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Basic understanding of PLC RTU DCS SCADA
- 1. Basic Understanding ofPLC, DCS and SCADA System • What are these terms: PLC, DCS, SCADA, RTU? • Why are they so important to industrial automation? • Explore how each build a comprehensive automated system. • Where & How they are used in ADNOC Onshore ? • As technology advances, the lines between various systems : PLC,DCS, SCADA become blurred. • Some devices move to obsolescence while others evolve and combine to create a single, more cost- effective solution. • It’s not important to spend time memorizing formal definitions since they are bound to change, but do understand them and remain open-minded to future trends and be prepared to learn how new technologies evolve can make you a more effective control engineer.
- 2. PLC • PLC :programmable logic controller. • These are the ‘brains’ of many different industrial processes. • The PLC was originally invented to replace relay banks as control systems for industrial automation. • This saves the massive costs over the relay controls by reducing the amount of hardware. Eliminate the need to physically re-wire each relay whenever a change needs to be made to the control system. • This is possible because PLCs can simply be reprogrammed. • Most PLCs use some form of ladder logic for programming which mimics the physical relay control system logic. Often called ladder logic. • This program looks like a ladder of relays and other electrical components with the ‘rungs’ placed between the power, represented on the sides. This can all be digitally displayed and reprogrammed on a computer or sometimes (especially in older systems) on a dedicated interface. • PLCs find use in many different processes in automation, controlling everything from lights to actuators and other control components. • PLC (but formal definition), only performs logical bit manipulation, it didn’t originally handle advanced communication and data sharing with higher and lower-level networks. When these functions started appearing, a new name for these devices began to take shape
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- 4. ADVANTAGES/DISADVANTAGE OF PLC Advantage •PLCs are known for their high level of reliability • Low maintenance requirements. • Due to the simple design, the system provides a quick response time. • Its simplicity allows for easy troubleshooting. • It delivers flexibility as the system is reprogrammable to perform different functions. • PLCs are relatively inexpensive. Disadvantage • Its design is not intended for large-scale operations due to its lack of modularity
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- 6. DCS • DCS :distributedcontrol system • DCS is a step up to a higher-level system used to control and monitor multiple process. • They often have a level of redundancy built into them to help mitigate the risk of downtime • They are used to monitor a series of process, often plant-wide, and monitor information to keep track of process data points and to control outputs. This allows for easier modifications when necessary within the series of process they are monitoring. • The DCS is not a single product that you can purchase, like a PLC, but rather an entire plant-level set of products from field-level I/O up through the controllers, all the way to software for production, monitoring, and scheduling. • Generally, most DCSs consist of like-branded electronic control components so the components can all communicate easily with each other. • For example, it makes sense for a new system to use all one brand of PLCs, I/O networks, and software to ensure that all of the equipment is compatible and able to communicate with the DCS. • Legacy equipment can be patch worked to accept a DCS, but this will usually be a more complicated and costly.
- 7. DCS • DCS :distributedcontrol system • DCS systems often contain an HMI (human machine interface) as part of its infrastructure, used to help an operator in a control room make decisions about the state of the system and make changes when necessary as equipment status is updated.
- 8. ADVANTAGES/DISADVANTAGE OF DCS Advantage •Sufficient redundancy as controllers exists for each subsystem, and all subsystems interconnect. Thus, one failure does not lead to the shutdown of the entire plant. • Dividing the system into various parts ensures no overload occurs. • The DCS provides a significant amount of data storage, allowing for the monitoring of process condition trends and analysis for accurate forecasting and predictive maintenance. Disadvantage • It is expensive to put together the entire system. • The DCS requires high maintenance needs and regular software and hardware system upgrades. • Due to the interconnectivity of all system parts, it is prone to cyber-attacks.
