Safety/Redundant Server Historical/Safety/Redundant Server   Logs the data from the SCADA server and Logs the data from the SCADA server and stores it as a backup, in case of a disaster stores it as a backup, in case of a disaster 25 25 stores it as a backup, in case of a disaster stores it as a backup, in case of a disaster   It is basically a safety server It is basically a safety server
HMI Computer HMI Computer Human Machine Interface Computer Human Machine Interface Computer   Access on the SCADA Server Access on the SCADA Server   Control the system Control the system   Operator Interface Operator Interface NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 26 26   Operator Interface Operator Interface   Software Software   User friendly User friendly   Programmable (C, C++) Programmable (C, C++)
DCS DCS DCS DCS – – Distributed Control System Distributed Control System   Process oriented Process oriented – – tendency to do something tendency to do something   Not event oriented Not event oriented – – does not depend on circumstances does not depend on circumstances   Local control over the devices Local control over the devices   Subordinate to SCADA Subordinate to SCADA 27 27  A Distributed Control System or DCS is A Distributed Control System or DCS is a computerized a computerized system that automates industrial equipment used in system that automates industrial equipment used in continuous and batch processes, while reducing the risk continuous and batch processes, while reducing the risk to people and the environment to people and the environment. .
The control architecture of most industrial automation The control architecture of most industrial automation systems is composed of four hierarchical levels, each systems is composed of four hierarchical levels, each with its own set of functions and capabilities. with its own set of functions and capabilities.  These four levels are These four levels are  the field level the field level Levels of SCADA Levels of SCADA 28 28  the field level the field level   the remote terminal unit (RTU) the remote terminal unit (RTU)   the Communications level and the Communications level and  the human the human- -machine interface (HMI). machine interface (HMI).
Central monitoring station Central monitoring station: is : is the human the human- -machine machine interface (HMI). interface (HMI). Includes one or more central servers connected Includes one or more central servers connected together, creating a system platform called a central together, creating a system platform called a central host computer server. At this monitoring station, the host computer server. At this monitoring station, the system will connect with the human system will connect with the human- -machine machine 29 29 system will connect with the human system will connect with the human- -machine machine interface (HMI) and software programs. interface (HMI) and software programs. Intermediate data collection station: Intermediate data collection station: These are RTUs These are RTUs (Remote Terminal Units) or PLCs (Programmable (Remote Terminal Units) or PLCs (Programmable Logic Controllers). These help communication Logic Controllers). These help communication between actuators such as sensors and switches between actuators such as sensors and switches actuators and control equipment. actuators and control equipment.
Communication system Communication system: : This contains industrial This contains industrial communication networks and equipment. The system also communication networks and equipment. The system also includes converters that control and deliver field includes converters that control and deliver field- -level level data to the server. data to the server. Field Field- -level devices level devices: : These will include sensors, These will include sensors, 30 30 Field Field- -level devices level devices: : These will include sensors, These will include sensors, measuring devices, and transducers. measuring devices, and transducers.
Levels of SCADA Levels of SCADA Four levels of SCADA system Four levels of SCADA system   Level IV Level IV - - Enterprise Enterprise   Corporate LAN/WAN Corporate LAN/WAN   World Wide Web World Wide Web 31 31   World Wide Web World Wide Web   Virtual Private Network Virtual Private Network   Firewall for remote users Firewall for remote users   Level III Level III – – SCADA / MTU SCADA / MTU   Operator Workstations Operator Workstations   Control Control   Engineering Workstations Engineering Workstations   Servers Servers – – Data logging Data logging
Levels of SCADA cont. Levels of SCADA cont. Four levels of SCADA system Four levels of SCADA system   Level II Level II – – Telecommunication Telecommunication   Fiber Fiber   Radio Radio 32 32   Radio Radio   Telephone leased line Telephone leased line   Protocols Protocols   Level I Level I – – Field Field   Devices Devices   RTUs / PLCs RTUs / PLCs   Sensors Sensors
Where is SCADA used? Where is SCADA used?   Water and Wastewater Water and Wastewater   Power Power   Oil and Gas, Oil and Gas, Energy, petroleum, etc Energy, petroleum, etc Main SCADA applications Main SCADA applications i.e i.e Some industries and Some industries and fields that are favoring SCADA applications are fields that are favoring SCADA applications are 33 33   Oil and Gas, Oil and Gas, Energy, petroleum, etc Energy, petroleum, etc   Research facilities Research facilities   Transportation Transportation   Security systems Security systems   Siren systems Siren systems   Irrigation Irrigation   Communication control Communication control  Medicine, Food and drink, Manufacturing sector Medicine, Food and drink, Manufacturing sector
SCADA examples SCADA examples SCADA examples: SCADA examples:   Gas control systems Gas control systems   Water control systems Water control systems 34 34   Water control systems Water control systems   Power systems Power systems
Gas SCADA Gas SCADA 35 35
Water SCADA Water SCADA 36 36
Power SCADA Power SCADA 37 37 power power control control
benefits of using a SCADA system benefits of using a SCADA system  Improve productivity: Improve productivity: The system can analyze data from the The system can analyze data from the production process. As a result, managers can leverage data to production process. As a result, managers can leverage data to improve work efficiency, technology, and productivity. improve work efficiency, technology, and productivity.  Improve product quality: Improve product quality: Managers can find deficiencies in the Managers can find deficiencies in the production process and improve them through data analysis. production process and improve them through data analysis.  Reduce operation and maintenance costs: Reduce operation and maintenance costs: The installation and use The installation and use 38 38  Reduce operation and maintenance costs: Reduce operation and maintenance costs: The installation and use The installation and use of SCADA systems will replace a large amount of manual monitoring of SCADA systems will replace a large amount of manual monitoring work. This helps businesses reduce redundant personnel and save work. This helps businesses reduce redundant personnel and save more maintenance costs for remote manufacturing plants. more maintenance costs for remote manufacturing plants.  Preserve investment capital: Preserve investment capital: SCADA allows the factory to ensure SCADA allows the factory to ensure long long- -term efficiency for the upgrading process. Hence, investors and term efficiency for the upgrading process. Hence, investors and business owners can adjust and modify for the appropriate production business owners can adjust and modify for the appropriate production scale. scale.
