SCADA

Current State
and

Perspective
Matthias Clausen, DESY (A. Daneels, CERN)

9 - 12 Oct. 2000

PCaPAC'2000 - DESY

Overview

What is SCADA (compared with DCS systems) Where and Why are SCADA systems used What do SCADA systems Provide? Evolution Benefits Experience from DESY Outlook

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Traditional Control

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Traditional Control 2nd

Dedicated Consoles Point to point communication No network

No remote access No remote diagnostic

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Distributed Control

Network Protocol PLCs

Field Bus Field Bus-Integrator

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Distributed Control 2nd

Advantages:

Distributed databases/ programs created from a single development environment (also in front end processor) Distributed access Distributed diagnostic Display everything everywhere

Disadvantages:

None of the DC systems are compatible to each other

Difficult: Integration of various field bus components

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SCADA ?
Supervisory Control
Graphics and Batch processing

And

Data Acquisition
Archiving, Logging, Access Control, Alarms

Distributed database Data Server Data Server PLCs Field Bus

Control Programs
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What, Where and Why

What is SCADAand where is it used

Supervisory Controls And Data Acquisition Application area : Industrial processes: chemical, power generation and distribution, metallurgy, Nuclear processes: reactors, nuclear waste, ... Experimental physics: Tokamaks, HEP laboratories Application size: 20 K I/O to 450 K I/O, two examples of 1 M I/O under development Reduction of resources CERN policy of outsourcing

Why SCADA systems were evaluated for LHC SLC ?

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What do SCADA Provide?

Flexible and open architecture Basic SCADA functionality

MMI Alarm Handling and Trending Access Control Automation Logging, Archiving, Report Generation

Interfaces to H/W and S/W Development Tools

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Generic Software Architecture

SCADA Client ASCII File Editor Graphics Editor MMI Trending Alarm Display Log Display Active X Controls Active X Container

SCADA Developt. Environt.

Library

ASCII Files

Client / Server - Publish / Subscribe - TCP/ IP SCADA Server Recipe RT & Event Manager DB Recipe Data Report Alarm Log Archive Gener. Managt Proces RT SQL Alarm DB Log DB Archive DB Ref. DB DB ODBC DDE Data API/DLL R/W Private Driver OPC EXCEL Application VME PLC PLC
10

Commercial DB Commercial Devel. tool

Export / Import

Project Editor Driver Toolkit

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SCADA functions (1): MMI

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SCADA functions (2)

Alarm

Handling

Based

on limit and status checking * More complicated expressions developed by creating derived parameters * Alarms are time stamped and logically centralised * Notifications (audible, visual, Email, GSM) Multiple alarm priority levels Grouping of alarms and handling of groups is possible Suppression and masking of alarms either individually or as a complete group Filtering of alarms is possible

* ! Experience @ DESY
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SCADA functions (3)

Trending
Multiple

trending charts Charts are pre-defined or configured on-line Charts contain multiple pens, Zooming, scrolling, panning, Hairline Real-time and historical trending

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SCADA functions (4)

Access

Control

Users

organised in groups with a set of allocated privileges Large number of groups possible Privileges limit write access to process parameters Some allow access to graphics and functionality to be limited

Automation
Actions can be initiated automatically triggered by an event * Recipes Sequencing and scripting possibilities

* ! Experience @ DESY
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SCADA functions (5)

Logging,
Data

Archiving

stored in compressed and proprietary format Logging / Archiving either for a set number of parameters or for a set period of time Logging / Archiving can be frequency or event driven * Logging of user actions together with a user ID VCR facility for playback of stored data

Report

Generation

Reports

created using SQL type queries to the RTDB or logs Automatic generation, printing and archiving of reports Use of components for report generation

* ! Experience @ DESY
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Interfaces to H/W and S/W

H/W

Multiple communication protocols supported in a single system (in particular CERN supported Field busses) Support for major PLCs/DCSs but not VME

S/W
API ODBC,

DDE and OLE I/F to PC Products OPC Client ActiveX Containers Web clients

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Development Tools

Project editor Graphics editor Configuration through parameter templates Scripting language Driver Development Tool Kit

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Evolution

Frequent new versions From tag/ channel-based to device oriented Multi-team development Web technology, Active X, Java, etc. OPC for internal communication Etc

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Why is OPC Data Access needed?

Display Application Trend Application Report Application

Software Driver

Software Driver

Software Driver

Software Driver

How does OPC Solve the Problem?

Display Application OPC Trend Application OPC Report Application OPC

OPC Software Driver

OPC Software Driver

OPC Software Driver

OPC Software Driver

Where does OPC Data Access Fit?

