This document provides an overview of the evolution of computer applications in industry, beginning with data logging and progressing to more advanced systems like SCADA (Supervisory Control and Data Acquisition) and DCS (Distributed Control System). It describes how data logging evolved from fixed loggers to portable loggers with the ability to record process data over time. It then explains key aspects of SCADA systems, including data acquisition, information display, supervisory control, alarm processing, information storage, and data calculations. SCADA systems acquire data from remote locations, display it for operators, allow control of remote devices, manage alarms, store information, and perform calculations on process variables.
This document provides an overview of the evolution of computer applications in industry, beginning with data logging and progressing to more advanced systems like SCADA (Supervisory Control and Data Acquisition) and DCS (Distributed Control System). It describes how data logging evolved from fixed loggers to portable loggers with the ability to record process data over time. It then explains key aspects of SCADA systems, including data acquisition, information display, supervisory control, alarm processing, information storage, and data calculations. SCADA systems acquire data from remote locations, display it for operators, allow control of remote devices, manage alarms, store information, and perform calculations on process variables.
This document provides an overview of the evolution of computer applications in industry, beginning with data logging and progressing to more advanced systems like SCADA (Supervisory Control and Data Acquisition) and DCS (Distributed Control System). It describes how data logging evolved from fixed loggers to portable loggers with the ability to record process data over time. It then explains key aspects of SCADA systems, including data acquisition, information display, supervisory control, alarm processing, information storage, and data calculations. SCADA systems acquire data from remote locations, display it for operators, allow control of remote devices, manage alarms, store information, and perform calculations on process variables.
By V.S.Krushnasamy Evolution of computer application in the industry Data logging SCADA DDC PLC DCS
Data logging Data logger Data logging With the development of high speed digital computers with mass storage,it became possible to record such data continuously and automatically,display the data on command,and perform calculations on the data to reduce it to a form suitable for evalution by appropriate technical individuals. The efficient operation of a manufacturing process may involve the interplay of many factors such as production rates,materials cost,efficiences of control. Data logging When the process requires implementation of many process-control loops,then the interaction of one stage of the system with another often can be analyzed interms of the controlled variables of the loops. Data logging divided in to two types Fixed data loggers Portable data loggers Data logging Fixed data loggers The process is under the control of many analog process control loops and there is provision for analog process variable measurements to be available as a commonly scaled voltage. Thus some signal conditioning coverts all measurements in to a given range,often a specified voltage range as required by data acquisition system.
Data logging Computer This is the central element of the system. Through programming, the computer accepts input data or state and perform the process or evaluates the program through arithmetic and logic operations. It act as a discrete-state control or programmable controller.
Data logging DAS/DAQ Data acquisition is the process of sampling signals that measure real world physical conditions and converting the resulting samples into digital numeric values that can be manipulated by a computer. Data acquisition systems (abbreviated with the acronym DAS or DAQ) typically convert analog waveforms into digital values for processing. The components of data acquisition systems include: Sensors that convert physical parameters to electrical signals. Signal conditioning circuitry to convert sensor signals into a form that can be converted to digital values. Analog-to-digital converters, which convert conditioned sensor signals to digital values.
Data logging Peripheral units The PU are the support equipment to communicate computer operations to outside world. This unit consists of operator console where the programs are entered and through which commands can be given to initiate specfic actions, such as calculations and data outputs by computer. The console usually has a CRT/key board and a typewriter unit for input and outputs mass storage system such as magnetic tape,is used to store data such as periodically sampled inputs from the process. Data logging Alarms An important part of any data logging is an alarm system.such an alarm system is usually a computers or for help in a situation beyond its direct control. Types of alarms Simple alarm Multivariable alarms
Data logging Simple alarm One of the simplest digital application to process control is the implementation of simple alarm circuits. These are very elementary binary processes because we are only concerned about whether a variable is above or below an alarm level. Simple alarm constructed from a comparator ,where a voltage level indicates the alarm condition.
Data logging Multivariable alarms If each of a variable expressed through two states[logic1 and logic 0], then digital approaches are ideally suited for a multivariable alarm. The general procedure is to express the variables as boolean parameters and to find the boolean equation between the variables that gives an alarm(0/1) This equation then is implemented using logic circuit elements.
