presentation scada group

8/3/2019 Presentation SCADA Group

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Introduction to process control

1. Process

Methods of changing or refining raw materials to create

end products.2. Process Control.

Tool that enables manufacturers to keep their operationsrunning within specified limits and to set more preciselimits to maximize profitability, ensure qualityand safety.

3. Types of Process.

a) Discreteb) Continuous

c) Batch


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SET POINTS

FAN

COOLANT

ROOM TEMPSENCE

ROOM

ProcessVariable Controller

ManipulatedVariable

ERROR

COMPRESSORON-OFFCONTROL

Control Theory

SET POINTS

COMPRESSOR

Measurement

Comparison

Adjustment

Control Theory revolves around three aspects:

Error: The importantfactors of the Error are itsvale, duration and rate.

Controller output may beprogrammed to be Proportionalto Value, Duration (Integral) orRate (Differential) of input(error). Accordingly Controllers

are named as PID controller.

Room Air-conditioner is a simple example of feedback control


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Process Control Elements

Field Instruments Primary Elements/ Sensors Transducer/ Converter

Transmitter

Communication Channel Signals (Analog, Digital, Pulse)

Cables, Connectors etc.

Control Room

Indicators Recorders

Controller System

SCADA Systems


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Field Instrumentation

Field Instrumentation are devices that are

connected to the process being controlled andmonitored. These are sensors for monitoring certainparameters; and actuators for controlling certainparameters of the system.

These instruments convert physical parameters (i.e.,fluid flow, velocity, fluid level, etc.) to electricalsignals (i.e., voltage or current or digital) readableby the Remote Telemetry units. Outputs can either

be in analog (continuous range) or in digital(discrete values).


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Instruments & Measurement in Oil Industry1. Pressure Measurement

a) Pressure Transmitters

Strain Gauge based,b)Pressure Switches

2. Temperature MeasurementRTDs and thermistors, Infrared Radiators,

Bimetallic Devices,

Lquid Expansion Devices, and Change-of StateDevices

3. Flow Measurement

a) Mass Flow Meterb) Coriolis Flow Meter.c) Ultrasonic Flow Meter.d) Gas Flow Meter.

4 Level Measurement

5 Calibrators


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Control Room Equipments

Indicators

Recorders

Controller System

Relay based Control System Digital Logic Gates based systems PLC (Programmable Logic Controllers)

Distributed Control System

SCADA Systems

RTU SCADA Servers


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SCADA

SCADA system consists of collecting information,transferring it back to a central site, carrying out necessaryanalysis and control, and then displaying this data on anumber of operator screens.

The SCADA system is used to monitor and control a plant orequipment. Control may be automatic or can be initiated by

operator commands. SCADA systems are used in nearly every industry e.g. steel,

power generation and distribution, chemical petrochemical,oil & natural gas, in the house and lately in sophisticated toystoo.

The size of such systems range from a few 1000 to severalthousands of input/output (I/O) channels.


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Components of SCADA

SystemA SCADA system generally comprises of thefollowing :

1. Field Instrumentation

2. Remote telemetry Units

3. Communication Networks

4. Central Monitoring Station.


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What is Data Acquisition?

Data acquisition refers to the method used to access

and control information or data from the equipmentbeing controlled and monitored. The data accessed

are then forwarded onto a telemetry system ready

for transfer to the different sites. They can be analog

and digital information gathered by sensors, such as

flow meter, ammeter, etc. It can also be data to

control equipment such as actuators, relays, valves,

motors, etc.


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What is Telemetry ?

Telemetry is usually associated with SCADAsystems. It is a technique used in transmitting andreceiving information or data over a medium. Theinformation can be measurements, such as

pressure, temperature, flow, level, speed, voltageand current etc. These data are transmitted toanother location through a medium such as cable,telephone or radio. Information may come frommultiple locations. A way of addressing these

different sites is incorporated in the system.


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Typical System Configurations

There are two typical network configurations for

the wireless telemetry radio-based SCADA

systems.

point-to-point

point-to-multipoint configurations.


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Point-to-Point Configuration

The Point-to-Point

configuration is thesimplest set-up for atelemetry system.Here data is

exchanged betweentwo stations. Onestation can be setup as the master

and the other as theslave.


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Point-to-Multipoint Configuration

The Point-to-Multipoint

configuration is where

one device is designated

as the master unit to

several slave units. The

master is usually the mainhost and is located at the

control room. While the

slaves are the remote

units at the remote sites.Each slave is assigned a

unique address or

identification number.