Why choosing SCADA software for Why choosing SCADA software for businesses businesses The more The more learning about the SCADA system learning about the SCADA system, the more , the more utility is found in this system. However, businesses utility is found in this system. However, businesses need to carefully consider the system before need to carefully consider the system before implementing it. implementing it. 39 39 implementing it. implementing it. There are some Areas which can be useful when There are some Areas which can be useful when choosing SCADA software. choosing SCADA software.
• •Currently, technology software is developing Currently, technology software is developing rapidly and is increasingly innovative. Therefore, rapidly and is increasingly innovative. Therefore, businesses need to pay attention to the expiry date businesses need to pay attention to the expiry date of SCADA. of SCADA. • •This is because software often becomes obsolete This is because software often becomes obsolete Date of validity Date of validity 40 40 • •This is because software often becomes obsolete This is because software often becomes obsolete after a period of time. SCADA systems in years of after a period of time. SCADA systems in years of use will be different from modern communication use will be different from modern communication standards. standards. So, You need to be aware of the lifecycle of SCADA So, You need to be aware of the lifecycle of SCADA
RFI RFI • •RFI (Request for Information) is the support of the RFI (Request for Information) is the support of the provider during the time the business uses SCADA. At provider during the time the business uses SCADA. At that time, businesses will be continuously updated with that time, businesses will be continuously updated with RFI (Request for Information) RFI (Request for Information) 41 41 that time, businesses will be continuously updated with that time, businesses will be continuously updated with features, errors fixed, or function expansion. features, errors fixed, or function expansion. RFI is the support of the supplier for RFI is the support of the supplier for the business the business
Ability to store data Ability to store data   SCADA software SCADA software also its data storage capacity? also its data storage capacity? The ability to record and store data of SCADA The ability to record and store data of SCADA helps managers analyze diverse factors. helps managers analyze diverse factors.  This secures the safety maintenance and This secures the safety maintenance and optimization of the production line. Businesses also optimization of the production line. Businesses also 42 42 optimization of the production line. Businesses also optimization of the production line. Businesses also reduce many costs and risks. reduce many costs and risks.  For industries, SCADA systems play a vital role in For industries, SCADA systems play a vital role in storing information. The medicine or food industry storing information. The medicine or food industry also has regulatory requirements for data recording also has regulatory requirements for data recording
Database Database It is beneficial to learn It is beneficial to learn what is SCADA what is SCADA and its database. and its database. SCADA's database is a place to store all the collected SCADA's database is a place to store all the collected information. Managers can use the database to build information. Managers can use the database to build reports and analyze internal factors. reports and analyze internal factors. SCADA's main database is SQL (Structured Query SCADA's main database is SQL (Structured Query 43 43 SCADA's main database is SQL (Structured Query SCADA's main database is SQL (Structured Query Language) Language) - - a popular programming language used to a popular programming language used to manage data. Businesses can use SQL to edit, import or manage data. Businesses can use SQL to edit, import or export data, or save their databases in the cloud or on a export data, or save their databases in the cloud or on a private server. private server.
Alarm system Alarm system Most SCADA systems will have warnings following Most SCADA systems will have warnings following order and priority. Users or systems can define this order and priority. Users or systems can define this warning alarm. The user will program it if the alarm is warning alarm. The user will program it if the alarm is hardware related. Currently, human hardware related. Currently, human- -programmed alarms programmed alarms are divided into two categories: analog alarms and are divided into two categories: analog alarms and discrete alarms. discrete alarms. 44 44 discrete alarms. discrete alarms. The discrete alarm type operates on the numeric state of The discrete alarm type operates on the numeric state of a bit. Otherwise, the same alarm will be triggered a bit. Otherwise, the same alarm will be triggered through values beyond the defined limit. However, the through values beyond the defined limit. However, the SCADA system is quite limited in setting alarms. Only SCADA system is quite limited in setting alarms. Only when a problem occurs that a new alarm is triggered. when a problem occurs that a new alarm is triggered.
Visual data Visual data  What is the visual data of the SCADA system? What is the visual data of the SCADA system?   These are screens that record the visual operation of the These are screens that record the visual operation of the system. system. 45 45 system. system.  Operators can easily monitor and control data through Operators can easily monitor and control data through these. these.  Visual data is often represented by graphs or charts, Visual data is often represented by graphs or charts, thereby helping managers to observe the change in thereby helping managers to observe the change in specific values. specific values.  Visual data helps operators easily control Visual data helps operators easily control
Ability to analyze data Ability to analyze data • •Businesses need to pay attention to SCADA's data Businesses need to pay attention to SCADA's data analysis capabilities. analysis capabilities. • •In the 4.0 technology era, the system needs to be further In the 4.0 technology era, the system needs to be further upgraded to survive. upgraded to survive. • •For the most part, SCADA will provide a place for data For the most part, SCADA will provide a place for data 46 46 • •For the most part, SCADA will provide a place for data For the most part, SCADA will provide a place for data reporting, presentation, and production. However, the reporting, presentation, and production. However, the operator needs to carefully analyze the information to operator needs to carefully analyze the information to optimize the production process. optimize the production process. SCADA has good data analysis capabilities SCADA has good data analysis capabilities • •It is essential for businesses to data collection and It is essential for businesses to data collection and remote management, businesses can optimize the remote management, businesses can optimize the production process. production process.