Data logging Portable data loggers There are many cases when data needs to be logged for a period of time from a loop and no fixed logger is provided. A portable logger can be temporarily connected to the measurement output of the loop for this purpose. The basic elements are DAS,computer/opertaor console, alarm. Some portable data loggers do not use a computer.They are merely strip chart/magnetic tape recorders. Data logging The computer based portable data loggers have some mechanism for saving the logged for later analysis. Recording mediums are Printed output Digitized strip-chart recording Magnetic tape Magnetic floppy disks Networked data communications In NDA the data logger may be connected to a LAN. The data then can be transmitted over the network to another, fixed computer installation. The data can be stored on mass storage facilities that are part of the network.
SCADA
SCADA
SCADA SCADA: Supervisory Control And Data Acquisition System A Supervisory System Encompasses all control ,indicating and associated telemetry equipments at the master station and all of the complimentary devices in the remote stations
SCADA SCADA stands for Supervisory Control And Data Acquisition. SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data.
WHAT IS DATA ACQUISITION Data acquisition is the process of retrieving control information from the equipment which is out of order or may lead to some problem or when decisions are need to be taken according to the situation in the equipment. So this acquisition is done by continuous monitoring of the equipment to which it is employed. The data accessed are then forwarded onto a telemetry system ready for transfer to the different sites. SCADA SCADA PURPOSE To Provide the user with the capability to exercise control over a specific device and confirm its performance in accordance with the directed action. To process those data for use by operator Operator control of remote devices
SCADA FUNCTIONS OF SCADA DATA ACQUISITION INFORMATION DISPLAY SUPERVISORY CONTROL ALARM PROCESSING INFORMATION STORAGE AND REPORTS DATA CALCULATIONS
SCADA DATA ACQUISITION Periodic acquisition of data from RTUs Data acquired on a polled basis Two options available on how a RTU responds: 1. Send the actual value of points 2. Send only those points where change has occurred The latter option preferred and referred to as Reporting By Exception Its a collective process of several specialized and highly related sub processes
SCADA INFORMATION DISPLAY This process consists of: 1. Retrieving both fixed and real time data from database 2. Combining them 3. Presenting them to the operator in the form of limited graphics CRT color pages This section is organized in a hierarchical tree structure Display selection by dedicated function keys provides very rapid access to frequently used displays
SCADA SUPERVISORY CONTROL Process of actuating equipment operation at remote locations This process includes: 1. Selection of station 2. Selection of the device to be controlled 3. Execution of desired commands such as TRIP or close Check-before-operate method is employed for security of personnel and electric system
SCADA ALARM PROCESSING This process includes: 1. Alerting the operator to unscheduled events 2. Informing him the time of occurrence, the station location, the device ID and the nature of event The most common output of the alarm are CRT alarm lists, hardcopy printouts and audible alarms
SCADA INFORMATION STORAGE AND REPORTS Accurate records are necessary to satisfy legal and governmental requirements for accounting, for support and forecasting future system operations and for engineering planning purposes Pre-selected data sets are captured at periodic intervals and saved in rotating file Periodicity of storage frequently set at certain time intervals called file time span
SCADA DATA CALCULATIONS Data calculations done with single variables are: 1. Determination of averages 2. Maximum or minimum values over given intervals 3. Integration with respect to time Calculations done with multiple variables include sums, differences, products, exponents, squares, square roots, exponentiation and others A practical application of such calculation is load monitoring of large transformer banks
SCADA FUNDAMENTALS OF OPERATION POLLING SCHEMES DATA INPUTS CONTROL OUTPUTS DATABASE MAN MACHINE INTERFACE
SCADA POLLING SCHEMES
SCADA In communications engineering this method is known as time division multiple access (TDMA) Master station controls and the RTUs respond to only polling requests. Following points are discussed through the diagram given: 1. Multiple 2 or 4 wire telephone grade circuits 2. Polling command requests, and RTU responses are time multiplexed 3. Automatic generation control (AGC)
SCADA DATABASE The newer database updates the real time part of the user programs which retrieves data from the database and save computed results back into the database They are not fixed in size but can easily be expanded provided the physical memory is available Information contained in SCADA database may be categorized into: 1. Real time 2. Parametric 3. Calculated 4. Application