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RTU

REMOTE TERMINAL

UNITS


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Basic operation

The RTU will operate scanning its inputs, normally ata fairly fast rate. It may do some processing such aschange of state processing, time-stamping of changes,and storage of the data awaiting polling from the

SCADA master. Some RTU's have the ability toinitiate reporting to the SCADA master, although morecommon is the situation where the SCADA masterpolls the RTU's asking for changes. The RTU may do

some alarm processing. When polled by the SCADAmaster, the RTU must respond to the request, whichmay be as simple as "give me all your data", to acomplex control function to be executed.


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Remote Terminal (Telemetry) Units -RTU

The SCADA RTU is a (hopefully) smallrugged computer which providesintelligence in the field, and allows thecentral SCADA master to communicatewith the field instruments.

It is a stand alone data acquisition andcontrol unit.

Its function is to control processequipment at the remote site, acquiredata from the equipment, and transferthe data back to the central SCADAsystem.


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There are two basic types of RTU

Single board RTU which is compact, and contains

all I/O on a single board

Modular RTU which has a separate CPU module,and can have other modules added, normally by

plugging into a common "backplane" (a bit like a

PC motherboard and plug in peripheral cards).


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Hardware functionality in an RTU

The RTU has the following hardware features:

CPU and volatile memory.

Non volatile memory for storing programsand data.

Communications capability either through

serial port(s) or sometimes with an on boardmodem.

Secure Power supply (with battery backup).

Watchdog timer (to ensure the RTU restarts if

something fails). Electrical protection against "spikes".

I/O interfaces to DI/DO/AI/AO's.

Real time clock.


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Software functionality in an RTUcontd..

Some method to allow the userapplications to be configured in theRTU. This may be simple parametersetting, enabling or disabling specific

I/O's or it may represent a completeuser programming environment.

Diagnostics.

Some RTU's may have a file systemwith support for file downloads. Thissupports user programs, andconfiguration files.


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SCADA

Supervisory Control &

Data Acquisition System


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Typical Functionalities of SCADA System

1. Real Time Data Acquisition2. Initiating Remote Controls

3. Historization

4. Alarm Generation/ Event Monitoring5. Man Machine Interface

6. Security/ User management

7. Trending8. Reporting

9. Interface to MIS/ Third Party

Applications

TYPICAL MULTI TIER SCADA ARCHITECTURE


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TYPICAL MULTI-TIER SCADA ARCHITECTURE

SCADA

SERVERCLIENTS

CLIENTS

CLIENTS

RTU

FIELD SENSORS

CONTROLLERS

ETHERNET

SCADA

SERVERCLIENTS

CLIENTS

CLIENTS

Local

Tier-1

RTU

FIELD SENSORS

CONTROLLERS

Radio

Radio

Tier-2


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Central Monitoring Station (CMS)

The Central Monitoring Station (CMS) is the master

unit of the SCADA system. It is in charge of

collecting information gathered by the remotestations and of generating necessary action for any

event detected. The CMS can have a single

computer configuration or it can be networked to

workstations to allow sharing of information fromthe SCADA system.


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Man-Machine Interface (MMI)

A Man-Machine Interface (MMI) program will berunning on the CMS computer. A mimic diagram ofthe whole plant or process can be displayed onscreenfor easier identification with the real system. Each I/O

point of the remote units can be displayed withcorresponding graphical representation and thepresent I/O reading. The flow reading can bedisplayed on a graphical representation of aflowmeter. A reservoir can be displayed with the

corresponding fluid contents depending on the actualtank level. The products support multiple screens,which can contain combinations of synoptic diagramsand text.


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The MMI program can alsocreate a separate window

for alarms. The alarmwindow can display thealarm tag name,description, value, trip

point value, time, date andother pertinentinformation. All alarmswill be saved on a separate

file for later review (referfigure)


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Trending

The products all provide trending facilities and one can

summarise the common capabilities as follows:

the parameters to be trended in a specific chart can be

predefined or defined on-line

a chart may contain more than 8 trended parametersor pens and an unlimited number of charts can be

displayed (restricted only by the readability)

real-time and historical trending are possible, although

generally not in the same chart


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historical trending is possible for any archivedparameter

zooming and scrolling functions are provided

parameter values at the cursor position can bedisplayed

The trending feature is either provided as aseparate module or as a graphical object(ActiveX), which can then be embedded into asynoptic display. XY and other statistical analysis

plots are generally not provided.


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A trending of requiredpoints can beprogrammed on thesystem.

Trending graphs can beviewed or printed at a

later time. Generation of

management reports canalso be scheduled on for a

specific time of day, on aperiodic basis, uponoperator request, or eventinitiated alarms


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Logging/Archiving logging can be thought of as medium-term

storage of data on disk archiving is long-term storage of data either on

disk or on another permanent storage medium.

Logging is typically performed on a cyclicbasis, i.e., once a certain file size, time period

or number of points is reached the data is

overwritten.