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- 13. DCS Brands List Thereare several major brands that produce and sell distributed control systems (DCSs), including: • Siemens: Siemens is a German multinational corporation that produces a wide range of industrial automation and control products, including DCSs. Their DCS is called Simatic PCS 7. • Yokogawa: Yokogawa is a Japanese multinational corporation that produces a wide range of industrial automation and control products, including DCSs. Their DCS is called CENTUM VP. • ABB: ABB is a Swedish-Swiss multinational corporation that produces a wide range of industrial automation and control products, including DCSs. Their DCS is called ABB Ability System 800xA. • Honeywell: Honeywell is an American multinational corporation that produces a wide range of industrial automation and control products, including DCSs. Their DCS is called Experion. • Rockwell Automation: Rockwell Automation is an American multinational corporation that produces a wide range of industrial automation and control products, including DCSs. Their DCS is called PlantPAx. • Schneider Electric: Schneider Electric is a French multinational corporation that produces a wide range of industrial automation and control products, including DCSs. Their DCS is called Foxboro Evo. • Emerson: Emerson is an American multinational corporation that produces a wide range of industrial automation and control products, including DCSs. Their DCS is called DeltaV
- 14. Applications of DCS DistributedControl Systems (DCSs) are widely used in a variety of industrial and infrastructure applications to control and automate complex processes. Some examples of applications of DCS include: • Power generation: DCSs are used to control and monitor power generation processes, such as coal-fired, gas-fired, and nuclear power plants. They are used to control and monitor the process variables such as temperature, pressure, flow, and level, to ensure the safe and efficient operation of the power plant. • Oil and gas: DCSs are used to control and monitor processes in the oil and gas industry, such as drilling, refining, and petrochemical production. They are used to control and monitor the process variables such as pressure, flow, and level, to ensure the safe and efficient operation of the process. • Water treatment: DCSs are used to control and monitor processes in water treatment plants, such as water purification, desalination, and wastewater treatment. They are used to control and monitor the process variables such as flow, pH, and temperature, to ensure the safe and efficient operation of the process. • Pharmaceuticals and biotech: DCSs are used to control and monitor processes in the pharmaceutical and biotech industry, such as fermentation, distillation, and purification. They are used to control and monitor the process variables such as temperature, pH, and pressure, to ensure the safe and efficient operation of the process. • Manufacturing: DCSs are used to control and monitor processes in manufacturing, such as assembly lines, robotic systems, and packaging systems. They are used to control and monitor the process variables such as temperature, pressure, flow, and level, to ensure the safe and efficient operation of the process. • Infrastructure: DCSs are also used to control and monitor processes in infrastructure, such as traffic control systems, building automation systems, and transportation systems. They are used to control and monitor the process variables such as temperature, pressure, flow, and level, to ensure the safe and efficient operation of the process.
- 15. SCADA • SCADA :Supervisory control and data acquisition. • SCADA, is the term used to describe a type of equipment monitoring and control system used in many different manufacturing processes. • These systems are often used for the efficient control of the hardware and software of many systems to help increase the efficiency of entire plant (or global) processes. • A SCADA works by monitoring many different systems within a plant and relaying them to a central location. • The data is either automatically monitored and dealt with in the SCADA programming or displayed on a monitor where an operator can then make the correct decisions and make changes to the system through the HMI. • A good SCADA example might be in a large process plant where product moves from location to location, changing states along the way. • A bulk cement plant, for example, needs to cook raw material at a high temperature, and an operator must monitor temperatures and the chemical makeup of the product as it moves through the plant. If, at any point, the product is not meeting spec, the operator can make the appropriate changes to bring it back into spec.