OPC (via DCOM)can also be used between subsystems and Management Consoles

OPC is generally used between Monitoring applications and I/O specific software drivers

Data Monitor SubSystem OPC Device Specific I/O Control

Low level sensors Typically use a dedicated Hardware Interface and protocol

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Benefits of SCADA

Standard frame for application Rich functionality (50 - 100 p-yrs investment) Reliability and Robustness (very large installed base, mission critical processes) Limited specific development Technical support and maintenance .. Etc

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Lets go for it ! ???

More Aspects to take into Account:

Configuration of SCADA Systems Data Access Mechanisms

DESY Experience:

Namespace: flat vs. OO System Load

Network Processor

Project Management

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Configuration of SCADA Systems

Data Server

Data Server

PLCs

Different Namespaces!!
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PLC

Configuration of SCADA Systems 2nd

Communication Processor Programs

SCADA

Analog-Input Value-AI-0 Value-AI-1 Analog-Output Value-AO-0 Value-AO-1

Mapping

Field Bus

Analog-Input Vacuum_VALUE Pressure_VALUE Analog-Output Valve_1_OUT Heater_1_OUT

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Configuration of SCADA Systems 3rd (Alarms)

SCADA
Data Server
Analog-Input Vacuum_VALUE Pressure_VALUE Analog-Output Valve_1_OUT Heater_1_OUT

Alarm Generation (generic) Alarm scripts:

IF (Pressure_VALUE > Pressure_HIHI_ALARMVAL) {Pressure_ALARM_HIHI=TRUE Pressure_ALARM_STATE=CRITICAL Pressure_ALARM_COLOR=RED } IF (Pressure_VALUE < Pressure_LOLO_ALARMVAL) {Pressure_ALARM_LOLO=TRUE Pressure_ALARM_STATE=ATTETION Pressure_ALARM_COLOR=BLUE }

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Winnings !!!
How many individual Tags did I create up to now in my example?

4
Vacuum_VALUE Pressure_VALUE Valve_1_OUT Heater_1_OUT

10

17

Pressure_VALUE Pressure_HIHI_ALARMVAL Pressure_ALARM_HIHI Pressure_ALARM_STATE Pressure_ALARM_COLOR

Pressure_VALUE Pressure_LOLO_ALARMVAL Pressure_ALARM_LOLO Pressure_ALARM_STATE Pressure_ALARM_COLOR

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Data Access Mechanism's

Alarm Server

Alarm Server typically poll data from the data server

( -> impact on network bandwidth)

Data Server

Data from field buses are mainly polled

Asynchronous protocols are difficult to handle

Field Bus

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DESY Experience 1st

Namespace

Individual tags for each property blow up the namespace Flat namespaces of thousands of tags can not be properly handled without adequate tools Latest SCADA technology clearly shows the trend to support the definition of objects which cleans up the namespace Additional non standard- features like calculating alarms for each channel temperature conversions ( 6th grade polynomial) ... can cause a lot of overhead which needs to be taken into account for the calculation of the system load on process controllers ( here: in a SCADA-like DCS system)

System Load

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DESY Experience 2nd

Project Management

Small systems can be easily handled with in-house personal Big systems (several thousand of channels) should be coordinated by an engineering office because of: The coordination of the Field Bus (PLC) databases and the SCADA databases The knowledge of the various tools which come along with a SCADA system One of the main arguments for SCADA systems is: outsourcing

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Lets go for it ! ???

Utility controls @ DESY use EPICS as a SCADA system H1 is going to use PVSS for their slow controls Theres no alternative for big projects like TESLA

Various subsystems can be controlled by SCADA systems: Utility Controls (water, energy, air, heating...) Cryogenic Controls (cryogenic plants, cryogenic distribution) Vacuum Systems (insulation vacuum, beam vacuum) Special developments i.e. for RF control should have a SCADAaware design

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Is SCADA the only Future ? ...

New Technology: JetWeb
Each node is an individual Web Server All nodes and all I/O hooked up to the Ethernet

... probably not, but a very attractive one.

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Thats all Folks

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SCADA functionality (1)

MMI
Library

of "generic" symbols with TAG links Dynamic linking of parameters to graphics On-line configuration and customisation of MMI Links can be created between display pages Animation and multimedia facilities

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SCADA functions (2):

Alarm Handling

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SCADA functions (3): Trending

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SCADA related Engineering: Examples

Define:

hierarchies and partitions and their distribution over the network user groups and their access rights naming convention for devices, etc. library of objects (PLC, devices, subsystems, ...) templates for different categories of "panels" mechanism to prevent conflicting controls (if not provided with the SCADA) alarm levels, behaviours, etc.

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Hardware Architecture
Client Client Dedicated Server

Ethernet

Data Server
Fieldbus

Data Server
Fieldbus

Controller

Controller

Controller

Controller

Controller
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