Scada System

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UNIT 2-SUPERVISORY & CONTROL FUNCTION

Data acquisitions system of digital device


Process Sensor Transducers Amplifier Signal Conditioning System

Display device

ADC

Data acquisition system in SCADA


Process Sensor/ Actuator RTU Monitoring system of SCADA

Data acquisition refers to the method used to access and control information or data from the equipment being controlled and monitored. They can be analog and digital information gathered by various sensors. It can also be data to control equipment such as actuators, relays, valves, motors, etc. In above block diagram. Sensor continuously monitoring the process .if any change of physical variable occurs in process then output of sensor will change. The output of Transducers connected to amplifier. In signal conditioning system, filtering, modulation, isolation of signal take place. Output of signal conditioning system is analog which is converting into digital signal by analog to digital converts. In SCADA system. All the signal processing take place in RTU. The output of RTU goes to the monitoring system of SCADA

STATUS INDICATION: SCADA provide status of any process running in particular time period. For example- if temperature of water inside the boiler is 23*C , then 23*C temperature shows on the monitoring screen of SCADA

RTU:
A remote terminal unit (RTU) is a microprocessor-controlled electronic device that interfaces objects in the physical world to a distributed control system or SCADA (supervisory control and data acquisition)

system by transmitting telemetry data to a master system, and by using messages from the master supervisory system to control connected objects. The remote terminal unit(RTU) connects to physical equipment. Typically, an RTU converts the electrical signals from the equipment to digital values such as the open/closed status from a switch or a valve, or measurements such as pressure, flow, voltage or current. By converting and sending these electrical signals out to equipment the RTU can control equipment, such as opening or closing a switch or a valve, or setting the speed of a pump.

Fig 1 :RTU System

How do they work? SCADA systems are primarily control systems. A typical control system consists of one or more remote terminal units (RTU) connected to a variety of sensors and actuators, and relaying information to a master station. Figure 2 illustrates this generic, three tiered approach to control system design. Figure 1 shows a typical RTU.

Fig 2: A typical 3-tiered approach to SCADA systems

Fig 3 :A generic representation of an RTU

Design and Implementation Protocols In SCADA Systems, the three major categories of protocols involve the specifications for design and manufacture of sensors and actuators, specifications for RTUs, and the specifications for communications between components of a control system.

These can be segregated into three levels for a functional representation as shown in Figure 4 below.

Figure 4: Segregation of the functions of a SCADA system, into a functional representation

Communications interfaces Modern RTUs and PLCs (Programmable Logic Controllers) offer a wide variety of communications means, either built in directly or through a module. The following list represents a variety of transmission methods supported: RS-232/RS-442/RS-485 Dialup telephone lines Dedicated telephone lines Microwave Satellite X.25 Ethernet 802.11a/b/g Radio (VHF, UHF, etc)

Regulatory function in SCADA


All process systems consist of three main factors or terms: the manipulated variables, disturbances, and the controlled variables (Figure 1). Typical manipulated variables: are valve positions, motor speed, damper position, or blade pitch. The controlled variables are those conditions such as temperature, level, position, pressure, pH, density, moisture content, weight, and speedthat must be maintained at some desired value. For each controlled variable there is an associated manipulated variable. Generally, set point: is fixed point set by
operator.

Fig 1

Disturbances: Enter or affect the process and tend to drive the controlled variables away from their desired value or set point condition. Typical disturbances include changes in ambient temperature, in demand for product, or in the supply of feed material . The control system must adjust the manipulated variable so the set point value of the controlled variable is maintained despite the disturbances. If the set point is changed, the manipulated quantity must be changed to adjust the controlled variable to its new desired value. For each controlled variable the control system operator selects a manipulated variable that can be paired with the controlled variable. Often the choice is obvious, such as manipulating the flow of fuel to a home furnace to control the temperature of the house. Sometimes the choice is not so obvious and can only be determined by someone who understands the process under control. The pairing of manipulated and controlled variables is performed as part of the process design.
a process control system consists of four essential elements: process, measurement, evaluation, and control. A block diagram of these elements is shown in Figure 1-3. The diagram also shows the disturbances that enter or affect the process. If there were no upsets to a process, there would be

no need for the control system. Figure 2 also shows the input and output of the process and the set point used for control.