SCADA system types SCADA system types Three types of basic SCADA systems Three types of basic SCADA systems: :   Basic SCADA Basic SCADA   One machine process One machine process 47 47   One machine process One machine process   One RTU and MTU One RTU and MTU   Integrated SCADA Integrated SCADA   Multiple RTUs Multiple RTUs   DCS DCS   Networked SCADA Networked SCADA   Multiple SCADA Multiple SCADA
Basic SCADA Basic SCADA 48 48  Car manufacturing robot Car manufacturing robot   Room temperature control Room temperature control
Integrated SCADA Integrated SCADA   Water systems Water systems   Subway systems Subway systems 49 49   Subway systems Subway systems   Security systems Security systems
Networked SCADA Networked SCADA   Power systems Power systems   Communication Communication NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 50 50   Communication Communication systems systems
Automation solutions Automation solutions SCADA system manufacturers SCADA system manufacturers   Modular SCADA, UK Modular SCADA, UK   MOSCAD, Motorola MOSCAD, Motorola   Rockwell Automation Rockwell Automation 51 51   Rockwell Automation Rockwell Automation   ABCO ABCO   ABB ABB   Lantronix Lantronix
SCADA Hardware SCADA Hardware SCADA Hardware manufacturers SCADA Hardware manufacturers   Rockwell Allen Bradley Rockwell Allen Bradley   General Electric (GE) General Electric (GE)   Emerson Emerson 52 52   Emerson Emerson   Schneider Electric Schneider Electric
SCADA Software SCADA Software SCADA Software manufacturers SCADA Software manufacturers   Intellution Intellution (Fix 32) (Fix 32)   Iconics Iconics (Genesis32 v7.0) (Genesis32 v7.0)   Wonderware Wonderware ( (InTouch InTouch) ) 53 53   Wonderware Wonderware ( (InTouch InTouch) )   Citect Citect ( (CitectSCADA CitectSCADA 5.42) 5.42)   National Instruments (Lookout SCADA) National Instruments (Lookout SCADA)
  P controllers P controllers provide proportional control based provide proportional control based on present error on present error  I controllers I controllers eliminate steady eliminate steady- -state error by state error by integrating past errors integrating past errors PID PID 54 54 integrating past errors integrating past errors   D controllers D controllers anticipate future trends by anticipate future trends by measuring the rate of change of the error measuring the rate of change of the error   and and PID controllers PID controllers combine all three actions to combine all three actions to achieve accurate and stable control achieve accurate and stable control
PID Block Diagram PID Block Diagram 55 55
How does a PID controller work? How does a PID controller work?   A PID controller continuously calculates an A PID controller continuously calculates an error signal as the difference between a desired error signal as the difference between a desired setpoint setpoint (the target value) and the current (the target value) and the current 56 56 setpoint setpoint (the target value) and the current (the target value) and the current process variable (the measured value). process variable (the measured value).   Based on this error signal, the controller adjusts Based on this error signal, the controller adjusts the system's control input to minimize the error the system's control input to minimize the error and maintain the process variable close to the and maintain the process variable close to the setpoint setpoint. .
 Error Calculation Error Calculation: The PID controller : The PID controller continuously calculates the error signal as the continuously calculates the error signal as the difference between the desired set point and difference between the desired set point and How does a PID controller work? How does a PID controller work? 57 57 difference between the desired set point and difference between the desired set point and the current process variable. the current process variable.  Proportional Control Proportional Control: The proportional (P) : The proportional (P) term responds to the current error by term responds to the current error by producing an output proportional to the producing an output proportional to the magnitude of the error. magnitude of the error.
 Integral Control Integral Control: The integral (I) term : The integral (I) term responds to the cumulative sum of past errors responds to the cumulative sum of past errors and aims to eliminate any steady and aims to eliminate any steady- -state error. It state error. It is calculated as the integral of the error over is calculated as the integral of the error over How does a PID controller work? How does a PID controller work? 58 58 is calculated as the integral of the error over is calculated as the integral of the error over time. time.  Derivative Control Derivative Control: The derivative (D) : The derivative (D) term responds to the rate of change of the term responds to the rate of change of the error and helps dampen rapid changes in the error and helps dampen rapid changes in the system. It is calculated as the derivative of the system. It is calculated as the derivative of the error over time. error over time.
 Control Output Control Output: The control output is the sum of the : The control output is the sum of the proportional, integral, and derivative terms. proportional, integral, and derivative terms.  Adjustment of Control Input Adjustment of Control Input: The control output is : The control output is applied as the input to the system being controlled. It applied as the input to the system being controlled. It adjusts system parameters such as valve positions, motor adjusts system parameters such as valve positions, motor speeds, or heating elements to bring the process variable speeds, or heating elements to bring the process variable How does a PID controller work? Cont.. How does a PID controller work? Cont.. 59 59 speeds, or heating elements to bring the process variable speeds, or heating elements to bring the process variable closer to the set point. closer to the set point.  Feedback Loop Feedback Loop: The process variable is continuously : The process variable is continuously measured and fed back to the controller, closing the control measured and fed back to the controller, closing the control loop. The controller adjusts the control input based on the loop. The controller adjusts the control input based on the feedback, aiming to minimize the error and maintain the feedback, aiming to minimize the error and maintain the process variable at the process variable at the setpoint setpoint. .
PID controller formats PID controller formats • •PID controllers are available as dedicated instruments, as PID controllers are available as dedicated instruments, as shown below. However, they are commonly integrated shown below. However, they are commonly integrated with with Programmable Logic Controllers (PLCs) Programmable Logic Controllers (PLCs) in industrial in industrial automation and control systems. automation and control systems. • •Engineers can configure PID parameters, Engineers can configure PID parameters, setpoints setpoints, and , and tuning values using ladder logic or structured text tuning values using ladder logic or structured text 60 60 tuning values using ladder logic or structured text tuning values using ladder logic or structured text programming languages within the PLC programming programming languages within the PLC programming environment. PLCs communicate with PID controllers using environment. PLCs communicate with PID controllers using industrial protocols like industrial protocols like Modbus Modbus, , Profibus Profibus, Ethernet/IP, or , Ethernet/IP, or OPC (Open Platform Communications). PID controllers OPC (Open Platform Communications). PID controllers receive process variable measurements from PLCs and send receive process variable measurements from PLCs and send control signals to adjust actuators in response. control signals to adjust actuators in response.
 Supervisory Control and Data Acquisition Supervisory Control and Data Acquisition (SCADA) (SCADA) systems systems monitor and control industrial processes. monitor and control industrial processes.   PID controllers integrated with PLCs can be seamlessly PID controllers integrated with PLCs can be seamlessly incorporated into SCADA systems, allowing operators to incorporated into SCADA systems, allowing operators to monitor and adjust control loops remotely from a central monitor and adjust control loops remotely from a central interface. interface. In addition to integration with PLC and SCADA systems, In addition to integration with PLC and SCADA systems, 61 61 In addition to integration with PLC and SCADA systems, In addition to integration with PLC and SCADA systems, PID controllers are sometimes implemented PID controllers are sometimes implemented in in microcontroller microcontroller and and embedded embedded systems systems, where real , where real- - time control is needed, but a PLC would be overkill. PID time control is needed, but a PLC would be overkill. PID algorithms can control devices such as motors, heaters, or algorithms can control devices such as motors, heaters, or sensors directly. sensors directly.
