Integrating Power Monitoring Data into SCADA

Transcription

1 Integrating Power Monitoring Data into SCADA Michael S. Watkins, CAP CDM Smith May 23, 2012 Overview What types of Power Monitoring Data is available How is the data integrated with SCADA systems How is the data utilized Examples of Integration and Usage of Power Monitoring Data Questions Page 1 1

2 Power Monitoring Data What types of data are available? Depends on the Equipment / Devices on your system! Typically large rotating equipment includes basic power data Amperage Voltage Dedicated Power Monitoring Devices Overwhelming amount of data available Power Monitoring Data What types of data are available? Power monitoring devices (Cutler Hammer, Allen-Bradley, GE, Schneider Electric, etc.) offer an extensive list of variables depending on the device. Schneider Electric PowerLogic PM 1000 Page 2 2

3 Power Monitoring Data What types are often collected? Typical Power Monitoring Data: Real Power Apparent Power Current per Phase Voltage per Phase Power Factor Energy usage (KWh) Equipment Safeties (temperature) Mains breaker status Integrating the data with SCADA Various methods utilized to integrate the devices into a SCADA system (hardwired, serial communication, Ethernet communication). Communication technology utilized in the Power Monitors follows the SCADA hardware technology. Transition to Ethernet communication and standard protocols Implementation of OPC when needed to enable data availability Page 3 3

4 Trends in SCADA Communication 1990s Discussion on implementing standard Ethernet (Would it be deterministic?) 2000s Wide spread implementation of Ethernet networks on control systems for HMI / PLC communication Current Trends Ethernet continues to push down into the SCADA network Device level communication Trends in SCADA Communication Ethernet standardized the physical hardware. Fiber Optic / Copper (CAT5 / CAT6) Network Hardware Various protocols implemented on the networks Push toward open protocols and standard communication methods Modbus TCP/IP Ethernet IP Development of OPC Page 4 4

5 Ethernet Protocols Protocol Set of rules devices use to transmit and receive data. Standard Ethernet (Office Network) uses TCP/IP. TCP Transmission Control Protocol IP Internet Protocol Widely used industrial protocols have been built upon the standard Ethernet protocol. Modbus TCP/IP Ethernet IP PROFINET Bridging Between Protocols Protocol Converters Communication modules in PLC rack for translating serial protocols Gateways connected to the network for translation OPC (OLE for Process Control) Attempts to provide universal connectivity Page 5 5

6 Integrating the data with an HMI Serial Protocols Modbus, DeviceNet Typical Use: Collect data in PLC for transfer to HMI graphics / historian. Serial Communication Control System Architecture Integrating the data with an HMI Ethernet Connectivity Uses Standard Protocols (Ethernet/IP, Modbus TCP/IP) Advantages HMI Connection for graphic displays Peer-to-Peer Communication with PLCs Ethernet Control System Architecture Page 6 6

7 Reminder for Questions Questions can be asked at the end of the presentation. How is Power Monitoring Data used? All installations add value in some fashion. Most do not use the abundance of data to fullest extent. Some use data in unique ways. Coupling OPERATIONAL decisions to DATA requires analysis, engineering effort, and planning in addition to the step of acquiring the hardware and software components themselves. Systems and use can be simple or complex (low or high maintenance). Page 7 7

8 How is it used? Tacoma, Washington Area WWTP Dedicated PMCS Monitor Power Quality and Reliability from Power Utility DFW Area WTP Dedicated PMCS Instantaneous Power / Motor & pump safeties (bearing temperatures) Coastal Virginia area WWTP Data brought into SCADA Instantaneous Power and Manual Load Shedding featuring big LED display How is it used? Cincinnati, OH MSD Data brought into SCADA Power Usage and Peak Monitoring Cleveland, OH Water Department Dedicated PMCS Power Monitor and Wire-to-Water calculations Page 8 8

9 Example Configuration using PLCs Metropolitan Sewer District of Greater Cincinnati Integration with SCADA: PLCs communicate via Ethernet/IP to Power Monitoring Devices Calculations for Power Usage in PLC Logic HMI Graphic Displays: Power Usage (KW) / Power Factor On Peak / Off Peak (Time Sensitive) Example Configuration Cincinnati, OH Device looks the same as a PLC on network. Ethernet network contains PLCs and the Power Monitors. HMI software is utilized to communicate from the HMI Servers to the devices on the Ethernet network. Page 9 9

10 Example Configuration Cincinnati, OH PLC logic polls the power monitors for data PLCs read data directly from the Power Monitors via polling logic in the PLC program. Example Configuration Cincinnati, OH PLC logic calculates usage for each unit process PLC logic sums the KW for each piece of equipment to calculate a total for each process area of the plant. Page 10 10

11 Example Configuration Cincinnati, OH HMI Graphic displays Graphic displays power monitoring data directly from power monitors and from PLCs. Example Configuration using PMCS Cleveland Water Department Integration with SCADA: OPC utilized to communicate to power monitoring system server. Calculations for Wire-to-Water in PLC Logic HMI Graphic Displays: Multiple power monitoring readings from motor management relays Page 11 11

12 Example Configuration Cleveland, OH OPC Communication to dedicated power monitoring server provides data-rich source. Example Configuration Overview HMI Graphic Display Page 12 12

13 Example Configuration, Equipment Power HMI Graphic Display Example Configuration Wire to Water HMI Graphic Display Page 13 13

14 Summary Utilities consider Power Monitoring valuable Display of acquired data is a standard feature in all systems. Only one plant explicitly uses power monitoring to load shed on a regular basis (Coastal Virginia WWTP). Columbus and Cleveland display custom information and leave at operations discretion how to use. Applications beyond display of metered data require detailed analysis and planning, with provision for ongoing maintenance. Questions Contact Information Mike Watkins watkinsms@cdmsmith.com Phone: (312) Page 14 14