Post on 25-May-2020
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Graham Nasby, P.Eng, PMP, CAP Water SCADA & Security Specialist
City of Guelph Water Services
SCADA 101
Introduction to SCADA Systems
-
Sensors, Data and Screens
SCOWWA Spring Conference – Ontario Water Works Association Wednesday, April 3, 2019 – St. Catherines, Ontario, Canada
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About the Speaker
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Graham Nasby, P.Eng., PMP, CAP
Water SCADA & Security Specialist
City of Guelph Water Services
• 10 years in the consulting sector
• Joined Guelph Water Services in 2015
• OWWA and WEAO Member, Member of OWWA Automation Committee
• Co-chair of ISA112 SCADA Systems standards committee
• Voting member of ISA101 HMI Design standards committee
• Voting member of ISA18 Alarm Management standards committee
• Named Canadian Expert on IEC/SCC-TC65 with Standards Council of Canada
• Has published over 30 papers and articles on automation topics
• Received University of Guelph “Mid Career Achievement Award” in 2014
• Named ISA’s technical division leader of the year award in 2013.
• Contact: graham.nasby@guelph.ca
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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City of Guelph Water Services
• Guelph, Ontario, Canada
• 140,000 residents
• 21 groundwater wells
• 3 water towers
• 549 km of water mains
• 49,000 service connections
• 2,750 fire hydrants
• 46,000 m3/day [12 MGD]
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Presentation Outline
• What is SCADA
• SCADA System Architecture
• Purpose of SCADA Systems
• SCADA View Nodes
• Instrumentation, Wiring, PLCs
• SCADA Screens & SCADA Alarm System
• Typical SCADA in Surface Water Systems
• Typical SCADA in Groundwater System
• Current Trends in SCADA Systems
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April 3, 2019 – SCOWWA Spring Workshop
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What is SCADA?
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SCADA = Supervisory Control and Data Acquisition
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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Why we have SCADA systems
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• Unattended automatic control of water facilities
• Logging of critical control parameters – Chlorine Residuals (e.g., every 5 minutes)
– Turbidity
– Well Flow Rates & Daily Flow Totals
– POE Flow Rates & Daily flow Totals
– Tower Levels & Pressure
• Provides “visualization” of water facilities to Operators
• Enables remote monitoring and control by Operators
• Triggering and Annunciation of Alarms
• Automated responses (increase chlorine dose, shutdown, etc.)
• Compliance reporting based on logged process data
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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I/O Level – a more complicated example
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UV Reactor
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SCADA callout System: SCADA Alarms
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What is an “alarm”?
• Notification of abnormal situation
• Requires an operator to respond
• Requires timely response
Order for Routing Alarms
-To SCADA View terminals
-Calls Supply Lead Hand
-after hours: On Call Supply
-then to a phone tree
Will keep calling until
acknowledged
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
“Teledac”
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Typical Instrumentation in Drinking Water Systems
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Common Instrumentation in Water Plants
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• Water Level
• Flow Transmitters
• Turbidity Meters
• Pressure Transmitters
• Differential Pressure (Head Loss in Filters)
• Chlorine Residual Analyzer
• Water Temperature
• pH
• Hardness and other special analyzers
• Ozone and Ambient Ozone Detectors
• Building Temperature
• Water Tower Level
Devices Controlled by SCADA
• Low lift Pumps
• Chemical Feed Systems
• Mixers/Flocculators
• Chemical Feed Pumps
• Disinfection Systems
• UV Systems
• Ozone Systems
• High Lift Pumps
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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Well Instrumentation
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• Well Flow Rate & Totalization – All flow from well (for permit)
– Flow to Treatment System
– Flow to Waste
• Well Level (Water Level)
• Well Pump Motor Electrical Power
• Pump Discharge Pressure
• Down-hole instrumentation
• Raw Water Analyzers for Studies
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What’s new in SCADA?
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• Is anything abnormal? • What if your are colour blind?
• What is running? • Is the process running well?
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SCADA: Situational Awareness
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To be an effective operator
–
you have to be aware of what your plant is doing
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Common SCADA problem
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In some SCADA systems….
You can’t see the whole picture
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Common SCADA problem
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What your SCADA system may not be showing you
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CAN
YOU
FIND
THE
PROBLEM
ON THE
SCADA
SCREEN?
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Situational Awareness
• To be able to react to a problem, Operators need to be aware of the problem
• Old way operating “by alarm” (reactively)
• New approach: Present data to operators so they can proactively respond to problems as they develop
• Reserve alarms only for events that require immediate action
• High Performance HMIs (Human Machine Interfaces)
• Alarm Management (better designed alarm systems)
• Understanding your operating envelope (know your plant’s limits)
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High Performance HMIs
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HMI = Human Machine Interface (computer screen)
Poor Colour Scheme
High Performance HMI Colour scheme
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High Performance HMI – Plant Running Normally
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Notice the Lack of Colour
HI
LO
F
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
There are 3 alarms active – can you
easily see them on the screen?
