study of an innovative scada system based on industrial ... of an... · study of an innovative...

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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• 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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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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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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https://www.arduino.cc/en/Main/Software

https://www.youtube.com/watch?v=_wsoQevRDAM

https://www.arduino.cc/en/Reference/SoftwareSerial

https://www.arduino.cc/en/Reference/SoftwareSerial

https://www.arduino.cc/en/Tutorial/TwoPortReceive

https://www.arduino.cc/en/Tutorial/TwoPortReceive

https://github.com/smarmengol/Modbus-Master-Slave-for-Arduino










https://code.google.com/archive/p/simple-modbus/




http://www.lammertbies.nl/comm/info/RS-232_specs.html




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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https://support.google.com/accounts/answer/6010255?hl=en

https://support.google.com/a/answer/176600?hl=es

http://www.anybus.com/technologies/modbusplus.shtml

https://www.youtube.com/watch?v=SfYPvzCQRQk

http://datasheets.maximintegrated.com/en/ds/MAX1487-MAX491.pdf



https://technet.microsoft.com/en-us/library/cc775383(v=ws.10).aspx



http://modbus.org/docs/PI_MBUS_300.pdf

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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http://www.ni.com/labview/esa/

http://zone.ni.com/reference/en-XX/help/371361H-01/lvcomm/tcp_listen/





http://www.ni.com/white-paper/2710/en/



http://www.unilibre.edu.co/revistaingeniolibre/revista-11/art13.pdf



http://www.simplymodbus.ca/




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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http://www.ti.com/lit/an/slla272b/slla272b.pdf

http://www.omnisecu.com/tcpip/application-layer.php



http://irtfweb.ifa.hawaii.edu/~smokey/software/about/sixnet/modbus/modbus_protocol.pdf

https://github.com/ntruchsess/arduino_uip

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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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