SCADA stands for Supervisory Control And Data Acquisition.
It generally refers to a system of remote monitoring and control stations linked to a computer or PLC at a main office.
These SCADA systems can sometimes be large in distance between monitoring stations. Because of this, many times, wireless or radio technology is used to connect the remote stations back to the main office. Also in most of the systems developed at Control Systems Inc., there is a web element allowing monitoring of remote locations from anywhere in the World a web connection is available.
Facility: Waste Water Treatment Plant
Location: Alpharetta GA
Customer: Utilities Inc. (www.utilitiesinc-usa.com)
This SCADA system was comprised of 5 main areas of data collection.
- Pump House
- SBR Basins (4) (2 RTU Stations)
- Settling Basin
- Lift Station
- Main control building
The Pump House SCADA RTU system comprised of two remote I/O collection points.
Firstly, a PLC based programmable controller to interpreter the signals from the Rotary Screen and analog water flow sensors and an Ethernet IP based remote I/O unit collecting additional information from this location. These units were then connected to a Radio unit that relayed these signals back to the Main control building. Programming included PLC controller programming, Ethernet IP remote I/O programming and programming of the radio specifications.
The SCADA SBR Basins system comprise of (2) RTU remote I/O collection points.
The two systems were distributed across (4) BSR basins, each unit collecting data from two basins. The systems were identical in construction consisting of an Ethernet IP remote I/O section and Radio transmitter. Analog and digital sensors collected data from the BSR basins which were relayed to the I/O. These units were then connected to a Radio unit that relayed these signals back to the Main control building. Programming included Ethernet IP remote I/O programming and programming of the radio specifications.
The Settling Basin were used to remove addition solids and add chemicals for turbidity. Two remote Ethernet IP I/O units were added to this area. These units monitored all the functions of agitation, etc. of this area. These units were then connected to a Radio unit that relayed these signals back to the Main control building. Also Turbidity levels we logged as part of the SCADA system. Programming included Ethernet IP remote I/O programming and programming of the radio specifications.
The Lift Station was geographically somewhat distant from the main location. A larger antenna and larger receiving antenna we added to this location and to the main control building to process this information. Use of a longer range frequency SCADA was employed and data was collected on faults and different pump operation times.
The Main Control Building SCADA had an existing Allen Bradley Rack PLC system in place. This was reprogrammed to accept these new pieces of information and to improve plant overall function. Added also to the Main Control Building was a Red Lion touch screen and (2) radio receivers. Also the original AB Panelview was reprogrammed and additional information and controls were added. Also an Ethernet connection was added to the main enclosure and routed to a new PC, which was supplied. Though this new PC a web application was developed to allow viewing of plant and lift station operations from any remote computer connected to the Web having the proper access codes.
This SCADA system was comprised of 9 main areas of data collection.
- (3) Cromajet Printing systems
- (4) Assembly Presses
- (1) Anti-fatigue Press
- (1) Automated Assembly line
- (1) Main IT Server Office
These systems all incorporated Allen Bradley PLC’s but incorporated different communications protocols. On some of these systems DH485 was available once programmed and others could be configured for Data Highway Plus.
The Cromajet printing system comprised of three separate lines. Each machine’s PLC program and Allen Bradley Panelviews were modified and addition data collection and calculation software was written. This was linked back to Main IT Server Office using WonderWare as the SCADA collection software.
The Assembly Presses comprised of four separated assembly lines used to attached printed mat materials like FanMats (www.fanmats.com) products to there backing. Also RFID chips were added to products in this area for tracking finished products.
These systems had independent PLC’s that were accessed and programmed to provide calculated data back to the Main IT Servers. This data then was displayed above the presses processes monitoring cycle time of each press operation and employee involvement in this process.
The Anti-fatigue Press ran an Allen Bradley rack system. This machine was imported from Taiwan and the total controls and electrical package was added by Control Systems Inc. I also wrote the operational PLC program for this machine and at a later date this SCADA network collection was added to the process.
The Automated Assembly Line consisted of 6 PLC systems, networked together. This line had many automated and employee cells. The entire system cover 25,000 sq feet and included an rubber extruder line, cooling line, Fanuc Robot cells, Trimming station, employee stations, automated carpet loading system, visual inspection stations, storage elevators, 35 foot tall main press, finished product removal system. The total electrical systems and PLC programs we also written and panels and installation work was completed by Control Systems Inc.. Utilizing the existing networks these PLC’s were polled and cycle-time and material usage information was routed to the Main IT Server Office.