Main applications of PID controllers Main applications of PID controllers  PID controllers are extensively used to PID controllers are extensively used to regulate regulate temperature temperature, including heating and cooling systems. , including heating and cooling systems. to maintain precise temperatures in environments such as to maintain precise temperatures in environments such as industrial processes, buildings, and climate control systems. industrial processes, buildings, and climate control systems.  In In industrial automation industrial automation  In In robotics robotics and and motion motion control systems control systems: : controllers controllers 62 62  In In industrial automation industrial automation for controlling parameters for controlling parameters such as pressure, flow rate, such as pressure, flow rate, level, and pH in level, and pH in manufacturing processes manufacturing processes like chemical processing, like chemical processing, water treatment, and food water treatment, and food production. production. control systems control systems: : PID PID controllers controllers regulate motor speed, position, regulate motor speed, position, and torque, ensuring smooth and and torque, ensuring smooth and accurate movement in accurate movement in applications such as CNC applications such as CNC machines, robotic arms, and machines, robotic arms, and automated guided vehicles automated guided vehicles (AGVs). (AGVs).
63 63

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Unit Three.pdfrhykyfgdsfuliuyfgm,i;poiuyrtghkl;ipoiy

  • 1.
  • 2.
  • 3.
  • 4.
  • 5.
    Introduction Introduction SCADA (Supervisory Controland Data Acquisition) SCADA (Supervisory Control and Data Acquisition) System System  Why Why SCADA? SCADA?   Definition of SCADA Definition of SCADA 5 5   Definition of SCADA Definition of SCADA
  • 6.
     The architecture ofSCADA consists of The architecture of SCADA consists of programmable logic controllers (PLC) or remote programmable logic controllers (PLC) or remote terminal units (RTU). Both act as a communicator with terminal units (RTU). Both act as a communicator with HMIs (Human HMIs (Human- -Machine Interfaces), machines, Machine Interfaces), machines, terminals, and sensors. terminals, and sensors. Architecture of SCADA Architecture of SCADA 6 6 terminals, and sensors. terminals, and sensors.  The SCADA software will then route the data to the The SCADA software will then route the data to the computer and start processing, analyzing, and computer and start processing, analyzing, and displaying the data. Hence, staff and operators can displaying the data. Hence, staff and operators can analyze information and make decisions. analyze information and make decisions.
  • 7.
    History History   Egyptian supervisory Egyptiansupervisory   First half of the 20 First half of the 20th th century century   Development from telemetry system Development from telemetry system Weather predictions Weather predictions 7 7   Weather predictions Weather predictions   Rail road tracks Rail road tracks   Two way system Two way system   1960s idea for supervisory 1960s idea for supervisory   1970s radio system 1970s radio system
  • 8.
    Why SCADA? Why SCADA?  Saves Time and Money Saves Time and Money   Less traveling for workers (e.g. helicopter ride) Less traveling for workers (e.g. helicopter ride)   Reduces man Reduces man- -power needs power needs   Increases production efficiency of a company Increases production efficiency of a company 8 8   Increases production efficiency of a company Increases production efficiency of a company   Cost effective for power systems Cost effective for power systems   Saves energy Saves energy   Reliable Reliable   Supervisory control over a particular system Supervisory control over a particular system
  • 9.
    What is SCADA? Whatis SCADA?   Supervisory Control and Data Acquisition Supervisory Control and Data Acquisition   Supervisory Supervisory   Operator/s, engineer/s, supervisor/s, etc Operator/s, engineer/s, supervisor/s, etc   Control Control   Monitoring Monitoring   Limited Limited 9 9   Limited Limited   Telemetry Telemetry   Remote/Local Remote/Local   Data acquisition Data acquisition   Access and acquire information or data from the Access and acquire information or data from the equipment equipment   Sends it to different sites through telemetry Sends it to different sites through telemetry   Analog / Digital Analog / Digital
  • 10.
    HMI SCADA HMI SCADAsystems are divided into 4 distinct systems are divided into 4 distinct generations based on their architecture generations based on their architecture 1) The initial stage of SCADA (Supervisory Control & Data 1) The initial stage of SCADA (Supervisory Control & Data Acquisition) systems was known as 'monolithic SCADA' which Acquisition) systems was known as 'monolithic SCADA' which marked the beginning of its use. marked the beginning of its use. 2) 2nd generation distributed Supervisory Control and Data 2) 2nd generation distributed Supervisory Control and Data Acquisition (SCADA) systems are being widely used to effectively Acquisition (SCADA) systems are being widely used to effectively manage and monitor large scale industrial processes. manage and monitor large scale industrial processes. 10 10 manage and monitor large scale industrial processes. manage and monitor large scale industrial processes. 3) The third generation of SCADA systems are connected through 3) The third generation of SCADA systems are connected through networks, enabling the sharing of data among multiple users and networks, enabling the sharing of data among multiple users and devices. devices. 4) Fourth generation SCADA, also known as the "Internet of Things" 4) Fourth generation SCADA, also known as the "Internet of Things" technology, is becoming more prominent in industries due to its technology, is becoming more prominent in industries due to its capabilities. It allows for improved sensing and control with enhanced capabilities. It allows for improved sensing and control with enhanced communication & integration of systems. communication & integration of systems.
  • 11.
    Elements of SCADA Elementsof SCADA Elements of a SCADA system Elements of a SCADA system   Sensors and actuators Sensors and actuators   RTUs/PLCs RTUs/PLCs   Communication Communication   MTU MTU NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 11 11   MTU MTU   Front End Processor Front End Processor   SCADA server SCADA server   Historical/Redundant/Safety Server Historical/Redundant/Safety Server   HMI computer HMI computer   HMI software HMI software
  • 12.
    Master Terminal Unit(MTU): Master Terminal Unit (MTU): This is mostly This is mostly considered as the heart of SCADA. considered as the heart of SCADA.  Other names of this component are central Other names of this component are central control system or central station or SCADA control system or central station or SCADA Master Terminal Unit (MTU) Master Terminal Unit (MTU) 12 12 control system or central station or SCADA control system or central station or SCADA master. master.  This component, initiates virtually all This component, initiates virtually all communication with remote sites and interface communication with remote sites and interface with an operator with an operator component. component.
  • 13.
