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Study of an innovative SCADA system based on Industrial Shields PLC
MSc in Automation Systems and Industrial Electronics
Electrical Energy Optimization
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Author: Oriol Filló Claret Supervisor: Jordi Zaragoza
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Automation Systems and Industrial Electronics Engineering
May 2016
1. Objectives 2. Scope 3. Justification 4. Specifications 5. Alternatives 6. Development
6. 1 Communications 6. 2 HMI
7. Budget & Economical feasibility 8. Environmental Impact 9. Planning 10. Environmental implications 11. Results & Conclusions 12. Future lines 13. Bibliography 14. Acknowledgements 15. Questions
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• Industrial communication protocols to Industrial Shields PLCs
• Development of a SCADA system prototype with Industrial Shields PLCs
• Proof of concept of a SCADA system based on alternative and open-source solutions
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Automation Systems and Industrial Electronics Engineering
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• Implementation Modbus RTU over RS-485 (master /slave)
• Development of an HMI supervision and control purposes
• Implementation of TCP over Ethernet in a LAN (PLC HMI) • Integration to the SCADA sytem of
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Sensors Data acquisition equipment Actuators
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Automation Systems and Industrial Electronics Engineering
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Automation Systems and Industrial Electronics Engineering
Open-standard systems • IoT • Industry 4.0 Modbus RTU (Modbus) • widely extended in the industry • demanded feature TCP-IP • Protocol of the Internet
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Automation Systems and Industrial Electronics Engineering
Case study – Reference plant Water tank in the save water system
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REFERENCE PLANT
STUDY PLANT
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Capabilities and system configuration
• Centralized configuration controller receives all the variable values (chloride, PH, turbidity). operates the dosing pumps accordingly.
• Adjustable variable limits from a remote location. • Variables updated on the HMI at a minimum rate of 15 minutes and stored in files. User interface • The user interfaces is an HMI on a remote PC with internet connection. • All variables and actuators states are visible on the HMI • The limits of the variables (max,min) are set manually on the HMI Data acquisition equipment and actuators • Inputs
o Seko Kontrol 800 chloride, PH, turbidity o Water intake and water outtake of the tank meters. Water tank level meter.
• Outputs o Dosing pumps Seko Tekna EVO APG800 (ANNEX D: Datasheets). o Each dosing pump have a digital control valve. o Water intake and outtake analog control valves.
Control of the variables Each variable has a maximum and minimum limit and its value must be contained within this range. Alarms • Upgraded compared to the reference plant:
o including more information on faults when there is an alarm. o up-to-date communication such as internet, instead of SMS.
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PLC • Industrial Shields (open-source )
o Low-cost o Flexibility o No-licensing o Accessibility o Programmed as an Arduino (C / C++ language)
• Standard industrial PLC (i.e.: Siemens )
o Widespread knowledge on the technology o Ready-to-use solutions. o More mature technology
HMI • LabView
o Ready –to-use graphical tools o Intuitive programming language o Extensive documentation and resources. o Previous experience
• C# and Visual Studio o Not-graphical language o Not ready-to-use tools o Extensive documentation resources
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6.1 COMMUNICATIONS IMPLEMENTATION Modbus RTU (RS-485)
• Search & adaption of Arduino IDE library SimpleModbus
• Master & Slave configurations
• Master & Slave simulator
• Final implementation
Master
(M-Duino)
Slave (Seko)
RS-485
RS-485
Master (M-Duino)
Slave (Ardbox)
Master (M-Duino)
RS-485
RS485 /USB
Slave simulator (PC)
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6.1 COMMUNICATIONS IMPLEMENTATION TCP (LAN) • Search & implementation of Arduino IDE library UIPEthernet
• TCP communication configuration
TCP Client (M-Duino)
TCP server (LabView) LAN
TCP
message=mes+iter;
i=i+1;
client.print(message.length());
client.print(message);
CLIENT (M-Duino)
SERVER (LabView)
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6.1 COMMUNICATIONS IMPLEMENTATION TCP (LAN) • TCP communication configuration
TCP
message = s_Var[0] + c + s_Var[1]… string MinFl+ c +MaxFl…
