SCADA & Communication

© ABB Group April 11, 2023 | Slide 1

Automation of Lift Irrigation Schemes Network Management

Archana Choudhary, 23rd January 2009, Power System – NM


Overview of Today’s Presentation

Water Automation projects with ABB India

Lift Irrigation projects under execution

Overview of SCADA system in Lift Irrigation projects

Product overview

Operation & Maintenance


Your Partner in turnkey solution for:

Motor Pump

Motor PumpMotor Pump

Motor Pump





Motor Pump

Motor Pump

Motor Pump

Motor Pump Irrigation

Substation & pumping station automation.

Water Transport and Supply

Water / Wastewater Treatment

Seawater Desalination


One stop shop solutions from ABB

Motors and Drives

Energy distributionEnergy supply

Actuators

Networks and controls

SCADA and Automation

Instrumentation


Network Management System


SCADA Defined

What is SCADA ?

SCADA stands for Supervisory Control and Data Acquisition

SCADA is a type of application

Not an off- the-shelf product or technology

Used in a wide range of industrial processes

Provide monitoring and control of remote equipment and facilities

Primary functions of SCADA system:

Data acquisition

Data communication

Data presentation

Control


Various protocols supported by SCADA

IEC 61850 Master Protocol for relay communicatios LONWORKS Devices DNP V3.00 Master Protocol DNP V3.00 Slave Protocol IEC 60870-5-101 Master/Slave Protocol IEC 60870-5-103 Master Protocol IEC 60870-5-104 Master/slave Protocol Modbus Master/slave Protocol OPC DA client for PLC communication


Data Acquisition Redundant Data Processing Calculations Supervisory Control Tagging Flexible Operator Authority Map board / Video Wall Alarm Handling & Presentation Historical and Planning data handling One-line and Tabular Presentation Trend Presentation Load Shed and Restore On-line Context Sensitive Help Disturbance Data handling Control System Supervision Full graphic HMI Network Topology Hot / standby redundant support Colour Setting tools Zooming, panning and de-cluttering Data storage into open databases like Ms-SQL server, Oracle etc.,

SCADA Features


SCADA User Benefits

User Benefits Always up-to-date and reliable information about network state

Secure operation of the network

Manual dressing of network operational state

Sorting of essential information at disturbances

Easy to define calculations and reports


Graphical User Interface

Operator Station based on Microsoft Component

Features

On-line Configurable Menus and Toolbars

Microsoft Excel for Report presentation

Trend and instantaneous curves based on ActiveX components

Support for large screen display walls

Support for Remote Workstations on many medias

WEB based system

User Benefits

Intuitive usage – less risk for operational errors

Reduced operator training costs

Advanced integration possibilities with minimal costs

“Future proof” - easy adaptation to new requirements


A4 Colour Printer

A4 B/W Laser Printer

SCADA Architecture for Master Control Center

GPS Antenna

HOPF

Engineering W/S

LAN A (Main)

LAN B (Hot SB)

Router/Firewall Main and Redundant HIS(UDW) Server

Main and Redundant SCADA/DMS Server

Workstation -1 Workstation -2 Workstation -3

Ethernet Switch

Ethernet Switch

To Backup Control Centre

Router

Redundant FEP For RTU’s & FRTU’s

Fiber Optic Network

Substation RTU’s

(220KV/132KV/66/11 KV)

For GIS services

Pumping station PLCs


Water Automation projects with ABB India


Water Projects with ABB India

Kerala Water Distribution System.

HNSS Lift Irrigation Project.

Indra Sagar Lift Irrigation Project.

PADA Lift Irrigation Project.

Sripada Sagar Lift Irrigation Project .

Rajiv Sagar Lift irrigation Project .

Dhummagudem Lift Irrigation Project Pkg-1 & Pkg-4.

Bhima Lift Irrigation Project .

Kalwakurty Lift Irrigation Project.

Pranahita Chevalla LIS Pkg-5, Pkg-7 and Pkg-12

Thotapalli Lift Irrigation Project.