    The main functionsof this SCADA masters are The main functions of this SCADA masters are as follows. as follows. • Interfacing with operators through monitors, • Interfacing with operators through monitors, operators console and printers. operators console and printers. MTU cont.. MTU cont.. 13 13 operators console and printers. operators console and printers. • Making communication through gathering, • Making communication through gathering, storing, and sending information to storing, and sending information to other systems other systems • Processing data to generate appropriate action • Processing data to generate appropriate action
  • 14.
    flow diagram ofMaster transfer unit flow diagram of Master transfer unit 14 14
  • 15.
    Sensors Sensors Types of sensors: Typesof sensors:   Pressure sensors Pressure sensors   Temperature sensors Temperature sensors 15 15   Temperature sensors Temperature sensors   Light sensors Light sensors   Humidity sensors Humidity sensors   Wind speed sensors Wind speed sensors   Water level sensors Water level sensors   Distance sensors Distance sensors
  • 16.
    Actuators Actuators Actuator Actuator: is apart of a device or machine that helps to : is a part of a device or machine that helps to achieve physical movement by converting energy often achieve physical movement by converting energy often electrical, air , or hydraulic in to mechanical force, torque electrical, air , or hydraulic in to mechanical force, torque etc.., etc.., 16 16 etc.., etc.., Actuator Examples Actuator Examples   Valves Valves   Pumps Pumps   Motors Motors
  • 17.
    RTUs RTUs RTU RTU – – RemoteTerminal Unit Remote Terminal Unit   Intelligent to control a process and multiple processes Intelligent to control a process and multiple processes   Data logging and alarm handling Data logging and alarm handling   Expandable Expandable 17 17   Expandable Expandable   Asks the field devices for information Asks the field devices for information   Can control IEDs (Intelligent Electronic Device) Can control IEDs (Intelligent Electronic Device)   Slave/Master device Slave/Master device
  • 18.
    Alarms Alarms Types of alarms: Typesof alarms:   Good alarms Good alarms   Critical failure alarms Critical failure alarms NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 18 18   Critical failure alarms Critical failure alarms
  • 19.
    Safety instrumented systems Safetyinstrumented systems Actions: Actions:   Override the normal control system Override the normal control system   Take over the actuators Take over the actuators 19 19   Take over the actuators Take over the actuators
  • 20.
    PLCs PLCs PLC PLC – – ProgrammableLogic Controller Programmable Logic Controller   Ladder logic Ladder logic   Industrial computer that replaced relays Industrial computer that replaced relays NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 20 20   Industrial computer that replaced relays Industrial computer that replaced relays   Not a protocol converter Not a protocol converter   Cannot control IEDs Cannot control IEDs   Communication compatibilities Communication compatibilities   Takes actions based on its inputs Takes actions based on its inputs
  • 21.
    Communication Communication Communication systems: Communication systems:  Switched Telephone Network Switched Telephone Network   Leased lines Leased lines   Private Network (LAN/RS Private Network (LAN/RS- -485) 485) 21 21   Private Network (LAN/RS Private Network (LAN/RS- -485) 485)   Internet Internet   Wireless Communication systems Wireless Communication systems   Wireless LAN Wireless LAN   Global System for Mobile Communication Global System for Mobile Communication (GSM) Network (GSM) Network   Radio modems Radio modems
  • 22.
    Communication cont. Communication cont. Protocols: Protocols:  MODBUS MODBUS   DNP 3.0 ( DNP 3.0 (Distributed Network Protocol Distributed Network Protocol ) )   Fieldbus Fieldbus NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 22 22   Fieldbus Fieldbus   Controller Area Network (CAN) Controller Area Network (CAN)   Profibus Profibus(Process Field Bus) (Process Field Bus)   DirectNet DirectNet   TCP/IP TCP/IP   Ethernet Ethernet
  • 23.
    Front End Processor FrontEnd Processor Front End Processor Front End Processor   Gathers all communications and converts them Gathers all communications and converts them into SCADA friendly communication into SCADA friendly communication 23 23 into SCADA friendly communication into SCADA friendly communication   Communication interface between several RTU Communication interface between several RTU channels and the host Master Station computer channels and the host Master Station computer
  • 24.
    SCADA server SCADA server SCADAServer SCADA Server   It can be a Web server It can be a Web server   Data logging Data logging 24 24   Data logging Data logging   Analyzing data Analyzing data   Serve the clients through a firewall Serve the clients through a firewall   Clients connected in the corporation or connected Clients connected in the corporation or connected outside through internet outside through internet   Real Real- -time decision maker time decision maker   Asks RTU for information Asks RTU for information
  • 25.
    Historical server Historical server Historical/Safety/RedundantServer Historical/Safety/Redundant Server   Logs the data from the SCADA server and Logs the data from the SCADA server and stores it as a backup, in case of a disaster stores it as a backup, in case of a disaster 25 25 stores it as a backup, in case of a disaster stores it as a backup, in case of a disaster   It is basically a safety server It is basically a safety server
  • 26.
    HMI Computer HMI Computer HumanMachine Interface Computer Human Machine Interface Computer   Access on the SCADA Server Access on the SCADA Server   Control the system Control the system   Operator Interface Operator Interface NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 26 26   Operator Interface Operator Interface   Software Software   User friendly User friendly   Programmable (C, C++) Programmable (C, C++)
  • 27.
    DCS DCS DCS DCS – – DistributedControl System Distributed Control System   Process oriented Process oriented – – tendency to do something tendency to do something   Not event oriented Not event oriented – – does not depend on circumstances does not depend on circumstances   Local control over the devices Local control over the devices   Subordinate to SCADA Subordinate to SCADA 27 27  A Distributed Control System or DCS is A Distributed Control System or DCS is a computerized a computerized system that automates industrial equipment used in system that automates industrial equipment used in continuous and batch processes, while reducing the risk continuous and batch processes, while reducing the risk to people and the environment to people and the environment. .
  • 28.
    The control architectureof most industrial automation The control architecture of most industrial automation systems is composed of four hierarchical levels, each systems is composed of four hierarchical levels, each with its own set of functions and capabilities. with its own set of functions and capabilities.  These four levels are These four levels are  the field level the field level Levels of SCADA Levels of SCADA 28 28  the field level the field level   the remote terminal unit (RTU) the remote terminal unit (RTU)   the Communications level and the Communications level and  the human the human- -machine interface (HMI). machine interface (HMI).
