SCADA 101 Introduction to SCADA Systems Sensors, Data and ... · Introduction to SCADA Systems - Sensors, Data and Screens SCOWWA Spring Conference – Ontario Water Works Association

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Graham Nasby, P.Eng, PMP, CAP Water SCADA & Security Specialist

City of Guelph Water Services

SCADA 101

Introduction to SCADA Systems

-

Sensors, Data and Screens

SCOWWA Spring Conference – Ontario Water Works Association Wednesday, April 3, 2019 – St. Catherines, Ontario, Canada

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About the Speaker

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Graham Nasby, P.Eng., PMP, CAP

Water SCADA & Security Specialist


• 10 years in the consulting sector

• Joined Guelph Water Services in 2015

• OWWA and WEAO Member, Member of OWWA Automation Committee

• Co-chair of ISA112 SCADA Systems standards committee

• Voting member of ISA101 HMI Design standards committee

• Voting member of ISA18 Alarm Management standards committee

• Named Canadian Expert on IEC/SCC-TC65 with Standards Council of Canada

• Has published over 30 papers and articles on automation topics

• Received University of Guelph “Mid Career Achievement Award” in 2014

• Named ISA’s technical division leader of the year award in 2013.

• Contact: [email protected]

SCADA 101 April 3, 2019 – SCOWWA Spring Workshop

mailto:[email protected]

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So, what do real engineers do?

3 SCADA 101 April 3, 2019 – SCOWWA Spring Workshop

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Ok…ok.. SCADA is ok too

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SCADA

GUY


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• Guelph, Ontario, Canada

• 140,000 residents

• 21 groundwater wells

• 3 water towers

• 549 km of water mains

• 49,000 service connections

• 2,750 fire hydrants

• 46,000 m3/day [12 MGD]

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April 3, 2019 – SCOWWA Spring Workshop

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Presentation Outline

• What is SCADA

• SCADA System Architecture

• Purpose of SCADA Systems

• SCADA View Nodes

• Instrumentation, Wiring, PLCs

• SCADA Screens & SCADA Alarm System

• Typical SCADA in Surface Water Systems

• Typical SCADA in Groundwater System

• Current Trends in SCADA Systems

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April 3, 2019 – SCOWWA Spring Workshop

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Not SCADA


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What is SCADA?

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SCADA = Supervisory Control and Data Acquisition


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Typical SCADA Architecture


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Why we have SCADA systems

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• Unattended automatic control of water facilities

• Logging of critical control parameters – Chlorine Residuals (e.g., every 5 minutes)

– Turbidity

– Well Flow Rates & Daily Flow Totals

– POE Flow Rates & Daily flow Totals

– Tower Levels & Pressure

• Provides “visualization” of water facilities to Operators

• Enables remote monitoring and control by Operators

• Triggering and Annunciation of Alarms

• Automated responses (increase chlorine dose, shutdown, etc.)

• Compliance reporting based on logged process data


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SCADA View Terminal


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More Realistic SCADA View Terminal


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I/O Level - Instrumentation


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I/O Level - Pumps


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I/O Level – a more complicated example

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UV Reactor


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PLC Control Panel


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PLCs – Programmable Logic Controllers


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SCADA Network


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SCADA Network (Fibre optic)


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SCADA Servers


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SCADA Servers - Example


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Screens


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Screens


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Screens – another example


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SCADA Alarm System


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SCADA callout System: SCADA Alarms

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What is an “alarm”?