Fig 2: Four elements of a control system Process


In general, a process consists of an assembly of equipment and material that is related to some manufacturing operation or sequence.

Measurement To control a dynamic variable in a process, you must have information about the entity or variable itself. This information is obtained by measuring the variable. Measurement refers to the conversion of the process variable into an analog or digital signal that can be used by the control system. The device that performs the initial measurement is called a sensor or instrument. Typical measurements are pressure, level, temperature, flow, position, and speed.The result of any measurement is the conversion of a dynamic variable into some proportional information that is required by the other elements in the process control loop or sequence.

Evaluation In the evaluation step of the process control sequence, the measurement value is examined, compared with the desired value or set point, and the amount of corrective action needed to maintain proper control is deter-mined. A device called a controller performs this evaluation. The controller can be a pneumatic, electronic, or mechanical device mounted in a control panel or on the process equipment. It can also be part of a computer control system, in which case the control function is performed by software.

Control The control element in a control loop is the device that exerts a direct influence on the process or manufacturing sequence. This final control element accepts an input from the controller and transforms it into some proportional operation that is performed on the process. In most cases, this final control element will be a control valve that adjusts the flow of fluid in a process. Devices such as electrical motors, pumps, and dampers are also used as control elements. Feedback loop in the process:

Fig : feedback loop in process control system An alarm system


In industrial plants and installations, control systems are used to monitor and control processes. Control Systems, whether a conventional Control Desk or a Computer/PLCs System with SCADA or a Distributed Control System (DCS), provides a man-machine-interface to monitor and control the plant equipment and processes. Alarm Systems are an integral part of manmachine interface. An alarm system consists of both hardware and software including; field signal sensors, transmitters, alarm generators & handlers, alarm processors, alarm displays, annunciator window panels, alarm recorders and printers. Alarm systems indicate the abnormal conditions and problems of the plant and equipment to the operators, enabling them to take corrective action and bring the plant/equipment back to normal conditions. Alarm systems give signals to the operators in the form of audible sound, visual indications in different colors and/or continuous blinking, text messages, etc. An alarm system brings the following to the notice of the operator:

problems that need operator attention process changes that require corrective action Unsafe operating conditions before Emergency Shut-down of the plant hazardous conditions deviations from desired/normal conditions

Functions of the plant or process operator An alarm system helps/assists the operators in monitoring and controlling the plant, equipment and processes within safe and normal operating conditions. In order to design a suitable alarm system, it is important to understand the functions of the operator who monitors and controls the equipment and processes in the plant. Generally, the functions of a plant operator are inclusive of the following activities but are not limited to: safe and normal operation of plant/equipment production at optimum levels identification of abnormal, hazardous and unsafe plant/equipment conditions and taking corrective action fault identification and communication of faults to maintenance

The above mentioned function and task priorities of a plant operator change with the changing
conditions of the plant. For instance:

during start-up when the plant is being stabilized when the plant is running under normal conditions when the plant is running in abnormal conditions when the plant is in emergency shut-down when the plant is in planned shut-down, when the plant, or sub-section of plant, is in manual mode of operation during automatic mode of operation

Functions of an alarm system

The main function of an alarm system is to direct the attention of an operator towards the plant abnormal conditions that need timely assessment and/or timely corrective action(s). An Alarm system alerts, informs and guides an operator regarding an abnormal situation and helps him to

take timely corrective action to bring back the plant to normal conditions. When an abnormal condition arises, the alarm system gives an alarm in the form of an audible warning, flashing or blinking alarm indication and an alarm message. The Alarm gives information about the problem or abnormal condition and its details. In a good alarm system, guidance or help messages on how to respond and take corrections are also provided. An ideal Alarm system also provides feedback on the corrective actions taken by the operator in response to the alarm. Such feedback is generally provided on supplementary display screens that can be accessed by selecting an alarm in the Alarm list.