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6.2 HMI
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• ForcedVariables • Non-forced variables • Logic state / motion
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6.2 HMI
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• Alarm Notifications • Save • Controls
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6.2 HMI
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• DSC Modul
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• Low cost of the controller • Development price within market range
FESEABILE PROJECT
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Upgrade of the management & maintenance system Savings of resources & time. i.e.: on plant check-ups Industrial Shields Flexibility & adaptability reduced incompatibilities Savings of resources . i.e.: retrofitting & extensions
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10 Industrial communication protocols to Industrial Shields PLCs
• Modbus RTU over RS-485 (master /slave) • TCP over Ethernet in a LAN
(PLC HMI)
Already has an effect for customers and projects
Development of a SCADA prototype with Industrial Shields PLCs
• Interaction between HMI and PLC • Meet the set sepcifications
Proof of concept of a SCADA system based on open-source tech
• Open-source based SCADA prototype
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Industrial communication protocols to Industrial Shields PLCs • All the set objectives at the beginning of this project have been
achieved.
• The developed communications and prototype have proved to be a useful realization. All parts of this project have already been applied by Industrial Shields customers.
• Industrial Shields dispose now of a prototype or SCADA example
developed with its PLCs which serves as model.
• It was shown that a SCADA system based on open-source is possible and already an alternative to standard automation systems.
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Possible lines to be explored in a second phase of this study Development of a thorough reconnection capability.
Creation of a database and web server application.
Development of security protocol.
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• AEG Schneider Automation. (1996). Modicon Modbus Plus Network Planning and Installation Guide. November 2015.Schneider Electric:
• Arduino. (2005). Arduino. January de 2016. https://www.arduino.cc/en/Main/Software
• Arduino Robotics. (2014). Send an Email from Labview. December de 2015. Youtube: https://www.youtube.com/watch?v=_wsoQevRDAM
• arduino.cc. (2012). SoftwareSerial. November 2015. arduino.cc: https://www.arduino.cc/en/Reference/SoftwareSerial
• arduino.cc. (2012). TwoPortReceive. November 2015. arduino.cc: https://www.arduino.cc/en/Tutorial/TwoPortReceive
• Armengol, S. (2014). Modbus-Master-Slave-for-Arduino. github.com: https://github.com/smarmengol/Modbus-Master-Slave-for-Arduino
• Bester, J. (2012). Simple Modbus. November 2015. code.google.com: https://code.google.com/archive/p/simple-modbus/
• Bies, L. (2002). RS232 Specifications and standard. November 2015. http://www.lammertbies.nl/comm/info/RS-232_specs.html
• Boot & Work Corp, S.L. (2016). Industrial Shields. http://www.industrialshields.com/es/
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• Forouzan, B. A. (2010). TCP/IP Protocol Suite. Mcgraw-Hill.
• Google. (2011). Allowing less secure apps to access your account. December 2015. google.com:
https://support.google.com/accounts/answer/6010255?hl=en
• Google. (2012). Configuración de SMTP de Google Apps para enviar correo desde una impresora, un escáner o una aplicación. December 2015.Google: https://support.google.com/a/answer/176600?hl=es
• HMS Industrial Networks. (2006). Modbus Plus - Local Area Network. November 2015 .HMS Industrial Networks: http://www.anybus.com/technologies/modbusplus.shtml
• IndView. (2014). SCADA in LabVIEW - Animating a fan. September 2015. Youtube: https://www.youtube.com/watch?v=SfYPvzCQRQk
• Maxim Integrated Products, Inc. (2012). Low-Power, Slew-Rate-Limited RS-485/RS-422 Transceivers. November 2015. Maxim Integrated: http://datasheets.maximintegrated.com/en/ds/MAX1487-MAX491.pdf
• Microsoft. (2005). Technet.microsoft. November 2015. https://technet.microsoft.com/en-us/library/cc775383(v=ws.10).aspx
• Modbus Organization, Inc. (1996). Modicon Modbus Protocol Reference Guide. January 2016. modbus.org: http://modbus.org/docs/PI_MBUS_300.pdf
• Modbus, I. (2006). Modbus messaging on tcp/ip implementation guide v1. 0b. January 2016. modbus.org: http://www.modbus.org/docs/Modbus_Messaging_Implementation_Guide_V1_0b.pdf
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• National Instruments. (2012). National Instruments Corporation-Labview. January 2016.