SCADA MAN MACHINE INTERFACE One of the greatest challenges in SCADA is to provide efficient and user-friendly man machine interface It consists of the hardware as well as the program function which makes it all work Example of such a man machine interface : now in SCADA systems the simple audible alarm has been supplanted with a voice synthesizer which actually verbalizes alarm messages
SCADA APPLICATIONS Industrial control Oil & gas transmission, production and distribution Waste water utilities Electric utility for remote control of substations Power distribution automation
SCADA SCADA ADVANTAGES CHEAPER CONTINOUS OPERATION RELIABLE IMPROVES MAINTAINANCE, OPERATION, CUSTOMER SERVICE FEW OPERATORS CONTROL LARGE NO. OF INDIVIDUAL ASSETS PROVIDE RAPID RESPONSE TO EMERGENCIES SCADA DISADVANTAGES TROUBLED ALARMS LACK OF TRAINED PERSONS
INITIAL CAPITAL INVESTMENT SCADA MANUFACTURER AND NAME OF THE SOFTWARE WONDERWARE Intouch ALLEN BRADLEY R.S View SIEMENS Wincc MODICON oriecon G E FANUC implicity INTELLUSION I Fix KPIT Ashtra
BENEFITS OF SCADA Long distance monitoring Long distance training Protection against terrorism/vandalism-alarm Data management (engineering and operations) Automated operations with real time control
CONCLUSION SCADA is a control system with More interfaces and efficient storage More record or device oriented configuration But system wide configuration tools are needed Are less expensive than DCS, but offer different functionality than DCS And finally various applications DIRECT DIGITAL CONTROL (DDC) DIRECT DIGITAL CONTROL (DDC) DIRECT DIGITAL CONTROL (DDC) DIRECT DIGITAL CONTROL (DDC) DIRECT DIGITAL CONTROL (DDC) In early systems a single mainframe computer accomplished DAS,control.reporting to the operator, and higher level computation. In one of the first systems, the computer directly controlled the process,without intervening controllers. This architecture became known as DDC. Only one computer was used in the first system because of the high cost per processor and because of the general absence of computer to computer communications. Later systems used an auxiliary computer.
DIRECT DIGITAL CONTROL (DDC) The DDC came into picture for thermal power plant operation sidelining analog control system due to following advantages. Easy configuration,re-configuration and parameterization of control loops. Simple introduction of new control loops Possibility of realization of advanced control algorithms Model based optimization of optimal set point values Comprehensive data acquisition and presentation
DIRECT DIGITAL CONTROL (DDC) Disadvantage of DDC Though DDC take care of many things required for power plant control,relization of logic and sequential control functions were missing. In case of boilers operations like startup and shutdown traditionally done by relays which are separate from control systems. These systems executed both logic and sequential control.hence overall system became expensive and the reliability suffered. To overcome these problems,PLC are introduced. They took care in addition to logic and sequence control functions,the function of timers,counters,registers,etc,besides diagnostic features
PROGRAMMABLE LOGIC CONTROLLER(PLC) PROGRAMMABLE LOGIC CONTROLLER(PLC) PROGRAMMABLE LOGIC CONTROLLER(PLC) Introduction PLCs are specialized industrial devices for interfacing to and controlling analog and digital devices. They are designed with a small instruction set suitable for industrial control applications. They are usually programmed with ladder logic,which is graphical method of laying out the connectivity and logic between system inputs and outputs. They are designed with industrial control and industrial environments specifically in mind. Therefore ,in addition to being flexible and easy to program,they are robust and relatively immune to external interference. PROGRAMMABLE LOGIC CONTROLLER(PLC) A programmable logic controller is a digital electronic device that uses a programmable memory to store instructions and to implement functions such as logic sequencing, counting and arithmetic in order to control machines and processes. It has been specifically designed to make programming easy. Uses of PLCs PLCs are widely used and extend from small contained units with perhaps 20 digital inputs/outputs to modular systems which can be used for large number of inputs/outputs handle digital or analog inputs/outputs,and also carry out PID control modes. PROGRAMMABLE LOGIC CONTROLLER(PLC) Selection of a PLC Types of inputs/outputs required such as Isolation Out-board power supply for inputs/outputs Signal conditioning Input/output capacity required Size of the memory required. This is linked to the number of inputs/outputs and the complexity of program used. Speed and power required for CPU-This is linked to the number of types of instructions that can be handled by a PLC