Lift Irrigation Projects Under Execution

HNSS Lift Irrigation Project –12 pumping stations.

Indra Sagar Lift Irrigation Project – 3 pumping stations

PADA Lift Irrigation Project – 5 pumping stations

Bhima Lift Irrigation Project – 2 pumping stations

Kalwakurty Lift Irrigation Project – 1 pumping station

Kerala Water Distribution System.


Overview of SCADA system in Lift Irrigation

projects


SCADA In Lift Irrigation Schemes

Functionalities Requirements

Remote operation and management

Operation on Unmanned location

Data collection, storage, retrieval and archive

Alarm and events management

Reports generating

Process monitoring and control


Lift Irrigation Scheme Requirement

The details of four levels of automation such as

Local equipment panel (Level 1)

Local PLC control (Level 2)

Regional Control through network and Local PC (Level 3)

Central Control through PCs and network of entire system (Level 4)

Benefits in terms of

Extent of control

Performance

Reliability

Reduction in manpower, etc


Automation in Pumping Station

Programmable Logic Controller

Field Instrumentation :

Pressure Measuring Instruments

Flow Measuring Instruments

Level Measuring Instruments

Temperature Measuring Instruments

Vibration Monitoring System

SCADA Equipments

Communication Equipments


Components of SCADA System

Larger computers( Servers & workstations) running various software

Provide Human-machine Interface( HMI) for operators

Accept, process and store data from RTU ( substation automation) and PLC ( pumping system automation).

Regulate the controlled system

Distribute data to other systems


Components of SCADA System

Communication Network

Connect Central Control Station and RTU/RPU/PLC

Types of Networks

Direct connection (Fiber Optic Backbone)

Telephone (leased or dial-up line)

Radio

Satellite (GPRS/CDMA)

VSAT


Technology Innovation and Future Trends

Integration of SCADA with corporate IT system

Integration of SCADA with GIS

Integration of advanced process control technologies

Standardization

More open system and interoperability

Wider use of wireless network


Application Example

Remote Access and Control

Provide continued operational control of the facilities in the event of a facility evacuation from any other facility.

Provide support staff with remote access to process control system for troubleshooting and maintenance.

Provide view-only access to process monitoring system for external end-users.


Radio Link

SCADA Workstation

Radio Equipment

Operator Workstation

Ethernet Switch

PLC Controller

SCADA Workstation

Radio Equipment


Ethernet Switch

SCADA Workstation

Radio Equipment


Ethernet Switch

SCADA Workstation

Radio Equipment

Operation Workstation

Ethernet Switch

SCAD Workstation

Radio Equipment


Ethernet Switch

SCADA Workstation

Radio Equipment


SCADA Workstation

Radio Equipment


Ethernet Switch

SCADA Workstation

Radio Equipment


Ethernet Switch

SCADA Workstation

Radio Equipment


Ethernet Switch

SCADA Workstation

Radio Equipment


Ethernet Switch

Main Server

Radio Equipment

Standby Server

Ethernet Switch

PLC Controller

PLC Controller PLC Controller PLC Controller PLC Controllerv PLC Controller PLC Controller

PLC Controller

PLC Controller

PLC ControllerPS-1

PS-2

PS-6 PS-7 PS-8 PS-9 PS-10

PS-11

PS-12

PS-4 (Main Control Center)

Note:-

Operating Workstations

PS-5

Overview Of HNSS Pumping Stations & Master Control Centre


11KV Switchyard

PLC Controller

Ethernet Switch-1

Standby Server

Dot Matrix printer

Main Server

Ethernet Switch-2

PRINT SERVER

Hardw

ires signals from field instrum

ents

DI, D

O, A

I & A

O

Unit Control Board, Synchronizing

Equipment

DI, D

O, A

I & A

O

Field Instruments

Dot Matrix printer

Workstation -3 Workstation -4 Workstation -5

Laser Jet printer

SCADA Architecture for Pump House in Kalwakurity LIS

Workstation -2Workstation -1


KWA : Reservoir Monitoring Through SCADA


KWA Process Layout


KWA : Overview of Control Center


Service

Trouble Shooting Experts, Consultancy SparesService Contracts

Modernization, Extension Remote service, Maintenance System Training


Product Overview


Automation Hardware & Software

Hardware

Remote Terminal Unit – RTU 560, RTU211. ( for substation automation)

