Practical Scada For Industry

Practical SCADA for Industry

Titles in the series Practical Cleanrooms: Technologies and Facilities (David Conway) Practical Data Acquisition for Instrumentation and Control Systems (John Park, Steve Mackay) Practical Data Communications for Instrumentation and Control (John Park, Steve Mackay, Edwin Wright) Practical Digital Signal Processing for Engineers and Technicians (Edmund Lai)Practical Electrical Network Automation and Communication Systems (Cobus Strauss) Practical Embedded Controllers (John Park) Practical Fiber Optics (David Bailey, Edwin Wright) Practical Industrial Data Networks: Design, Installation and Troubleshooting (Steve Mackay, Edwin Wright, John Park, Deon Reynders) Practical Industrial Safety, Risk Assessment and Shutdown Systems (Dave Macdonald) PracticalModern SCADA Protocols: DNP3, 60870.5 and Related Systems (Gordon Clarke, Deon Reynders) Practical Radio Engineering and Telemetry for Industry (David Bailey) Practical SCADA for Industry (David Bailey, Edwin Wright) Practical TCP/IP and Ethernet Networking (Deon Reynders, Edwin Wright) Practical Variable Speed Drives and Power Electronics (Malcolm Barnes)

Practical SCADA for Industry
DavidBailey BEng, Bailey and Associates, Perth, Australia +J]OT =XOMNZ MIPENZ, BSc(Hons), BSc(Elec Eng), IDC Technologies, Perth,
Australia

Newnes An imprint of Elsevier Linacre House, Jordan Hill, Oxford OX2 8DP 200 Wheeler Road, Burlington, MA 01803 First published 2003 Copyright  2003, IDC Technologies. All rights reserved
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Typeset andEdited by Vivek Mehra, Mumbai, India (vivekmehra@tatanova.com) Printed and bound in Great Britain

Contents
Preface 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

xiii Background to SCADA
Introduction and brief history of SCADA Fundamental principles of modern SCADA systems SCADA hardware SCADA software Landlines for SCADA SCADA and local area networks Modem use in SCADA systems Computer sites andtroubleshooting System implementation

1
1 2 4 5 6 7 7 8 9

2
2.1 2.2

SCADA systems, hardware and firmware
Introduction Comparison of the terms SCADA, DCS, PLC and smart instrument
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 SCADA system Distributed control system (DCS) Programmable logic controller (PLC) Smart instrument Considerations and benefits of SCADA system Control processor (or CPU) Analoginput modules Typical analog input modules Analog outputs Digital inputs Counter or accumulator digital inputs Digital output module Mixed analog and digital modules Communication interfaces Power supply module for RTU RTU environmental enclosures Testing and maintenance Typical requirements for an RTU system

11
11 12
12 15 15 16 17

2.3

Remote terminal units
2.3.1 2.3.2 2.3.3 2.3.4 2.3.52.3.6 2.3.7 2.3.8 2.3.9 2.3.10 2.3.11 2.3.12 2.3.13

17
19 19 26 27 28 29 31 33 33 33 33 34 35

2.4 2.5

Application programs PLCs used as RTUs
2.5.1 2.5.2 2.5.3 PLC software Basic rules of ladder-logic The different ladder-logic instructions Master station software

36 36
37 38 40

2.6

The master station
2.6.1

46
48

vi Contents

2.6.2 2.6.3 2.6.4 2.6.5 2.6.6...