  • 29.
    Central monitoring station Centralmonitoring station: is : is the human the human- -machine machine interface (HMI). interface (HMI). Includes one or more central servers connected Includes one or more central servers connected together, creating a system platform called a central together, creating a system platform called a central host computer server. At this monitoring station, the host computer server. At this monitoring station, the system will connect with the human system will connect with the human- -machine machine 29 29 system will connect with the human system will connect with the human- -machine machine interface (HMI) and software programs. interface (HMI) and software programs. Intermediate data collection station: Intermediate data collection station: These are RTUs These are RTUs (Remote Terminal Units) or PLCs (Programmable (Remote Terminal Units) or PLCs (Programmable Logic Controllers). These help communication Logic Controllers). These help communication between actuators such as sensors and switches between actuators such as sensors and switches actuators and control equipment. actuators and control equipment.
  • 30.
    Communication system Communication system: :This contains industrial This contains industrial communication networks and equipment. The system also communication networks and equipment. The system also includes converters that control and deliver field includes converters that control and deliver field- -level level data to the server. data to the server. Field Field- -level devices level devices: : These will include sensors, These will include sensors, 30 30 Field Field- -level devices level devices: : These will include sensors, These will include sensors, measuring devices, and transducers. measuring devices, and transducers.
  • 31.
    Levels of SCADA Levelsof SCADA Four levels of SCADA system Four levels of SCADA system   Level IV Level IV - - Enterprise Enterprise   Corporate LAN/WAN Corporate LAN/WAN   World Wide Web World Wide Web 31 31   World Wide Web World Wide Web   Virtual Private Network Virtual Private Network   Firewall for remote users Firewall for remote users   Level III Level III – – SCADA / MTU SCADA / MTU   Operator Workstations Operator Workstations   Control Control   Engineering Workstations Engineering Workstations   Servers Servers – – Data logging Data logging
  • 32.
    Levels of SCADAcont. Levels of SCADA cont. Four levels of SCADA system Four levels of SCADA system   Level II Level II – – Telecommunication Telecommunication   Fiber Fiber   Radio Radio 32 32   Radio Radio   Telephone leased line Telephone leased line   Protocols Protocols   Level I Level I – – Field Field   Devices Devices   RTUs / PLCs RTUs / PLCs   Sensors Sensors
  • 33.
    Where is SCADAused? Where is SCADA used?   Water and Wastewater Water and Wastewater   Power Power   Oil and Gas, Oil and Gas, Energy, petroleum, etc Energy, petroleum, etc Main SCADA applications Main SCADA applications i.e i.e Some industries and Some industries and fields that are favoring SCADA applications are fields that are favoring SCADA applications are 33 33   Oil and Gas, Oil and Gas, Energy, petroleum, etc Energy, petroleum, etc   Research facilities Research facilities   Transportation Transportation   Security systems Security systems   Siren systems Siren systems   Irrigation Irrigation   Communication control Communication control  Medicine, Food and drink, Manufacturing sector Medicine, Food and drink, Manufacturing sector
  • 34.
    SCADA examples SCADA examples SCADAexamples: SCADA examples:   Gas control systems Gas control systems   Water control systems Water control systems 34 34   Water control systems Water control systems   Power systems Power systems
  • 35.
  • 36.
  • 37.
  • 38.
    benefits of usinga SCADA system benefits of using a SCADA system  Improve productivity: Improve productivity: The system can analyze data from the The system can analyze data from the production process. As a result, managers can leverage data to production process. As a result, managers can leverage data to improve work efficiency, technology, and productivity. improve work efficiency, technology, and productivity.  Improve product quality: Improve product quality: Managers can find deficiencies in the Managers can find deficiencies in the production process and improve them through data analysis. production process and improve them through data analysis.  Reduce operation and maintenance costs: Reduce operation and maintenance costs: The installation and use The installation and use 38 38  Reduce operation and maintenance costs: Reduce operation and maintenance costs: The installation and use The installation and use of SCADA systems will replace a large amount of manual monitoring of SCADA systems will replace a large amount of manual monitoring work. This helps businesses reduce redundant personnel and save work. This helps businesses reduce redundant personnel and save more maintenance costs for remote manufacturing plants. more maintenance costs for remote manufacturing plants.  Preserve investment capital: Preserve investment capital: SCADA allows the factory to ensure SCADA allows the factory to ensure long long- -term efficiency for the upgrading process. Hence, investors and term efficiency for the upgrading process. Hence, investors and business owners can adjust and modify for the appropriate production business owners can adjust and modify for the appropriate production scale. scale.
  • 39.
    Why choosing SCADAsoftware for Why choosing SCADA software for businesses businesses The more The more learning about the SCADA system learning about the SCADA system, the more , the more utility is found in this system. However, businesses utility is found in this system. However, businesses need to carefully consider the system before need to carefully consider the system before implementing it. implementing it. 39 39 implementing it. implementing it. There are some Areas which can be useful when There are some Areas which can be useful when choosing SCADA software. choosing SCADA software.
  • 40.
    • •Currently, technology softwareis developing Currently, technology software is developing rapidly and is increasingly innovative. Therefore, rapidly and is increasingly innovative. Therefore, businesses need to pay attention to the expiry date businesses need to pay attention to the expiry date of SCADA. of SCADA. • •This is because software often becomes obsolete This is because software often becomes obsolete Date of validity Date of validity 40 40 • •This is because software often becomes obsolete This is because software often becomes obsolete after a period of time. SCADA systems in years of after a period of time. SCADA systems in years of use will be different from modern communication use will be different from modern communication standards. standards. So, You need to be aware of the lifecycle of SCADA So, You need to be aware of the lifecycle of SCADA
  • 41.
    RFI RFI • •RFI (Request forInformation) is the support of the RFI (Request for Information) is the support of the provider during the time the business uses SCADA. At provider during the time the business uses SCADA. At that time, businesses will be continuously updated with that time, businesses will be continuously updated with RFI (Request for Information) RFI (Request for Information) 41 41 that time, businesses will be continuously updated with that time, businesses will be continuously updated with features, errors fixed, or function expansion. features, errors fixed, or function expansion. RFI is the support of the supplier for RFI is the support of the supplier for the business the business
  • 42.