- 16. ADVANTAGES/DISADVANTAGE OF SCADA Advantage •Provides access to real-time data, allowing rapid decision-making from operators and engineers. • Enables distant communication, so operators may work remotely from a variety of sites. • Advanced tools such as trend monitoring and historical data make implementing predictive maintenance easier. Disadvantage • Requires a high skill level from operators. • Can only process data when the system is available. • Compatibility issues may arise when dealing with multiple PLCs and RTUs, especially from different vendors
- 17. The Four Generationsof SCADA Architectures • The Four Generations of SCADA Architectures • First Developed in the 1950s, SCADA has evolved from its use in telephone relay systems and minicomputers. With common, tedious tasks, being increasingly automated rather than performed by humans, it has become ubiquitous. The generations of SCADA Architectures are as followed: • First Generation – Monolithic (1960) - The original SCADA system was created during a time where networks did not exist. These first systems were not designed to connect to other systems. Wide Area Networks (WANs) communicated with remote terminal units (RTUs). Redundancy was achieved by the connection of a back-up mainframe to all the RTUs. • Second Generation – Distributed (1970) - The second generation of SCADA was able to take advantage of LAN and were smaller and cheaper than its predecessor. In almost real-time, information was shared across stations that each had their own tasks. Distribution increased the processing power and redundancy of the system. • Third Generation - Networked - Communication over WANs and utilizing PLCs for monitoring, this generation is much like the 2nd generation. However, it is able to connect to the internet and third-party peripherals. • Fourth Generation - Internet of Things (IoT) - Combining SCADA with the cloud, IoT provides SCADA systems with an alternative to PLCs and the use of data modeling and complex algorithms. • Apart of nearly every industry, SCADA is one of the vital technologies for automation. Human errors are reduced and virtually eliminated. With the coming fourth generation, the capacity to share massive amounts of data with wireless technology is bringing new possibilities of cost reduction and reliability to industries
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- 20. ONGC SCADAvantage SystemArchitecture Internet Casual Web User 13 x Tier 2 Asset data Center Redundant LAN Workstation1 multi-purpose Web Application Training Simulator Workstation n multi-purpose ... ... Remote Low Power RTUs polled via two Tier 1 sites 12 High Prod. Wells 4 CBM Wells Redundant LAN 172 x Tier 1 Onshore (Typical) SCADA Vision Terminal Server Workstation1 Multi-purpose Event Workstation n Multi-purpose Laser ... SpreadSpectrum Radio RTU Existing Equipment DCS Links via OPC Redundant LAN Workstation1 Multi-purpose Event 8 x Tier 1 Offshore (Typical) SCADA Vision ... Web Applications Workstation n Multi-purpose TDMA Radio RTU Laser SCADA Vision Network Mgt Event Laser Tier 3 Corporate (Delhi) Fiber Optic Link Multi-Well Platforms RTU Multi-Well Platforms RTU Training Workstations Link active if DRC in control Applications ... Common DB Svr From Drilling SCADA to Enterprise Applications LAN SCADA Vision Common DB Svr Network Mgt Web 2x HMI, 1x Help Desk Worksations Corporate Data Users From Drilling SCADA to Enterprise Applications Tier 3 Disaster Recovery Centre (Mumbai) LAN SCADA Vision Network Mgt Web 2x HMI, 1x Help Desk Worksations Corporate Data Users From Drilling SCADA Common DB Svr to Enterprise Applications Applicaitons Applicaitons 13 x Tier 2 Locations 163 x Tier 1 Onshore SCADA Locations 8 x Tier 1 Offshore SCADA Locations 278 x RTU Locations Tier 3 in Delhi with backup in Mumbai
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- 22. DIFFERENCES BETWEEN PLC V/SDCS V/S SCADA DCS PLC SCADA Scope of control function Has a dedicated controller for each subsystem, which is interconnected. So can cover an entire plant. Provides local (on-site) controls using a centralized controller. Limited to control only a section of a plant. Uses proprietary software to integrate PLCs and RTUs remotely across different locations. Software Comes only from a DCS vendor. The software for programming a PLC comes from its manufacturer. Clients can choose from several vendors available in the market. Communication Uses both analog and digital signals. Binary. Can use different protocols for different layers of the system. However, compatibility is key. Cost The most expensive to implement. Cheapest to implement. More expensive than PLC but less expensive than DCS. Speed Operates at the fastest speed in comparison to other control systems. Lower than PLC but quicker than SCADA. The speed of the system is limited due to remote communication. Susceptibility to errors Has several controllers and redundancy at all levels, so low margin for errors. Prone to errors because it uses only one controller. Redundancy and data-driven decision-making limit the possibility of errors.
- 23. RTU • RTU :remote terminal unit • RTU is a control device located separate from a larger control unit, usually as part of a much larger system. • In many cases, they are part of a DCS or SCADA system, and comprise some of the individual components that a SCADA is used to monitor. • RTUs often control or monitor individual sub-units of equipment, such as sensors, valves, fans, and actuators. • RTUs have advanced over time and are often capable of executing programmable logic, similar to that of a modern PLC. • RTUs use Ethernet or Modbus for sending the information to main control system Lie DCS or SCADA. • RTU is like a very basic PLC used to control some external, isolated I/O device or network, forming a part of a larger-level control system.