An effective alarm system For designing an effective Alarm system, it is important to consider the following key points: Present only relevant and useful alarms to the operator Each alarm should have a defined response from the operator Configure and present only a good alarm Allow adequate time for an operator to respond to an alarm Protection provided by the alarm system Protection provided by an alarm system can take place in two ways. The operator is warned by the alarm and he/she takes corrective action before the protection operates, or the operator is warned that the protection has failed to operate and he/she takes corrective action.
Safety related alarms

As per the international standard IEC 61508, an alarm system, whether electrical or electronic or programmable, should be considered as safety related only if: It is a claimed part of the facilities for reducing the risk(s) from hazards to people to an acceptable or tolerable level, and The claimed reduction by the alarm system in the risk(s) is significant. Here the significant reduction means a claimed Average Probability of Failure on Demand (PFDAvg) < 0.1, It is designed, operated and maintained as per the requirements defined in the standard, It is independent and separate from the process control system, unless the process control system itself has been identified as a safety related system and implemented accordingly

Control valve
Control valves are valves used to control conditions such as flow, pressure, temperature, and liquid level by fully or partially opening or closing in response to signals received from controllers that compare a "set point" to a "process variable" whose value is provided by sensors that monitor changes in such conditions The opening or closing of control valves is usually done automatically

by electrical, hydraulic or pneumatic actuators. Positioners are used to control the opening or closing of the actuator based on electric or pneumatic signals. These control signals, traditionally based on 3-15psi (0.2-1.0bar), more common now are 4-20mA signals for industry A control valve consists of three main parts in which each part exist in several types and designs: Valve's actuator Valve's positioner Valve's bod

Flow Characteristics: It describes how the flow rate changes with the movement or lift of the stem. The shape of the plug primarily decides the flow characteristics. However, the design of the shape of a control valve and its shape requires further discussions. The flow characteristic of a valve is normally defined in terms of:

(a) inherent characteristics An inherent characteristic is the ideal flow characteristics of a control valve and is decided by the shape and size of the plug. Three types of control valves are normally in use. They are: (a) Quick opening (b) Linear (c) Equal Percentage A control valve is labelled LINEAR if its inherent flow characteristics can be represented by a straight line on a rectangular plot of flowrate F (or % F, or Cv or % Cv) versus % travel m (or Z for opening position) at the ideal condition of constant valve pressure drop (DPV). Therefore equal increment of travel or opening m produce equal increment of flow F (or Cv) at constant valve pressure drop (DPV). If m represents travel and F represents flow rate, then dm = k dF, where k is a proportional constant. Thus the valve gain or sensitivity, which is change in flow F divided by the change in travel m is constant, whether at low flow or high flow i.e. valve gain Kv = Df/dm = constant, independent of flow rate and valve opening A control valve is said to be EQUAL % if equal increment of valve travel or opening m (or Z) produces equal PERCENT (%) increment in flow F. If this occurs at the ideal condition of constant valve pressure drop (DPV), the valve is said to be inherently EQUAL % The Quick-Opening characteristic control valve has a flat disk instead of a contoured valve
plug. Its flow (or Cv) increase rapidly to its maximum flow with minimum initial valve opening. At the initial or lower portion of travel position, the valve gain Kv is too high for use in modulating control. Thereafter, the slope is flattish, where the flow rate hardly increases with valve opening m. Therefore, such control valve is limited to ON-OFF service and application or in specific application which requires fast initial release or discharge of flow.