Programmable Logic Controller – AC800, AC500, AC31 ( pumping station automation)

Software

SCADA – Network Manager, Micro SCADA Pro, 800xa

GIS – Facilplus.


Market Requirements for Modern RTUs

NCC Process

Commands

MonitoringDirection

+serial

interfacingof

IEDsStation HMI

Integrated HMI PLC functions Data archives


Maintenance


Maintenance Overview

Maintenance, which has been a non-core area for a pumping Stations, is an integral area, which has to be looked in for better performance. Maintenance of equipment is of primary importance for every plant.

Maintenance procedures should be given a high priority in the daily work schedule, because making sure that the plant equipment functions properly is an important factor in achieving the proper water quality discharge.

By proper Maintaining the Plant Equipment, an operator can extend its Plant Life by at least 25 %.


Maintenance in LIS

Proper Maintenance is required for all the systems in the Pumping Stations.

Electrical Systems

Mechanical Equipments

Automation Equipments

Instrumentation


Maintenance Overview

Types of Maintenance:

Preventive Maintenance.

Predictive Maintenance.

Breakdown maintenance.


Preventive Maintenance It should be considered as a part of your normal daily work routine

and something that is necessary to keep the plant operation at full capacity.

Preventive Maintenance is the form of Inspection and tests that are performed every day.

Types of Preventive Maintenance

Planned Maintenance:

Planned Maintenance is defined as the periodic scheduled

removal of equipment from service for the disassembly and

inspection of Internal working parts.

Routine Maintenance:

Routine maintenance is best described as the daily general

Inspections and test including regular lubrication, that are

performed as a part of regular operation of the Plant.


Predictive Maintenance

Predictive Maintenance is regular monitoring of the actual mechanical condition, operating efficiency, and other indicators of the operating Condition of process systems will provide the data required to ensure the maximum interval between repairs and minimize the number and cost of unscheduled outages created by failures.


Key points for Predictive Maintenance:

Based on the Criticality of the Process Value & Instruments Value the Checking and Calibration should be done.

Improper Functioning of Instruments.

SCADA Value is not matching with the Field Values.

Based on the Alarm Generated.


Breakdown Maintenance

During the Shut Down Operation Breakdown Maintenance should be done.

Breakdowns in industrial manufacturing systems can have significant impact on the profitability of a business. Expensive production equipment is idled, labor is no longer optimized, and the ratio of fixed costs to product output is negatively affected. Rapid repair of down equipment is critical to business success; and this can be overcome by proper Preventive and Predictive maintenance.


Key Points for Breakdown Maintenance:

Before shutdown Collect the required data for preparing shutdown procedures.

During Shut down Clean all the Instruments and Equipments by dismantling.

Critical Instruments can be Calibrated during this Time.


Self-diagnostics

Hot swap maintenance

On-line changes of application program and configuration

Compact Flash memory for storage of application and data

Search & Navigation

Comprehensive maintenance features reduce down-time

Cost Effective Maintenance


Steps to Deploy SCADA System

Analyze process requirements

System design

Hardware selection and procurement

Control system programming

HMI development

Installation

Testing

Startup system


Calibration:

Calibration is the process of establishing the relationship between a measuring device and the units of measure. This is done by comparing a device or the output of an instrument to a standard having known measurement characteristics.

Calibration can be called for:

with a new instrument

when a specified time period is elapsed. For example PG,PS,PT etc

when a specified usage (operating hours) has elapsed.

when an instrument has had a shock or Vibration which potentially may have put it out of calibration

whenever observations appear questionable

SCADA & Communication

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