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High Performance HMI – Status Indicators
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Red and Green really stand out to the user!
Don’t use bright colours to show status. Reserve bright colours for alarms!
Use muted colours with backup text to show status.
Pumps not monitored by SCADA (no status information) are just shown as mid-gray:
Not
Running
Running
STOPPED
RUNNING
L
A A
L
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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High Performance HMI – Analog Values
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Diagnostic
Priority
Priority 3 Priority 2 Priority 1
480.1 psi 480.1 psi 480.1 psi480.1 psi
2 1
Diagnostic
Priority
Priority 3 Priority 2 Priority 1
480.1 psi 480.1 psi 480.1 psi480.1 psi4 3
Better
Betterer
Best! Suppressed
Alarm
480.1 psi S
480.1 psi No Alarm Indication 480.1 psi Often
Seen Only a Colour Change!
Show alarms in multiple ways: Colour, Shape, Text (“redundant coding”)
480.1 psi 480.1 psi 480.1 psi 480.1 psi
Diagnostic
Priority
Priority 3 Priority 2 Priority 1
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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High Performance HMI – Analog Values Another Way
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Cool
gpm
RECYCLE COMPRESSOR K43
Alarm Indicator
Desirable Operating Range
Alarm Range
Alarm Range
Show Values Show Trends
Buttons for additional functionality
2
Suct
psig Inter
psig
Dsch
psig
Suct
degF Inter
degF
Dsch
degF
E. Vib
mil
N. Vib
mil
W. Vib
mil
Motor
Amps
Oil
psig
Oil
degF
42.7
38.7 93.1
185 95 120
170
12
8 9
170
80
290
Interlock Indicator
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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High Performance HMI – Tank Levels Depiction
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Source: High Performance HMI Handbook
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High Performance HMI Diagnostics for Pumps
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Source: High Performance HMI Handbook
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High Performance HMI – Embedded Trends
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Source: High Performance HMI Handbook SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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High Performance HMI – Display Hierarchy
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• Level 1 – Plant or Entire System Overview– Entire Operator Span of Control “Single-Glance”
• Level 2 – Sub-Process Overview– More details than a Level 1 display, smaller area
• Level 3 – Equipment or Details Screen– Specific details about part of the process or control
• Level 4 – Specific Task or Diagnostic Screen– Very detailed screen, only used for diagnostics
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High Performance HMI – The Old Way
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R77
N28
Farnam 6
C16
Marcum
CSX9
Tempe
Adams 3
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High Performance HMI – Level 1 Display
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Altair 4
A A A A M A A A
113113
112113
0113
112112
A B C D E F G H
A A A A M A A A
4243
4244
043
4343
A B C D E F G H
A A A A M A A A
8.09.8
10.09.5
0.69.8
9.59.0
A B C D E F G H
ON
Station Status
G
E
C
A
B
D
H
F
ON
ON
ON
ON
ON
ON
Diag
H
TX LAAltair 4
Mesklin
Trantor
Minbari
Arrakis
River
Terminus
Mesklin Arrakis
7574
7877
7845
7574
5150
5050
7565
5551
A A A A M A A A
A B C D E F G H
H H
Trantor
ON
OFF
XFER
PULV A PULV B PULV C PULV D PULV E PULV F PULV G PULV HL1 OVERVIEW
08-15-2009 14:22:09
RUNBACK 1 RUNBACK 2 PULV OV
UNIT 2: RUNBACK Graphic 2
Gross MW 562
DECREASE
LOAD
TRICON
DEMAND:
ACS
DEMAND:
100.0%
100.0%
INCREASE
LOAD
Econ
O2 %
AUTO
5.0
50%
A2 BFP
KLB/HR
AUTO
1800
50%
B2 BFP
KLB/HR
AUTO
1800
50%
VALVE
FORCED
OPEN
VALVE
CONTROLLED
A2 BFP
Recirc
Selector
VALVE
FORCED
OPEN
VALVE
CONTROLLED
B2 BFP
Recirc
Selector
AUTO
2400
50.1%
BOILER
MASTER MAN
5.0 1800 1800
AUTO
65.0
50.1%
FUEL
MASTER MAN
2202 65.1
Input new ACS
DEMAND or
use buttons:
25% 50% 75%
Valve
SV-1
SV-2
SV-3
CV-1
CV-2
CV-3
CV-4
RHS-1
RHS-2
IV-1
IV-2
100%
100%
95%
88%
100%
100%
75%
0%
55%
100%
100%
100%0%
Valve Position
90.0%
TRICON
LOAD RATE:
VERY
FAST
TURBINE
MASTERMAN
TURBINE
FOLLOW
BOILER
FOLLOW
COORD
CONTROL
CONSTANT
PRESSURE
VARIABLE
PRESSURE
Gateway
Breaker 15 Power
Oil Temp 16-33
Oil Pres Status
Level in TK-8776
Gen System Status
Comp 88 in Auto
Lineup Ready
Sys Status Checks
Bearing Readouts
Comm check
Outlet Temp < 250
Cooling Flow
Internal Circuit Check
Bypass Closed
AFS Function
OK
NOT OK
OK
OK
OK
NOT OK
OK
OK
OK
OK
OK
OK
OK
OK
Pipeline Permissives
NOT OK
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