Fig: Flow characteristics of control valves

Different flow characteristics can be obtained by properly shaping the plugs. Typical shapes of the three types of valves are shown in Fig. 5 Equal

Fig. 5 Valve plug shapes for the three common flow characteristics

(b) effective/installed characteristics. On the other hand, when the valve is connected to a pipeline, its overall performance is decided by its effective characteristic. So far we have
discussed about the ideal characteristics of a control valve. It is decided by the shape of the plug, and the pressure drop across the valve is assumed to be held constant. But in practice, the control valve is installed in conjunction with other equipment, such as heat exchanger, pipeline, orifice, pump etc. The elements will have their own flow vs. pressure characteristics and cause additional frictional loss in the system and the effective characteristics of the valve will be different from the ideal characteristics. Example of control valve Based on this characterstics: 1. Single seat plug valve 2. Double seat plug valve 3. Rotating shaft control valve 4. Butterfly valve

Comparison of ideal and effective characteristics for a linear valve A control valve is the final control element in a process control. Thus the effectiveness of any

control scheme depends heavily on the performance of the control valve. The proper design and fabrication of the valve is very important in order to achieve the desired performance level. Moreover control valves are of different size and shapes. Only few types of control valves have

been discussed here, leaving a large varieties of valves, those are in use, to name a few, globe valves, butterfly valves, V-port valves etc. We have discussed here the pneumatically actuated control valves, though electrically and hydraulically actuated valves are also not uncommon.
The shape of a valve plug is not the only deciding factor for determining its effective flow characteristics, but other equipment connected in the line along with the control valve, also affects its flow characteristics. Thus the effective flow characteristics of a linear valve may become nonlinear, as has been shown in this lesson. For this reason, equal percentage valves are preferred in many cases, since their effective characteristics tend to be linear, in presence of head loss in the pipeline. There are distinct guidelines for selecting the valve size and shape depending on load change, pipeline diameter etc. Bypass lines are sometimes used with a control valve in order to change the flow characteristics of the valve.

Transducers
The sensor or the sensing element is the first element in a measuring system and takes information about the variable being measured and transforms it into a more suitable form to be measured. The following figure illustrates the difference between sensor and transducer.

Fig 1:Principle of Sensor/Transducer Sensor is sometimes called a primary measuring element, it can be found simply as a mercury thermometer to measure the temperature. It may be embedded in the transducer to perform its function. That means the transducer consists of a primary element (sensor) plus a secondary

element (signal conditioning circuit) that transforms the passive change or small voltage signal into active signal range that can be easily used in other chains of the control loop. Active transducers: Does not need an external power source to produce output. Example thermocouple, Passive transducers: required external power sources Example RTD, Thermistors

Resistance-temperature Detectors (RTD)

The RTD temperature sensor is based on a particular property of metals wherein their electrical resistance changes with temperature. In particular, as temperature increases, so does electrical resistance. This is due to the fact that a higher temperature in a metal results in electron vibrations that impede the flow of free electrons in the metal. When discussing strain gages, we introduced the relationship

where R is resistance in ohms, is resistivity constant, which is a property of the specific conductor material being in the wire. It is measured in the unit of ohm-cm, L is the length of the wire in cm and A is the cross-sectional area in cm2 Thermocouple (Based on variation of inductance)
When a temperature differential exists across the length of a metal, a small voltage differential will exist due to the migration of electrons in the metal. By joining two dissimilar metal wires together at one end, a small current will be induced at the junction due to differences in the molecular structure of the metals. Generally , one junction is cold which is known as reference junction. Point (b), the other ends of the metal wires, is held at a reference temperatures & anthor is hot which associated with unknown temperature.

Fig 2 Principle of Thermocouple For dissimilar metals at a given temperature, the density of free electrons are different. This results in an electron migration at junction (a), causing a small current to flow from one metal to other. This small induced electric differential, with proper signal conditioning is measured. The electric signal has the property of being linear with the temperature differential between points (a) and (b). In particular, as simplified model is of the form :

where Vout is the induced voltage, is a constant in volts/degrees K and T, TRef are the measured temperature and the reference temperature respectively. Temperature range of thermocouple (-200*C to 2300*C) Output of thermocouple-mV (P.S.U Exam) J type T/C- Iron Vs Constantan up to 850*c (O.N.G.C 2011,B.A.R.C) K type T/C chromal Vs alumel up to 1150*C (B.A.R.C Exam ,2010,2011) S type T/C- Plantinum Vs alloy up to 2300*C

Various Monitoring screen of SCADA

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