• Notification of abnormal situation

• Requires an operator to respond

• Requires timely response

Order for Routing Alarms

-To SCADA View terminals

-Calls Supply Lead Hand

-after hours: On Call Supply

-then to a phone tree

Will keep calling until

acknowledged


“Teledac”

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Typical Instrumentation in Drinking Water Systems


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Surface Water Treatment Plant

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Common Instrumentation in Water Plants

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• Water Level

• Flow Transmitters

• Turbidity Meters

• Pressure Transmitters

• Differential Pressure (Head Loss in Filters)

• Chlorine Residual Analyzer

• Water Temperature

• pH

• Hardness and other special analyzers

• Ozone and Ambient Ozone Detectors

• Building Temperature

• Water Tower Level

Devices Controlled by SCADA

• Low lift Pumps

• Chemical Feed Systems

• Mixers/Flocculators

• Chemical Feed Pumps

• Disinfection Systems

• UV Systems

• Ozone Systems

• High Lift Pumps


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Well Instrumentation

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• Well Flow Rate & Totalization – All flow from well (for permit)

– Flow to Treatment System

– Flow to Waste

• Well Level (Water Level)

• Well Pump Motor Electrical Power

• Pump Discharge Pressure

• Down-hole instrumentation

• Raw Water Analyzers for Studies


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What’s New in SCADA?


SCADA

GUY

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What’s new in SCADA?

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• Is anything abnormal? • What if your are colour blind?

• What is running? • Is the process running well?


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SCADA: Situational Awareness

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To be an effective operator

–

you have to be aware of what your plant is doing


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Common SCADA problem

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In some SCADA systems….

You can’t see the whole picture


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Common SCADA problem

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What your SCADA system may not be showing you


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CAN

YOU

FIND

THE

PROBLEM

ON THE

SCADA

SCREEN?


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Friendly

SCADA Guy


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Situational Awareness

• To be able to react to a problem, Operators need to be aware of the problem

• Old way operating “by alarm” (reactively)

• New approach: Present data to operators so they can proactively respond to problems as they develop

• Reserve alarms only for events that require immediate action

• High Performance HMIs (Human Machine Interfaces)

• Alarm Management (better designed alarm systems)

• Understanding your operating envelope (know your plant’s limits)


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High Performance HMIs


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High Performance HMIs

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HMI = Human Machine Interface (computer screen)

Poor Colour Scheme

High Performance HMI Colour scheme


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High Performance HMI – Plant Running Normally

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Notice the Lack of Colour

HI

LO

F


There are 3 alarms active – can you

easily see them on the screen?

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High Performance HMI – Status Indicators

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Red and Green really stand out to the user!

Don’t use bright colours to show status. Reserve bright colours for alarms!

Use muted colours with backup text to show status.

Pumps not monitored by SCADA (no status information) are just shown as mid-gray:

Not

Running

Running

STOPPED

RUNNING

L

A A

L


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High Performance HMI – Analog Values

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Diagnostic

Priority

Priority 3 Priority 2 Priority 1

480.1 psi 480.1 psi 480.1 psi480.1 psi

2 1

Diagnostic

Priority


480.1 psi 480.1 psi 480.1 psi480.1 psi4 3

Better

Betterer

Best! Suppressed

Alarm

480.1 psi S

480.1 psi No Alarm Indication 480.1 psi Often

Seen Only a Colour Change!

Show alarms in multiple ways: Colour, Shape, Text (“redundant coding”)

480.1 psi 480.1 psi 480.1 psi 480.1 psi

Diagnostic

Priority



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High Performance HMI – Analog Values Another Way

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Cool

gpm

RECYCLE COMPRESSOR K43

Alarm Indicator

Desirable Operating Range

Alarm Range

Alarm Range

Show Values Show Trends

Buttons for additional functionality

2

Suct

psig Inter

psig

Dsch

psig

Suct

degF Inter

degF

Dsch

degF

E. Vib

mil

N. Vib

mil

W. Vib

mil

Motor

Amps

Oil

psig

Oil

degF

42.7

38.7 93.1

185 95 120

170

12

8 9

170

80

290

Interlock Indicator


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High Performance HMI – Tank Levels Depiction


Source: High Performance HMI Handbook

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High Performance HMI Diagnostics for Pumps



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High Performance HMI – Embedded Trends

