Designing SCADA application software: a practical approach

Front Cover......Page 1
Designing SCADA Application Software......Page 4
Copyright Page......Page 5
Contents......Page 6
About the Author......Page 12
Preface......Page 14
1.1.1 Early Automation Systems......Page 20
1.1.3 Communications and Integration......Page 21
1.2 Basics of SCADA Signal Processing......Page 22
1.3 Defining the Scope of SCADA Software......Page 23
1.4 Use of Generalized Terminology......Page 24
1.5.1 Need for Design Standards......Page 25
1.6 The Importance of Software Documentation......Page 26
1.6.2 Upgrades and Revisions......Page 27
1.7.2 Complete Software Documentation......Page 28
1.7.3 Adherence to Programming Standards......Page 29
2.1 Understanding the Elements of SCADA Software......Page 30
2.2 Typical SCADA System Architecture......Page 31
2.2.1 Field Devices and Signals......Page 32
2.2.2 Programmable Process Controller......Page 33
2.2.4 Communication Network......Page 34
2.2.5 SCADA Server Computer......Page 37
2.3.2 Pretreatment......Page 38
2.3.3 Filtration......Page 39
2.4 Getting the Most from Field Data......Page 40
3.1 Life Cycle of a SCADA Project......Page 44
3.1.2 Development of SCADA Project......Page 45
3.1.4 Commissioning and Site Acceptance Testing......Page 46
3.1.5 The Final Step – Documentation......Page 47
3.2.2 Identifying Input and Output Signals......Page 48
3.3 Creating and Documenting Application Databases......Page 50
3.3.2 Creating Points Lists Using Spreadsheets......Page 51
3.4.1 The Initial Process Narrative......Page 52
3.4.2 Developing the Detailed Process Logic Descriptions......Page 54
3.5.1 Developing the Controller (PPC) Application Software......Page 55
3.5.2 Developing the SCADA Workstation (SOW) Application Software......Page 56
3.6.3 System Acceptance Test Procedures......Page 57
3.7.2 Structure of the User Operations Manual......Page 58
4.1 SCADA Software Documentation......Page 60
4.2 Database Reference......Page 61
4.2.2 Programmable Controller Database......Page 62
4.3 Process Control Logic Descriptions......Page 63
4.3.4 Special Considerations......Page 64
4.5 SCADA Workstation Application Software Reference......Page 65
4.6 SCADA User Operations Reference......Page 66
4.6.1 General System Overview......Page 67
4.6.4 Historical Reports and Trend Displays......Page 68
4.6.5 Special Operating Procedures......Page 69
5.1 Original Signal Tagnames......Page 70
5.2 Purpose of Standardized Tagnames......Page 71
5.3 Constructing Tagnames with Phrases......Page 72
5.4.1 Structure of the TSNC Tagname......Page 73
5.4.4 Component Fragment......Page 74
5.5 Tagname Fragment Dictionaries......Page 75
5.6 Illustration of Tagname Application......Page 77
6.1.1 Raw Field Signal Data......Page 78
6.1.2 PPC Data Types......Page 79
6.2 Using Spreadsheets to Create Points Lists......Page 80
6.2.2 Populating Points List Spreadsheets......Page 81
6.3 Developing the Controller Database......Page 83
6.3.1 Hardware Field I/O Signals......Page 86
6.3.2 Software Program Points......Page 89
6.3.3 Application of Program Points in Logic......Page 90
6.3.4 Internal Program Support Points......Page 91
6.3.5 Procedures for Creating Controller Spreadsheet Database......Page 93
6.3.6 Sample Controller Database......Page 98
6.4 Developing the SCADA Workstation Database......Page 100
6.4.1 Controller Related Data Points......Page 102
6.4.2 SCADA Workstation Database Components......Page 103
6.4.3 Procedures for Creating Workstation Spreadsheet Database......Page 104
7.1 Purpose of PCLDs......Page 106
7.3.1 Overview of Process Areas......Page 107
7.4.1 Summary of Equipment......Page 108
7.5.1 General Requirements......Page 109
7.5.3 Remote Manual Control Mode......Page 110
7.6.1 Software Interlocks......Page 111
7.6.4 Software Interfacing......Page 112
7.7 Sample PLCD for Pump Station......Page 113
8.1 Structure and Purpose of User Reference Manual......Page 114
8.2.2 Central Control Facilities......Page 115
8.2.3 Display Conventions and Navigation......Page 116
8.2.4 Security Levels and Passwords......Page 117
8.3.1 System Overview Displays......Page 118
8.4 Process Graphic Displays......Page 119
8.5.2 Historical Reports......Page 122
8.6.1 Startup and Shutdown Procedures......Page 123
8.6.2 System Backup Procedures......Page 124
9.1.1 Isolate and Define Processes......Page 126
9.1.2 Organize Processes for Programming......Page 127
9.2.2 Defining and Refining Software Points......Page 128
9.3.1 Organize the Controller Project......Page 129
9.3.2 Define the Required Tasks and Programs......Page 132
9.3.3 Creating the Main Program Structure......Page 133
9.3.4 Defining the Synchronous and Asynchronous Logic......Page 135
9.3.5 Choosing the Programming Languages......Page 136
9.4 Programming Guidelines and Style......Page 139
9.4.2 Programming of Diagnostics......Page 140
9.4.3 Top-Down Structured Programming......Page 142
9.4.4 Program Design Using Function Blocks......Page 144
9.4.5 Database Maintenance Using Spreadsheets......Page 146
9.5 Some Final Notes on Programming......Page 148
10.1 Identifying the Process Areas......Page 150
10.1.2 Identifying Information for Displays......Page 151
10.1.3 Defining Historical Data Requirements......Page 152
10.2.1 Functionality of Server Workstations......Page 153
10.3.1 Creating the HMI Workstation Database......Page 155
Display Navigation......Page 157
Colour Conventions......Page 163
Alarm Notification......Page 164
Current Process Operations......Page 166
Alarm and Event Summaries......Page 168
Trends and Historical Reports......Page 169
Maintenance Displays......Page 171
10.5.1 Conceptual Operation of the I/O Server......Page 172
10.5.2 Considerations of the Network Topology......Page 174
11.1.1 Checking Overall Program Flow......Page 176
11.1.2 Testing Program Logic Using Simulation......Page 179
Process Verifications......Page 180
11.1.3 Factory Acceptance Testing......Page 182
11.2.1 Field I/O Signal Checklists......Page 184
11.2.3 Correlating Field Wiring and Logic States......Page 187
11.3.2 Site Acceptance Testing......Page 189
11.3.3 Final Project Sign Off......Page 190
12.1 Overview of Project......Page 192
12.3.1 Developing the Controller Database......Page 193
12.3.2 Developing the SCADA Workstation Database......Page 200
12.4.1 Process Summary and Overview......Page 201
System Control Strategy Overview......Page 202
Pump Control Mode Selection......Page 203
Pump Runtime Accumulation......Page 204
12.5.1 Developing the Overall Project Structure......Page 205
Layout and Standards......Page 206
Graphic Animation and Data......Page 207
Control Actions......Page 208
12.7 Commission the Completed System......Page 209
12.8 Finalize Software Documentation......Page 210
Appendix A: Glossary of Technical Terms......Page 212
B.1 Tagname Signal Naming Convention......Page 216
C.1 System Control Strategy Overview......Page 226
C.2 Facilities and Parameters......Page 227
C.3 Control Logic Description......Page 228
C.4 Special Considerations......Page 230
D.1 Program Structure......Page 232