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Logging of data can be performed at a set

frequency, or only initiated if the value changes or

when a specific predefined event occurs.

Logged data can be transferred to an archive once

the log is full. The logged data is time-stamped and

can be filtered when viewed by a user. The logging of user actions is in general performed

together with either a user ID or station ID.

There is often also a VCR facility to play backarchived data.

Logging/Archivingcontd.


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Report Generation One can produce reports using SQL type queries to

the archive, RTDB or logs. Although it is sometimespossible to embed EXCEL charts in the report, a "cutand paste" capability is in general not provided.

Facilities exist to be able to automatically generate,print and archive reports


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Automation

The majority of the products allow actions to beautomatically triggered by events. A scripting language

provided by the SCADA products allows these actions tobe defined. In general, one can load a particular display,send an Email, run a user defined application or scriptand write to the RTDB.

The concept of recipes is supported, whereby aparticular system configuration can be saved to a fileand then re-loaded at a later date.

Access Control

Access to the program is permitted only to qualified

operators. Each user is given a password and a privilegelevel to access only particular areas of the program. Allactions taken by the users are logged on a file for laterreview


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Scalability Scalability is understood as the possibility to extend

the SCADA based control system by adding moreprocess variables, more specialised servers (e.g. foralarm handling) or more clients. The products achievescalability by having multiple data servers connectedto multiple controllers. Each data server has its ownconfiguration database and RTDB and is responsiblefor the handling of a sub-set of the process variables

(acquisition, alarm handling, archiving).


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Data Transfer &

Communication inSCADA


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Communications in SCADA

Internal Communication

Instrumentation to Controllers (4-20 mA, HART,Foundation Fieldbus etc)

Controllers to SCADA Servers

In-between SCADA Servers

External Communication

Communication with Third Party Applications


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CommunicationsChannels / Modes

Directly Connected on LAN

This is mostly applicable in PC based local SCADAsystems. Used in Drilling Rigs, and Onshore Production

Installations such as GGGs, GCS

Connected through Radio/ Telephone / VSAT

These cannels are used for Remote Stations. Used in

Offshore Unmanned Production Platforms and OnshoreRemote Production Installations.

Some Industry Standard


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Some Industry StandardCommunications Protocols

MODBUS

MODBUS protocol is a messaging structure widely used toestablish Master Slave communication between intelligentdevices.

It is independent of underlying physical layers. It is traditionally implemented using RS232, RS 422 or

RS485 over a variety of media (eg. Fiber, radio).

MODBUS TCP/IP was recently developed to provide afaster interface and uses TCP/IP and Ethernet to carry the

MODBUS messaging structure. It requires a license but all specifications are public and

open so there is no royalty paid for the license.



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DNP-3

DNP was originally created by Westronic in 1990.

DNP 3.0 is an open, intelligent, robust and efficient modernSCADA protocol.

It is based on the standards of the INTERNATIONALELECTROTECHNICAL COMMISSION(IEC) TechnicalCommittee.

It is used to exchange data between RTUs and Remotecentral points

DNP3 is an open and public protocol


S S


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ICCP

ICCP maximizes the use of existing standard protocols inall layers up to and including the lower layers of layer 7 inthe OSI reference model. This has the benefit of requiringnew protocol development for ICCP only in the upper sub-layer of layer 7.

ICCP utilizes the services of the Application ControlService Element(ACSE) in layer 7 to establish and managelogical associations and connections between sites.

It relies on the ISO Presentation Layer 6 and Session Layer5 as well.




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OPC (OLE for Process Control)

OPC(OLE for Process Control) is a software standard foropen software application interoperability betweenautomation/control application, field systems/devices andbusiness/office applications.

OPC defines a common, high performance interface basedon Microsofts COM/DCOM technology.

COM(Microsofts Component Object Model) enables thedefinition of standard objects, methods and properties forservers of real time information such as DCS, PLCs, I/Osystems and smart field devices.

DCOM(Distributed Component Object Model) is thenetwork-aware version of Com technology, providing datavia LANs, remote sites or the internet.



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Application Interfaces / Openness

The provision of OPC client functionality for

SCADA to access devices in an open and standardmanner is developing

The products also provide an Open Data Base

Connectivity (ODBC) interface to the data in thearchive/logs, but not to the configuration database,an ASCII import/export facility for configurationdata, a library of APIs supporting C, C++, andVisual Basic (VB) to access data in the RTDB, logs

and archive. The API often does not provide accessto the product's internal features such as alarmhandling, reporting, trending, etc.