Source: High Performance HMI Handbook
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High Performance HMI – ISA101 Standard
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DESIGNSYSTEM STANDARDS
OPERATEIMPLEMENT
CONTINUOUS WORK PROCESSES
Continuous Improvement
RE
VIE
W
Philosophy
Style Guide
Toolkits
In Service
Maintain
Decommission
Continuous Improvement
Build Displays
Build Console
Test
Train
Commission
Verification
Console Design
HMI System Design
User, Task, Functional
Requirements
Display Design
New DisplayDisplay Changes
New SystemMajor Changes
ENTRYENTRY
MOC Audit Validation
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Alarm Management: ISA18.2
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ANSI/ISA-18.2-2016 * Management of Alarm Systems for the Process Industries
Alarm: An audible and/or visible means of indicating to the operator an equipment malfunction, process deviation or abnormal condition requiring a timely response.
Methodology for identifying, rationalizing and designing alarms to be a powerful tool for operations, and eliminating non-useful alarms
*originally published as ISA-18.2-2009, now also IEC-62682
Typical example of
results of ISA-18.2
being implemented
(showing before/after)
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Alarm Management: ISA18.2 Alarm Mgmt. Lifecycle
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Alarm Management: Master Alarm Database
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• MADB
– Central repository of approved alarms and their configuration (below is a wastewater example)
Tag Priority Desc. Condition Consequence If Ignored
Consequence Severity
Expected Operator Response
Time to Respond
P1-380-LAH-201 LOW Aeration 1 High Level
High Level Switch Activated for 10sec
Overflows in Secondary clarifiers.
MINOR Check Level Controller
2 hours
P1-380-AAL-102 MED Aeration 1 Low DO
DO below 3ppm for 30min
Loss of Biological Action, Risk of Damage to Biological Mass
MAJOR Investigate and turn on additional blowers
1 hour
P1-380-PALL-456A LOW Aeration 1 Air Pres. Low Low
Less than 15psi for 5min
Loss of Energy if Air Leak, Poor Aeration (Note: there is a low DO alarm)
MINOR Check pressures in air distribution system via HMI, check valves in field
4 hrs
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Alarm Management: Master Alarm Database
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• Alarm Tag
• Alarm Description (full description & what is shown on HMI)
• Identification: Trigger Condition, Purpose
• Rationalization:
– Consequence & Severity if Ignored
– Expected Operator Response, Time to Respond
– Alarm Priority & Alarm Class
– Justification for having this alarm configured!
• Design: Trigger Condition, On/Off Delays, Additional Filtering Logic, Setpoints, Routing/grouping information for the HMI
• Operation: When put into service, If Periodic Testing is required
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop
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Alarm Management: Non-Alarms
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HMI: Alarms, Events and Notifications • SCADA Systems can have multiple types of notifications
• SCADA systems should have support for:
– Alarms
– Other notifications: alerts, prompts, maintenance messages
– Event messages
– Logged-only events
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Alarm Management: Dedicated Alarm Display
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• Dedicated screen for displays alarms – only alarms
• Ideally on its own dedicated monitor in multi-monitor setup
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SCADA Cyber Security
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• You need to protect your SCADA system from unauthorized access
• In the past this was difficult to do….
• Requires multipronged approach
– People
– Process
– Technology
• There is guidance now available on how to do this
– ISA/IEC-62443 (formerly known as ISA-99)
– AWWA GW430
– NIST Cyber Security Framework
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SCADA Cyber Security Example: ISA/IEC-62443
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Zones and Conduits
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Wrapping Up
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• Structure of a SCADA system
• Typical SCADA for Surface Water Systems
• Typical SCADA for Ground Water Systems
• SCADA is essential for both Operations and Compliance
• Operators Need Situational Awareness to Operate Effectively
• HMIs need to provide Situational Awareness
• SCADA Alarms systems must be rationalized/documented
• Cyber Security requires a multi-pronged approach
• Remember the SCADA System is a tool for you: Put it Work!
SCADA 101 April 3, 2019 – SCOWWA Spring Workshop