PROGRAMMABLE LOGIC CONTROLLER(PLC) Special features The interfacing for inputs and outputs is inside the controller Easy programmable. They have an easily understood programming language. Programming is mainly concerned with logic and switching operation. Rugged and designed to withstand vibrations,temperatures,humidity and noise. PROGRAMMABLE LOGIC CONTROLLER(PLC) PLC consists of the following main components CPU[Central Processing Unit] Memory Input / Output circuitry
PROGRAMMABLE LOGIC CONTROLLER(PLC) Main units of PLC Power supply Input/output (I/O) system Real-time central processing unit Memory unit Programmer units Peripheral devices PROGRAMMABLE LOGIC CONTROLLER(PLC) CPU[Central Processing Unit] It controls and processes all the operations with in the PLC. It is provided with a clock with a frequency of typically between 1 and 8 MHz.This frequency determines the operating speed of PLC and provides the timing and synchronisation for all elements of the system. A bus system carries information and data to and from the CPU,memory and input/output units. PROGRAMMABLE LOGIC CONTROLLER(PLC) The various memory elements available in a PLC are A system ROM to give permanent storage for operating system and fixed data. RAM for users program Temporary buffer stores for input/output channels The program in the RAM can be changed by the user.However to prevent the loss of these programs when the supply is switched off a battery is likely to be used in the PLC to maintain the RAM contents for a period of time. Specifications for small PLCs often specify the program memory size in terms of the number of program step(A program step is an instruction for some event to occur)that can be stored. Typically the number of steps that can be handled by a small PLC is the order of 300 to 1000,which is generally more than adequate for most control situations. PROGRAMMABLE LOGIC CONTROLLER(PLC) Input/output(I/O) circuitry The I/O unit provides the interface between the system and the outside world. Programs are entered in to the I/O unit from a panel which can vary from small keyboards with LCDs to those using visual display unit with keyboard and screen display. The programs,alternatively,can be enter in to the system by means of a link to a personal computer which is loaded with an appropriate software package. The I/O channel provides signal conditioning and isolation functions so that sensors and actuators can be generally directly connected to them without the need for other circuitry.
PROGRAMMABLE LOGIC CONTROLLER(PLC) The basic form of programming commonly used with the PLCs is ladder programming. This involves each program task being specified as through a rung of a ladder. Following methods can be used for I/O processing Continuous updating Mass I/O copying
PROGRAMMABLE LOGIC CONTROLLER(PLC) Timers The timers are commonly regarded as relays with coils which,when energized,result in the closing or opening of input contacts after some preset time. A timing circuit is specified by starting the interval to be timed and the conditions or events that are to start and /or stop the timer. PLCs are generally provided with only delay-on timers that is a timer which comes on after time delay. Internal relays These relays are often used when there are programs with multiple input conditions. The internal relays are also used for starting of multiple outputs.
PROGRAMMABLE LOGIC CONTROLLER(PLC) Counters The use of counters is restored to when there is a need to count a specified number of contact operations. Counter circuits are supplied as an internal feature of PLCs. Shift registers Several internal relays can be grouped together to form a register which can provide a storage area for a series sequence of individual bits. Thus a 4-bit and 8-bit registers would be formed by using four and eight internal registers respectively. The term shift register is used because the bits can be shifted along by one bit when there is a suitable input to the register. PROGRAMMABLE LOGIC CONTROLLER(PLC) Advantages Flexibility Implementing changes and correcting errors Large quantities of contacts Pilot running Visual observation Speed of operation Ladder programming method Reliability and maintainability Security Fail-safe operation PROGRAMMABLE LOGIC CONTROLLER(PLC) Low cost Easy to install Ensures increased productivity Faster operation speed Provides high reliability and easier maintenance Can withstand harsh industrial environment/manufacturing environment Provides consistency in manufacturing Can input/output both analog and digital signals Reduced cost of scrap and rework(since the user/designer can change the PLC program without changing any hardware or scraping the present hardware). Small size PLC modules can be added, depending upon the input/output requirements Easier troubleshooting PROGRAMMABLE LOGIC CONTROLLER(PLC) Disadvantages Lacks the flexibility for expansion and reconfiguration. The operator interface in PLC systems is also limited. Implementing advanced control algorithms is also limited.