Introduction to SCADA Systems - Sensors, Data and Screens Graham Nasby, P.Eng, PMP, CAP Water SCADA & Security Specialist City of Guelph Water Services SCOWWA Spring Conference Ontario Water Works Association Wednesday, April 3, 2019 St. Catherines, Ontario, Canada 1
About the Speaker Graham Nasby, P.Eng., PMP, CAP Water SCADA & Security Specialist City of Guelph Water Services 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: graham.nasby@guelph.ca 2 2
So, what do real engineers do? 3 3
Ok ok.. SCADA is ok too SCADA GUY 4 4
City of Guelph Water Services 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 m 3 /day [12 MGD] 5 5
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 6 6
Not SCADA 7 7
What is SCADA? SCADA = Supervisory Control and Data Acquisition 8 8
Typical SCADA Architecture 9 9
Why we have SCADA systems 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 10 10
SCADA View Terminal 11 11
More Realistic SCADA View Terminal 12 12
I/O Level - Instrumentation 13 13
I/O Level - Pumps 14 14
I/O Level a more complicated example UV Reactor 15 15
PLC Control Panel 16 16
PLCs Programmable Logic Controllers 17 17
SCADA Network 18 18
SCADA Network (Fibre optic) 19 19
SCADA Servers 20 20
SCADA Servers - Example 21 21
Screens 22 22
Screens 23 23
Screens another example 24 24
SCADA Alarm System 25 25
SCADA callout System: SCADA Alarms 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 26 26
Typical Instrumentation in Drinking Water Systems 27 27
Surface Water Treatment Plant 28 28
Common Instrumentation in Water Plants 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 29 29
Well Instrumentation 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 30 30
What s New in SCADA? SCADA GUY 31 31
What s new in SCADA? What is running? What if your are colour blind? Is the process running well? Is anything abnormal? 32 32
SCADA: Situational Awareness To be an effective operator you have to be aware of what your plant is doing 33 33
Common SCADA problem In some SCADA systems. You can t see the whole picture 34 34
Common SCADA problem What your SCADA system may not be showing you 35 35
CAN YOU FIND THE PROBLEM ON THE SCADA SCREEN? 36 36
Friendly SCADA Guy 37 37
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) 38 38
High Performance HMIs 39 39
High Performance HMIs HMI = Human Machine Interface (computer screen) High Performance HMI Colour scheme Poor Colour Scheme 40 40
High Performance HMI Plant Running Normally There are 3 alarms active can you easily see them on the screen? F HI LO Notice the Lack of Colour 41 41
High Performance HMI Status Indicators Red and Green really stand out to the user! Not Running L L STOPPED Don t use bright colours to show status. Reserve bright colours for alarms! Running A A RUNNING Use muted colours with backup text to show status. Pumps not monitored by SCADA (no status information) are just shown as mid-gray: 42 42
High Performance HMI Analog Values Often Seen 480.1 psi No Alarm Indication 480.1 psi Only a Colour Change! Better 480.1 psi 480.1 psi Diagnostic Priority 480.1 psi 480.1 psi Priority 3 Priority 2 Priority 1 Betterer 480.1 psi Diagnostic Priority 480.1 psi 480.1 psi 480.1 psi Priority 3 Priority 2 Priority 1 Best! 4 3 480.1 psi Diagnostic Priority 2 1 480.1 psi 480.1 psi 480.1 psi Priority 3 Priority 2 Priority 1 S 480.1 psi Suppressed Alarm Show alarms in multiple ways: Colour, Shape, Text ( redundant coding ) 43 43
High Performance HMI Analog Values Another Way RECYCLE COMPRESSOR K43 Cool gpm 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 2 Alarm Indicator 290 Alarm Range 170 38.7 93.1 185 95 120 12 8 9 170 Desirable Operating Range 42.7 80 Alarm Range Show Values Show Trends Interlock Indicator Buttons for additional functionality 44 44
High Performance HMI Tank Levels Depiction Source: High Performance HMI Handbook 45 45
High Performance HMI Diagnostics for Pumps Source: High Performance HMI Handbook 46 46
High Performance HMI Embedded Trends Source: High Performance HMI Handbook 47 47
High Performance HMI Display Hierarchy 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 48 48
High Performance HMI The Old Way R77 N28 Farnam 6 Adams 3 Marcum C16 CSX9 Tempe 49 49
High Performance HMI Level 1 Display Station Status XFER A B C D ON ON ON ON E OFF F ON G ON H ON Diag H Altair 4 A B C D E F G H A A A A M A A A 113 113 112 113 0 113 112 112 Mesklin A B C D E F G H A A A A M A A A 42 43 42 44 0 43 43 43 Arrakis A B C D E F G H A A A A M A A A 8.0 9.8 10.0 9.5 0.6 9.8 9.5 9.0 Trantor A B C D E F G H A A A A M A A A 75 74 H H 78 78 75 51 50 75 55 77 45 74 50 50 65 51 Pipeline Permissives 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 OK OK OK OK NOT OK OK OK NOT OK OK OK NOT OK OK OK OK 08-15-2009 14:22:09 Econ O2 % A2 BFP KLB/HR B2 BFP KLB/HR A2 BFP Recirc Selector VALVE FORCED.0 1800 OPEN 1800 VALVE CONTROLLED B2 BFP Recirc Selector VALVE FORCED OPEN VALVE CONTROLLED Minbari River AUTO 5.0 50% AUTO 1800 50% AUTO 1800 50% Arrakis Trantor Terminus Gateway Mesklin FUEL MASTER MAN Altair 4 65.1 TX LA 50 Source: High Performance HMI Handbook 50
High Performance HMI ISA101 Standard CONTINUOUS WORK PROCESSES MOC Audit Validation New System Major Changes SYSTEM STANDARDS Philosophy Style Guide Toolkits ENTRY New Display Display Changes DESIGN Console Design HMI System Design ENTRY User, Task, Functional Requirements REVIEW IMPLEMENT Build Displays Build Console Test Train OPERATE In Service Maintain Decommission Continuous Improvement Continuous Improvement Display Design Commission Verification 51 51
Alarm Management 52 52
Alarm Management: ISA18.2 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 Typical example of results of ISA-18.2 being implemented (showing before/after) 53 *originally published as ISA-18.2-2009, now also IEC-62682 53
Alarm Management: ISA18.2 Alarm Mgmt. Lifecycle 54 54
Alarm Management: Master Alarm Database 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 55 55
Alarm Management: Master Alarm Database 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 56 56
Alarm Management: Non-Alarms 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 57 57
Alarm Management: Dedicated Alarm Display Dedicated screen for displays alarms only alarms Ideally on its own dedicated monitor in multi-monitor setup 58 58
Last of All: Cyber Security 59 59
SCADA Cyber Security 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 60 60
SCADA Cyber Security: ISA/IEC-62443 61 61
SCADA Cyber Security Example: ISA/IEC-62443 Zones and Conduits 62 62
Wrapping Up 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! 63 63
Any Questions? * Not a High Performance SCADA System 64 64