DCS- SCADA

An Introduction
Prof. Kapse C.D.
 What is Automation
Controlling and managing the plant operations with less number of
human operators

With goals

Better Production rate

Good Consistency

Good Efficiency

High Safety

Less Cost
 Automation Applications
Power generation hydro, coal, gas, oil, shale, nuclear, wind, solar

Transmission electricity, gas, oil

Distribution electricity, water

Process paper, food, pharmaceutical, metal production and

processing, glass, cement, chemical, refinery, oil & gas

Manufacturing computer aided manufacturing, flexible fabrication,

appliances, automotive, aircrafts

Storage silos, elevator, harbor, retail houses, deposits, luggage

handling

Building heat, ventilation, air conditioning (HVAC)access control,

fire, energy supply, tunnels, parking lots, highways,....

Transportation rolling stock, street cars, sub-urban trains,busses, trolley

busses, cars,ships, airplanes, rockets, satellites,...
 Automation
numerous conveyors, robots, CNC machines,
paint shops, logistics.
Download from production management,

• Factory connection to administration

• Process Continuous flow of materials, often 24 hours a day

Cement

• Building
Basics: fire, climate, energy management
HVAC = Heat, Ventilation and Cooling = air
conditioning
Automation Techniques
• Analog controller
• Single loop controller (SLC)
• PC
• CNC
• DDC
• Supervisory control
• PLC
• Centralized
• DCS
• DAS
 Evolution of Process
Automation
• Early control
• Discrete mechanical devices and switches
» Many operators
» Tour the plant
• Beginning of local control Room panels
• Pneumatic transmission
» indicating moved to one location
» Back transmission of control signals
» Less no of operators
» Bringing plant to the operator
» Still need to visit plant to adjust setting of final control
elements
» Not much monitoring, control and alarming
» Size of panel Bigger
• Electronic miniaturization
» Controller size smaller can fit on panel
» Size of panel reduced
» More complex control room and wiring
 Computer Control
• Direct Digital Control

Computer Process

Analog
Backup
Disadvantages

Advantages Computer reliability

Sophisticated Control Backup required

Flexible control Wiring Complex

Data Acquisition and HMI required high level

alarms operators
Expensive
• Supervisory control (Digitally Directed Analog Control
-DDAC)

Computer Analog Panel Process

Advantages Disadvantages

High Reliability
Complex wiring and Installation
Adequate HMI
Difficult to make strategy
Data acquisition and alarms changes
Sophisticated control Expensive
Complete redundancy
Centralized control

DDC and/or supervisory mode

SLCs

More organized centralized view Many wires

Easy to make control strategy Not scalable
changes
Information processing at single place
Alarms more flexible and effective thus Risky
 Distributed Process
control

Data Highway

I/O Cards

Sensors and actuators

Centralized information Less wiring & its cost

Processing Decentralized Digital communication thus can
Less risk (functional and physical) transmit more information
 Function of computers in control systems

open-loop functions closed-loop functions

Data acquisition and pre-processing Protection and interlocking

Data transfer between plant and operator Regulation

Display the plant state
Process-driven sequential
Simulation and training control

Logging and history Recording

Process optimization algorithms

Determining - Correct set point &

Ideal process recipe
 DCS
• Functions are distributed

• Micro computer based modules

• DCS is a computer network with real time

processing

• Modules distributed geographically and

functionally
 DCS functions
– Accept std inputs and digitize it

– Control – analog, discrete and advanced control

– Execute special programmed logic

– Monitor inputs

– Alarm the plant operations

– Trend, log, and report data

 DCS Architecture
Operator Work
Station Engineering Work
station

Data Highway

Communication
Module

Controller module

Local I/O Bus

I/O Module

Field Devices

PROCESS PROCESS
 I/O Module
• Functions
• Main interface between DCS and Process
• AIs, AOs, DIs , Dos are connected
• Convert information in to digital form
• Does signal filtering, signal characterizing and low level logic

• Board Design options

• Connected to single field device – single point integrity
• Connected to single input and single out put device- single loop integrity
• Connected to multiple inputs
• Connected to multiple outputs
• Connected to multiple inputs and multiple outputs
 Local I/O Bus
• Restricted to geographical area

• Communication Rate – 9600 to 250,000 b/s

• Connect many number of I/O and controller

module

• Serial/parallel communication or combination of

both

• Critical component
 Controller Module
• Brain of the DCS – main
function to control loops

• Functions Control interlocks

Sequencing
I/O signal characterization
Batch control
Signal filtering
Passing on trending
Alarming I/O module information
Ranging and engineering units passing on report
information
Control logic
 Controller module selection
considerations
• Available memory for configuration

• Available idle time

• I/O loading

• Available software addresses for I/O blocks and control

blocks
 Communication Module
• Microcomputers

• Manages flow of information between the data

highway and controller modules, user interfaces
and gateways to host computers and PLCs