Communications External to


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Communications External toSCADA System


ODBC (Open Database Connectivity), JDBC,

XTML etc

Enterprise Application Interface / Enterprise

Service Bus

li i f / O


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Application Interfaces / Openness

The provision of OPC client functionality for

SCADA to access devices in an open and standardmanner is developing

The products also provide an Open Data Base

Connectivity (ODBC) interface to the data in thearchive/logs, but not to the configuration database,an ASCII import/export facility for configurationdata, a library of APIs supporting C, C++, andVisual Basic (VB) to access data in the RTDB, logs

and archive. The API often does not provide accessto the product's internal features such as alarmhandling, reporting, trending, etc.

Communications External to


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Communications External toSCADA System


ODBC (Open Database Connectivity), JDBC,

XTML etc

Enterprise Application Interface / Enterprise

Service Bus


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Applications

ofSCADA


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SCADA From the cold of Siberia tothe heat, salt and moisture of

offshore oil platforms, SCADA(Supervisory Control and Data)systems are proven performers in awide variety of industries and

applications.

Oil & Gas Production & Drilling. Oil refineries

Electrical Generation, Transmission & Distribution Chemicals & Petrochemicals Fertilizers Water Distribution Sewerage


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END USERS OF SCADA DATA

1. At Production Facilities such as Operators and In-charges

Well Head Platform , of the facilitiesProcess complex.

2. At Drilling Rigs Drillers, Drill site Geologist,Chemist and DIC

3. MIS at reports on Production OperationsProduction facilities Managers

4. MIS reports Drilling Operationsfrom Drilling Rigs Managers

5. Corporate Office Chief of Production & DrillingDirectors and C&MD ofcompany

6. Remote Users R&D Institutes


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Applications of Drilling SCADA

Software packages are available performing offlinecalculations of Drilling Parameters related to the following:

Bottom Hole Assembly

Casing design

Cement Cost Modules

Drilling & Drill String Mechanics

Mud Control

Well Control

Well path

Monitoring of Following type of wells


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Monitoring of Following type of wells- High Oil Producers

- Critical Wells

- Observation Wells

Comparison of Well & Header Pressure

5.5

6

6.5

7

1 4 710

13

16

19

22

Time in Hours

Pressure

in

Kg/cm2g

Header Pressure

Time in Hours

Comparison of Well & Header Pressure

5.6

5.8

6

6.2

6.4

6.6

1 5 913

17

21

Time in Hours

Pressurein

Kg/cm2g

Header

Pressure

Well Pressure

PT

PT

Computer aided automatic Well Testing


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Computer aided automatic Well Testing


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Produced

Hydrocarbon

Out

Injection

Gas In

Side Pocket

Mandrel with

Gas Lift

Valve

Completion

Fluid

Side Pocket

Mandrel with

Gas Lift

Valve

Single

Production

Packer

Side Pocket

Mandrel with

Gas Lift

Valve

ON-LINE OPTIMISATION AND


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ON LINE OPTIMISATION AND

CONTROL OF GAS-LIFT WELLS

BY ASSET

H.P. GAS LINE

FT

TEST

Oil Flow Meter

TEST

HEADER

TESTGas Flow Meter

Test Separator

RTU

FLOW

SENSOR

Modified Set-up

ANNULUS

VALVE

Downhole

Parameters


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GAIN IN OIL RATE=80bblINCREASE IN GI RATE=12000SCMD

39783, 69549184, 709

56520, 847

66880, 889

75367, 822

650

700

750

800

850

900

950

39783 49184 56520 66880 75367

Gas Input (SCMD)

OilOutput(BOPD

)

RANGE OF PROD.BEFORE STUDY

AFTER STUDY

Gas Lift Optimization

Control Room at

POINT TO POINT


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LKW-CTF MORAN

Pressure, Temp, Total Qty &

Water Cut of Oil Dispatched to Uran

Pressure, Temp, Total Qty &

Water Cut of Oil Received

Control Room at

Asset HQ

MMIS

MASS BALANCING

POINT TO POINT

TRUNK PIPE LINEMASS BALANCING

BY USING SOFTWARE

AND AVAILABLEINSTRUMENTATION

AT EITHER ENDS OF

PIPE LINES

PIPE LINE

COMPUTER ASSISTED MONITORING OF ESP


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Optimal Pumping System

COMPUTER ASSISTED MONITORING OF ESP

The objective is to maximize the productionwithout damaging the formation

Production optimization and protection of the

system through the proper speed control as

function of:

Pump and motor temperatures

Fluid level conditions

Pressure (absolute and differential pressuremeasurements in the system)

High and low pump torque

Shut down backspin control

MIS DELHIGENERATION OF


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DPRs from GGSs & GCS

ASSET DPR

Field DPR


Field DPR


Field DPR

MIS DELHIREPORTS

BY SCADA


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