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Source: High Performance HMI Handbook SCADA 101 April 3, 2019 – SCOWWA Spring Workshop

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High Performance HMI – Display Hierarchy

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• Level 1 – Plant or Entire System Overview– Entire Operator Span of Control “Single-Glance”

• Level 2 – Sub-Process Overview– More details than a Level 1 display, smaller area

• Level 3 – Equipment or Details Screen– Specific details about part of the process or control

• Level 4 – Specific Task or Diagnostic Screen– Very detailed screen, only used for diagnostics


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High Performance HMI – The Old Way

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R77

N28

Farnam 6

C16

Marcum

CSX9

Tempe

Adams 3


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High Performance HMI – Level 1 Display

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Altair 4

A A A A M A A A

113113

112113

0113

112112

A B C D E F G H

A A A A M A A A

4243

4244

043

4343

A B C D E F G H

A A A A M A A A

8.09.8

10.09.5

0.69.8

9.59.0

A B C D E F G H

ON

Station Status

G

E

C

A

B

D

H

F

ON

ON

ON

ON

ON

ON

Diag

H

TX LAAltair 4

Mesklin

Trantor

Minbari

Arrakis

River

Terminus

Mesklin Arrakis

7574

7877

7845

7574

5150

5050

7565

5551

A A A A M A A A

A B C D E F G H

H H

Trantor

ON

OFF

XFER

PULV A PULV B PULV C PULV D PULV E PULV F PULV G PULV HL1 OVERVIEW

08-15-2009 14:22:09

RUNBACK 1 RUNBACK 2 PULV OV

UNIT 2: RUNBACK Graphic 2

Gross MW 562

DECREASE

LOAD

TRICON

DEMAND:

ACS

DEMAND:

100.0%

100.0%

INCREASE

LOAD

Econ

O2 %

AUTO

5.0

50%

A2 BFP

KLB/HR

AUTO

1800

50%

B2 BFP

KLB/HR

AUTO

1800

50%

VALVE

FORCED

OPEN

VALVE

CONTROLLED

A2 BFP

Recirc

Selector

VALVE

FORCED

OPEN

VALVE

CONTROLLED

B2 BFP

Recirc

Selector

AUTO

2400

50.1%

BOILER

MASTER MAN

5.0 1800 1800

AUTO

65.0

50.1%

FUEL

MASTER MAN

2202 65.1

Input new ACS

DEMAND or

use buttons:

25% 50% 75%

Valve

SV-1

SV-2

SV-3

CV-1

CV-2

CV-3

CV-4

RHS-1

RHS-2

IV-1

IV-2

100%

100%

95%

88%

100%

100%

75%

0%

55%

100%

100%

100%0%

Valve Position

90.0%

TRICON

LOAD RATE:

VERY

FAST

TURBINE

MASTERMAN

TURBINE

FOLLOW

BOILER

FOLLOW

COORD

CONTROL

CONSTANT

PRESSURE

VARIABLE

PRESSURE

Gateway

Breaker 15 Power

Oil Temp 16-33

Oil Pres Status

Level in TK-8776

Gen System Status

Comp 88 in Auto

Lineup Ready

Sys Status Checks

Bearing Readouts

Comm check

Outlet Temp < 250

Cooling Flow

Internal Circuit Check

Bypass Closed

AFS Function

OK

NOT OK

OK

OK

OK

NOT OK

OK

OK

OK

OK

OK

OK

OK

OK

Pipeline Permissives

NOT OK



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High Performance HMI – ISA101 Standard

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DESIGNSYSTEM STANDARDS

OPERATEIMPLEMENT

CONTINUOUS WORK PROCESSES

Continuous Improvement

RE

VIE

W

Philosophy

Style Guide

Toolkits

In Service

Maintain

Decommission

Continuous Improvement

Build Displays

Build Console

Test

Train

Commission

Verification

Console Design

HMI System Design

User, Task, Functional

Requirements

Display Design

New DisplayDisplay Changes

New SystemMajor Changes

ENTRYENTRY

MOC Audit Validation


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Alarm Management


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Alarm Management: ISA18.2

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ANSI/ISA-18.2-2016 * Management of Alarm Systems for the Process Industries

Alarm: An audible and/or visible means of indicating to the operator an equipment malfunction, process deviation or abnormal condition requiring a timely response.