• Should have room for expansion

• Critical – without them operator may blind to the

process
 Data Highway
• Is Back bone of DCS

• Real time information transmission

• It updates consoles, gateways , and other modules connected

• it is common to all plant wide components thus most critical

module

• Must redundant
 Data high way design considerations
• Design means
considering and/or selecting Factors affecting Design

– speed of transmission Number of tags ( I/O and

– Control loops)
– capacity
Amount of Trending and
– transmission efficiency reporting
information transferred
– Topologies
Volume of
– Protocols used communication link

– Maximum transmission Number of alarm points

distance

If more capacity needed Use two data highways

Two approaches for connecting --- 1- using gateways and Superhighway

2- Hw to Hw using high way interface module
User Interface ( consoles)
Interface between operator and DCS
CRT Based
Multiple displays on a single CRT – less no of
consoles
Multitasking ability

Displays the current state of the process (visualization)

- display the alarms and events (alarm log, logbook)
- display the trends (historians) and analyze them
- display handbooks, data sheets, inventory (documentation)
-allows communication and data synchronization with other centers
-Allows to make set pint point changes and control configuration of
control loops
 Features of User Interface

• Access to and size of database

– Tag limited console - RAM resident data base – access to limited
data base
– Display based console – consists number of pages- dynamic points
directly refreshed from field measurement

• Speed at which the screen builds

– Size of static and dynamic data
– Location of resident display pages ( hard or floppy)
– Use of display pages from another highway module

• Reliability and redundancy

 Role of operator in DCS

Plant condition Operator role

Steady- state operation Overall process

surveillance

Minor plant/unit upset Unit and section

monitoring

Planned Interactive
startup/shutdown

Major plant upset or Priority loop interaction

emergency
 Display Hierarchy

Plant overview
Display

Area 1
Status Trend
Area 2
Alarm Graphics

Group 1
Status Trend

Alarm Graphics

Detail display
Overview Display
 Engineering work Station

• Configure /update the data base and

console
• Implement application software
• Online and offline analysis of data
• To provide Process optimization results to
change control parameters
 SCADA
Supervisory control and Data Acquisition
• Acquires data
• Transmit data at longer distance
• Allows operator
» To make set point changes
» To open or close valves or switches
» To monitor alarms
» To gather measurement information
• Cost effective for process spread over longer
area with simple controls
 Components of SCADA

Operator
console
MTU
Communication
Medium

Modem

RTUs

Field
Devices
 Features of SCADA

• Advanced version of telemetry

• Two way communications

• Powerful HMI

• Real time system

• Master slave access method

• Serial communications

• Synchronous or asynchronous communication

• Half duplex or full duplex system

• Communication mediums – data rate and cost dependent

coaxial cables, leased telephone lines, optical fiber or radio link
 Scan interval and its importance
To ensure real time SCADA

• Scan interval – time between one conversation with an RTU

and next conversion with the same RTU
• Time required to complete scanning sequence
RTU1,RTU2…RTU1

• For real time operation Scan interval < fastest change

time of any variable connected to any RTU
• Factors Affecting Scan Interval
» No of RTUs

» Amount of data passed on each conversion

» Date rate

» Communication Efficiency
 PROTOCOL Structure Used in SCADA
Message Establishment DATA Message Termination

Synchronization Subfield Address Subfield Message Establishment

Function Subfield (close all) Internal Address Subfield ( starting Address)

SP. Features Subfield DATA

Modifier Subfield (no of DATA
valves ) (Flags)
 Functions of MTU
• Issues all commands

• Gather all the data

• Stores information

• processes information

• Interfaces with the operators

 Functions of RTU
• Discrete control

• Analog control

• Pulse control

• Monitor discrete signals

• Monitor analog signals

• Monitor pulse count signals

 Analog control
Bit 0 1 50%
1 25 %
0
0 7.5 v
To
D/A
0 field
device
0
0 I/O card
Bit 7 0 0.39 %
Analog Buffer
control
register 34
To store action information of one
CV 34 valve - needs one 8- bit or 16-bit
register
 Discrete control

Register Num
Buffer
0
0 0 1 1 0
1
Bit number
Relay To Field
1 0 Logic devices

0 1

0 1

To store action information of

8 valves - needs one 8- bit
registers
 Selection of PC , DCS or PLC
Based on SCAN time
Scan Typical function Likely
time system
1 month Computer
Corporate update -plant operational summary
1 day, Production report
shift
Off line optimization/analysis
1 hour
Batch management, batch scheduling DCS
1 minute Unit process optimization
1 second Display update, analog control ,process
calculations, batch sequencing
100 ms Flow control

20 ms High speed sequencing, interlocks PLC

1ms Sequence of events
 PLC, DCS or PC
based on I/O count and types
Large DCS Large DCS with Large DCS
Over
medium PLC with Large
150
PLC
Small DCS Small DCS with Small DCS
No of 3o to medium PLC with large PLC
analog loops 15o

Small PLC with medium PLC with large PLC with

Under PC or PC & PC or with SLCs integrated
30 SLCs work station

Under 200 200 to 600 Over 600

No of discrete I/O
Questions ?

UNCLASSIFIED