http://www.ni.com/labview/esa/
• National Instruments Corp. (2011). TCP Listen VI. January 2016. http://zone.ni.com/: http://zone.ni.com/reference/en-XX/help/371361H-01/lvcomm/tcp_listen/
• National Instruments Corporation. (2013). When to Use UDP Instead of TCP. November 2015. National Instruments Corporation.
• National Instruments Corporation. (2015). Basic TCP/IP Communication in LabVIEW. January 2016. National Instruments Corporation: http://www.ni.com/white-paper/2710/en/
• Saboya, N. G. (2012). Serial Communication Standards: RS-232,RS-422 y RS-485. November 2015. unilibre.edu.co: http://www.unilibre.edu.co/revistaingeniolibre/revista-11/art13.pdf
• Siemens Energy & Automation. (2005). Modbus and ION Technology. January 2016. Siemens Corporation:
• Simplymodbus. (2006). Data Communication Solutions.November 2015. .Simplymodbus: • http://www.simplymodbus.ca/
• SparkFun Electronics. (2013). Serial Communication. November 2015. SparkFun Electronics:
https://learn.sparkfun.com/tutorials/serial-communication
• Texas Instruments Incorporated. (2011). RS-485 Unit Load and Maximum Number of Bus. November 2015.Texas Instruments Incorporated: http://www.ti.com/lit/an/slla166/slla166.pdf
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• Texas Instruments Incorporated. (2011). The RS-485 Design Guide. November 2015. Texas Instruments
Incorporated: http://www.ti.com/lit/an/slla272b/slla272b.pdf
• Thomas, J. (2012). TCP/IP Application Layer, Application Layer Protocols. November 2015. OmniSecu.com: http://www.omnisecu.com/tcpip/application-layer.php
• Trexon Inc. (2002). Modbus Protocol Specification. November 2015. Trexon Inc: http://irtfweb.ifa.hawaii.edu/~smokey/software/about/sixnet/modbus/modbus_protocol.pdf
• Truchsess, N. (2015). Arduino UIP. November 2015. github.com: https://github.com/ntruchsess/arduino_uip
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Diapositiva 25 de 20
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Special thanks and gratitude are extended to: o Project supervisor : Jordi Zaragoza o Project collaborators: Industrial Shields team
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THANK YOU VERY MUCH FOR YOUR ATTENTION
QUESTIONS?
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MILLORES REPORT: DEFINIR MILLOR LES ESPECIFICACIONS (INPUTS OUTPUTS/COM EN LA PRESENTACIÓ ) AFEGIR ESQUEMA PLANTA REFERÈNCIA DE CONTROL GPRS!!? Com es transmet el SMS? ESQUEMA PLANTA HADRWARE (configuració dipòsit, válvules, bombes i equip de mesura) EXPLICACIÓ EMMAGATZEMATGE DE DADES (comentar els valors que s’emmagatzemen i posar estructura) POSAR DESAVANTATGES EN LES ALTERNATIVES AFEGIR APARTAT CONCLUSIONS & RESULTS
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• Alternatives (labview-industrial shields Arduino
• Structure of the protocol
• Budget
• Environmental implic
• concusions
• acknowledgements)
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