Methodology for identifying, rationalizing and designing alarms to be a powerful tool for operations, and eliminating non-useful alarms

*originally published as ISA-18.2-2009, now also IEC-62682

Typical example of

results of ISA-18.2

being implemented

(showing before/after)


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Alarm Management: ISA18.2 Alarm Mgmt. Lifecycle


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Alarm Management: Master Alarm Database

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• MADB

– Central repository of approved alarms and their configuration (below is a wastewater example)

Tag Priority Desc. Condition Consequence If Ignored

Consequence Severity

Expected Operator Response

Time to Respond

P1-380-LAH-201 LOW Aeration 1 High Level

High Level Switch Activated for 10sec

Overflows in Secondary clarifiers.

MINOR Check Level Controller

2 hours

P1-380-AAL-102 MED Aeration 1 Low DO

DO below 3ppm for 30min

Loss of Biological Action, Risk of Damage to Biological Mass

MAJOR Investigate and turn on additional blowers

1 hour

P1-380-PALL-456A LOW Aeration 1 Air Pres. Low Low

Less than 15psi for 5min

Loss of Energy if Air Leak, Poor Aeration (Note: there is a low DO alarm)

MINOR Check pressures in air distribution system via HMI, check valves in field

4 hrs


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Alarm Management: Master Alarm Database

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• Alarm Tag

• Alarm Description (full description & what is shown on HMI)

• Identification: Trigger Condition, Purpose

• Rationalization:

– Consequence & Severity if Ignored

– Expected Operator Response, Time to Respond

– Alarm Priority & Alarm Class

– Justification for having this alarm configured!

• Design: Trigger Condition, On/Off Delays, Additional Filtering Logic, Setpoints, Routing/grouping information for the HMI

• Operation: When put into service, If Periodic Testing is required


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Alarm Management: Non-Alarms

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HMI: Alarms, Events and Notifications • SCADA Systems can have multiple types of notifications

• SCADA systems should have support for:

– Alarms

– Other notifications: alerts, prompts, maintenance messages

– Event messages

– Logged-only events


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Alarm Management: Dedicated Alarm Display

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• Dedicated screen for displays alarms – only alarms

• Ideally on its own dedicated monitor in multi-monitor setup


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Last of All: Cyber Security


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SCADA Cyber Security

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• You need to protect your SCADA system from unauthorized access

• In the past this was difficult to do….

• Requires multipronged approach

– People

– Process

– Technology

• There is guidance now available on how to do this

– ISA/IEC-62443 (formerly known as ISA-99)

– AWWA GW430

– NIST Cyber Security Framework


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SCADA Cyber Security: ISA/IEC-62443


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SCADA Cyber Security Example: ISA/IEC-62443


Zones and Conduits

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Wrapping Up

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• Structure of a SCADA system

• Typical SCADA for Surface Water Systems

• Typical SCADA for Ground Water Systems

• SCADA is essential for both Operations and Compliance

• Operators Need Situational Awareness to Operate Effectively

• HMIs need to provide Situational Awareness

• SCADA Alarms systems must be rationalized/documented

• Cyber Security requires a multi-pronged approach

• Remember the SCADA System is a tool for you: Put it Work!


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* Not a High Performance SCADA System

Any Questions?

Documents

SCADA 101 Introduction to SCADA Systems Sensors, Data and ... · Introduction to SCADA Systems - Sensors, Data and Screens SCOWWA Spring Conference – Ontario Water Works Association