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- 25. Differences Between aPLC and RTU • In terms of the installed base, PLCs have long overtaken RTUs and have been dominating the market for decades, practically becoming commodities. • SCADAs and RTUs were first introduced in the telecommunications industry, then later in power generation plants in the 1950s. The problem they were trying to solve was the communication of data from field instruments over very long distances. • PLCs came into the scene later, in the early 1970s. PLCs went straight into the industrial manufacturing world, replacing complex, inflexible circuitry consisting of numerous relays with a compact device that could more easily fit on the production floors. The automobile manufacturing sector was among the first to benefit from the introduction of PLCs. • PLCs are more compact in part because they are meant for industries and factories where available space is normally not abundant. • RTUs are generally larger than PLCs. • RTUs are, on average, more expensive than PLCs due to the size and endurance requirements. • RTUs are better-suited for remote monitoring, such as utilities and agriculture industries. Meanwhile, PLCs are largely used in all industries,
- 26. The First PLC •The very first production PLC was the Modicon model 084, built in 1968-69. • In a brief glance, it wouldn’t look very fancy or high-tech in today’s world. • But considering any previous alternative which consisted of thousands of mechanical relays, this small computer could perform more operations in a fraction of the time. • It was definitely a breakthrough innovation. Shortly after the Modicon PLC and brand was formed, the familiar name of Allen- Bradley launched into the PLC world in the early 1970s. In fact, it was the Allen- Bradley company that popularized the PLC name and acronym. Up until then, it had simply been called a ‘Programmable Controller’.
- 27. The Inventor ofthe PLC Two innovators share the title ‘Father of the PLC’ Richard (Dick) Morley Richard (Dick) Morley was one of the founding members of the Modicon brand, and the main driver in the invention of the device. He grew up on a farm, occasionally repairing equipment, and later working his way through a partial degree at MIT. Dr. Odo Struger The other Father of the PLC is Dr. Odo Struger, who worked for Allen-Bradley during the time of PLC innovation, and eventually became the VP of Technology for Rockwell Automation, the owner of Allen-Bradley.
- 28. The history ofRTU & SCADA • The history of RTUs is closely connected to the history of SCADA. • The earliest SCADA systems originated in power generation plants in the 1950s. • The challenge at the time was collecting data from interconnected substations and sending it to the main control room. This was achieved thanks to the first telemetry applications, essentially, the first RTUs. • Later, in the 1960s and 1970s, with the advances in computer science, it became possible to implement the first electronics-based SCADA and RTU systems. • Instrumentation was installed at longer distances than before, and RTUs offered the ability to acquire larger volumes of data and perform some basic control functions. • The modern version of the RTU was introduced in the 1980s and developed throughout the 1990s. The RTU was now microprocessor-based and able to execute more advanced logic, similar to PLCs. • New communication protocols were introduced, allowing for even more information to be exchanged reliably. RS-232, RS-482, and later Ethernet are some of the most widely used protocols. Contemporary RTUs come with more features and functionalities.
- 29. The history ofDCS • The DCS was introduced in 1975. Both Honeywell and Japanese electrical engineering firm Yokogawa introduced their own independently produced DCSs at roughly the same time, with the TDC 2000 and CENTUM systems, respectively. US-based Bristol also introduced their UCS 3000 universal controller in 1975. • In 1980, Bailey (now part of ABB) introduced the NETWORK 90 system. • Also in 1980, Fischer & Porter Company (now also part of ABB) introduced DCI-4000 (DCI stands for Distributed Control Instrumentation).
- 30. DCS / PLCMERGING 1970s Divergent Functionality PLC DCS Discrete Control Applications Process Control Applications PLC DCS 1980s Common Functionality Discrete Control Applications Process Control Applications GAP PLC DCS 1990s Overlapping Functionality GAP Discrete Control Applications Process Control Applications Discrete Control Applications Process Control Applications PLC DCS Year 2000 Convergent Functionality
- 31. Control System Insights •The distributed control systems (DCS) segment dominated the market and accounted for the largest revenue share of over 34% in 2022. • The Supervisory Control and Data Acquisition (SCADA) control system segment are anticipated to grow at the highest CAGR of over 11% during the forecast period owing to the increase in adoption of industry 4.0.
- 32. Control System Insights •Some of the prominent players in the industrial automation and control systems market include: – ABB Ltd. – Emerson Electric Co. – Honeywell International, Inc. – Kawasaki Heavy Industries, Ltd. – Mitsubishi Electric Corporation – OMRON Corporation – Rockwell Automation, Inc. – Schneider Electric – Siemens AG – Yokogawa Electric Corporation