    Ability to storedata Ability to store data   SCADA software SCADA software also its data storage capacity? also its data storage capacity? The ability to record and store data of SCADA The ability to record and store data of SCADA helps managers analyze diverse factors. helps managers analyze diverse factors.  This secures the safety maintenance and This secures the safety maintenance and optimization of the production line. Businesses also optimization of the production line. Businesses also 42 42 optimization of the production line. Businesses also optimization of the production line. Businesses also reduce many costs and risks. reduce many costs and risks.  For industries, SCADA systems play a vital role in For industries, SCADA systems play a vital role in storing information. The medicine or food industry storing information. The medicine or food industry also has regulatory requirements for data recording also has regulatory requirements for data recording
  • 43.
    Database Database It is beneficialto learn It is beneficial to learn what is SCADA what is SCADA and its database. and its database. SCADA's database is a place to store all the collected SCADA's database is a place to store all the collected information. Managers can use the database to build information. Managers can use the database to build reports and analyze internal factors. reports and analyze internal factors. SCADA's main database is SQL (Structured Query SCADA's main database is SQL (Structured Query 43 43 SCADA's main database is SQL (Structured Query SCADA's main database is SQL (Structured Query Language) Language) - - a popular programming language used to a popular programming language used to manage data. Businesses can use SQL to edit, import or manage data. Businesses can use SQL to edit, import or export data, or save their databases in the cloud or on a export data, or save their databases in the cloud or on a private server. private server.
  • 44.
    Alarm system Alarm system MostSCADA systems will have warnings following Most SCADA systems will have warnings following order and priority. Users or systems can define this order and priority. Users or systems can define this warning alarm. The user will program it if the alarm is warning alarm. The user will program it if the alarm is hardware related. Currently, human hardware related. Currently, human- -programmed alarms programmed alarms are divided into two categories: analog alarms and are divided into two categories: analog alarms and discrete alarms. discrete alarms. 44 44 discrete alarms. discrete alarms. The discrete alarm type operates on the numeric state of The discrete alarm type operates on the numeric state of a bit. Otherwise, the same alarm will be triggered a bit. Otherwise, the same alarm will be triggered through values beyond the defined limit. However, the through values beyond the defined limit. However, the SCADA system is quite limited in setting alarms. Only SCADA system is quite limited in setting alarms. Only when a problem occurs that a new alarm is triggered. when a problem occurs that a new alarm is triggered.
  • 45.
    Visual data Visual data  Whatis the visual data of the SCADA system? What is the visual data of the SCADA system?   These are screens that record the visual operation of the These are screens that record the visual operation of the system. system. 45 45 system. system.  Operators can easily monitor and control data through Operators can easily monitor and control data through these. these.  Visual data is often represented by graphs or charts, Visual data is often represented by graphs or charts, thereby helping managers to observe the change in thereby helping managers to observe the change in specific values. specific values.  Visual data helps operators easily control Visual data helps operators easily control
  • 46.
    Ability to analyzedata Ability to analyze data • •Businesses need to pay attention to SCADA's data Businesses need to pay attention to SCADA's data analysis capabilities. analysis capabilities. • •In the 4.0 technology era, the system needs to be further In the 4.0 technology era, the system needs to be further upgraded to survive. upgraded to survive. • •For the most part, SCADA will provide a place for data For the most part, SCADA will provide a place for data 46 46 • •For the most part, SCADA will provide a place for data For the most part, SCADA will provide a place for data reporting, presentation, and production. However, the reporting, presentation, and production. However, the operator needs to carefully analyze the information to operator needs to carefully analyze the information to optimize the production process. optimize the production process. SCADA has good data analysis capabilities SCADA has good data analysis capabilities • •It is essential for businesses to data collection and It is essential for businesses to data collection and remote management, businesses can optimize the remote management, businesses can optimize the production process. production process.
  • 47.
    SCADA system types SCADAsystem types Three types of basic SCADA systems Three types of basic SCADA systems: :   Basic SCADA Basic SCADA   One machine process One machine process 47 47   One machine process One machine process   One RTU and MTU One RTU and MTU   Integrated SCADA Integrated SCADA   Multiple RTUs Multiple RTUs   DCS DCS   Networked SCADA Networked SCADA   Multiple SCADA Multiple SCADA
  • 48.
    Basic SCADA Basic SCADA 48 48  Carmanufacturing robot Car manufacturing robot   Room temperature control Room temperature control
  • 49.
    Integrated SCADA Integrated SCADA  Water systems Water systems   Subway systems Subway systems 49 49   Subway systems Subway systems   Security systems Security systems
  • 50.
    Networked SCADA Networked SCADA  Power systems Power systems   Communication Communication NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY NORWICH UNIVERISTY CENTER OF EXELLENCE IN DISTRIBUTED CONTROL SYSTEM SECURITY 50 50   Communication Communication systems systems
  • 51.
    Automation solutions Automation solutions SCADAsystem manufacturers SCADA system manufacturers   Modular SCADA, UK Modular SCADA, UK   MOSCAD, Motorola MOSCAD, Motorola   Rockwell Automation Rockwell Automation 51 51   Rockwell Automation Rockwell Automation   ABCO ABCO   ABB ABB   Lantronix Lantronix
  • 52.
    SCADA Hardware SCADA Hardware SCADAHardware manufacturers SCADA Hardware manufacturers   Rockwell Allen Bradley Rockwell Allen Bradley   General Electric (GE) General Electric (GE)   Emerson Emerson 52 52   Emerson Emerson   Schneider Electric Schneider Electric
  • 53.
    SCADA Software SCADA Software SCADASoftware manufacturers SCADA Software manufacturers   Intellution Intellution (Fix 32) (Fix 32)   Iconics Iconics (Genesis32 v7.0) (Genesis32 v7.0)   Wonderware Wonderware ( (InTouch InTouch) ) 53 53   Wonderware Wonderware ( (InTouch InTouch) )   Citect Citect ( (CitectSCADA CitectSCADA 5.42) 5.42)   National Instruments (Lookout SCADA) National Instruments (Lookout SCADA)
  • 54.
      P controllers Pcontrollers provide proportional control based provide proportional control based on present error on present error  I controllers I controllers eliminate steady eliminate steady- -state error by state error by integrating past errors integrating past errors PID PID 54 54 integrating past errors integrating past errors   D controllers D controllers anticipate future trends by anticipate future trends by measuring the rate of change of the error measuring the rate of change of the error   and and PID controllers PID controllers combine all three actions to combine all three actions to achieve accurate and stable control achieve accurate and stable control
  • 55.
    PID Block Diagram PIDBlock Diagram 55 55
  • 56.
    How does aPID controller work? How does a PID controller work?   A PID controller continuously calculates an A PID controller continuously calculates an error signal as the difference between a desired error signal as the difference between a desired setpoint setpoint (the target value) and the current (the target value) and the current 56 56 setpoint setpoint (the target value) and the current (the target value) and the current process variable (the measured value). process variable (the measured value).   Based on this error signal, the controller adjusts Based on this error signal, the controller adjusts the system's control input to minimize the error the system's control input to minimize the error and maintain the process variable close to the and maintain the process variable close to the setpoint setpoint. .
  • 57.
     Error Calculation Error Calculation:The PID controller : The PID controller continuously calculates the error signal as the continuously calculates the error signal as the difference between the desired set point and difference between the desired set point and How does a PID controller work? How does a PID controller work? 57 57 difference between the desired set point and difference between the desired set point and the current process variable. the current process variable.  Proportional Control Proportional Control: The proportional (P) : The proportional (P) term responds to the current error by term responds to the current error by producing an output proportional to the producing an output proportional to the magnitude of the error. magnitude of the error.
  • 58.
     Integral Control Integral Control:The integral (I) term : The integral (I) term responds to the cumulative sum of past errors responds to the cumulative sum of past errors and aims to eliminate any steady and aims to eliminate any steady- -state error. It state error. It is calculated as the integral of the error over is calculated as the integral of the error over How does a PID controller work? How does a PID controller work? 58 58 is calculated as the integral of the error over is calculated as the integral of the error over time. time.  Derivative Control Derivative Control: The derivative (D) : The derivative (D) term responds to the rate of change of the term responds to the rate of change of the error and helps dampen rapid changes in the error and helps dampen rapid changes in the system. It is calculated as the derivative of the system. It is calculated as the derivative of the error over time. error over time.
  • 59.
     Control Output Control Output:The control output is the sum of the : The control output is the sum of the proportional, integral, and derivative terms. proportional, integral, and derivative terms.  Adjustment of Control Input Adjustment of Control Input: The control output is : The control output is applied as the input to the system being controlled. It applied as the input to the system being controlled. It adjusts system parameters such as valve positions, motor adjusts system parameters such as valve positions, motor speeds, or heating elements to bring the process variable speeds, or heating elements to bring the process variable How does a PID controller work? Cont.. How does a PID controller work? Cont.. 59 59 speeds, or heating elements to bring the process variable speeds, or heating elements to bring the process variable closer to the set point. closer to the set point.  Feedback Loop Feedback Loop: The process variable is continuously : The process variable is continuously measured and fed back to the controller, closing the control measured and fed back to the controller, closing the control loop. The controller adjusts the control input based on the loop. The controller adjusts the control input based on the feedback, aiming to minimize the error and maintain the feedback, aiming to minimize the error and maintain the process variable at the process variable at the setpoint setpoint. .
  • 60.
    PID controller formats PIDcontroller formats • •PID controllers are available as dedicated instruments, as PID controllers are available as dedicated instruments, as shown below. However, they are commonly integrated shown below. However, they are commonly integrated with with Programmable Logic Controllers (PLCs) Programmable Logic Controllers (PLCs) in industrial in industrial automation and control systems. automation and control systems. • •Engineers can configure PID parameters, Engineers can configure PID parameters, setpoints setpoints, and , and tuning values using ladder logic or structured text tuning values using ladder logic or structured text 60 60 tuning values using ladder logic or structured text tuning values using ladder logic or structured text programming languages within the PLC programming programming languages within the PLC programming environment. PLCs communicate with PID controllers using environment. PLCs communicate with PID controllers using industrial protocols like industrial protocols like Modbus Modbus, , Profibus Profibus, Ethernet/IP, or , Ethernet/IP, or OPC (Open Platform Communications). PID controllers OPC (Open Platform Communications). PID controllers receive process variable measurements from PLCs and send receive process variable measurements from PLCs and send control signals to adjust actuators in response. control signals to adjust actuators in response.
  • 61.
     Supervisory Control andData Acquisition Supervisory Control and Data Acquisition (SCADA) (SCADA) systems systems monitor and control industrial processes. monitor and control industrial processes.   PID controllers integrated with PLCs can be seamlessly PID controllers integrated with PLCs can be seamlessly incorporated into SCADA systems, allowing operators to incorporated into SCADA systems, allowing operators to monitor and adjust control loops remotely from a central monitor and adjust control loops remotely from a central interface. interface. In addition to integration with PLC and SCADA systems, In addition to integration with PLC and SCADA systems, 61 61 In addition to integration with PLC and SCADA systems, In addition to integration with PLC and SCADA systems, PID controllers are sometimes implemented PID controllers are sometimes implemented in in microcontroller microcontroller and and embedded embedded systems systems, where real , where real- - time control is needed, but a PLC would be overkill. PID time control is needed, but a PLC would be overkill. PID algorithms can control devices such as motors, heaters, or algorithms can control devices such as motors, heaters, or sensors directly. sensors directly.
  • 62.
    Main applications ofPID controllers Main applications of PID controllers  PID controllers are extensively used to PID controllers are extensively used to regulate regulate temperature temperature, including heating and cooling systems. , including heating and cooling systems. to maintain precise temperatures in environments such as to maintain precise temperatures in environments such as industrial processes, buildings, and climate control systems. industrial processes, buildings, and climate control systems.  In In industrial automation industrial automation  In In robotics robotics and and motion motion control systems control systems: : controllers controllers 62 62  In In industrial automation industrial automation for controlling parameters for controlling parameters such as pressure, flow rate, such as pressure, flow rate, level, and pH in level, and pH in manufacturing processes manufacturing processes like chemical processing, like chemical processing, water treatment, and food water treatment, and food production. production. control systems control systems: : PID PID controllers controllers regulate motor speed, position, regulate motor speed, position, and torque, ensuring smooth and and torque, ensuring smooth and accurate movement in accurate movement in applications such as CNC applications such as CNC machines, robotic arms, and machines, robotic arms, and automated guided vehicles automated guided vehicles (AGVs). (AGVs).
  • 63.