© ABB Group April 11, 2023 | Slide 1
Automation of Lift Irrigation Schemes Network Management
Archana Choudhary, 23rd January 2009, Power System – NM
© ABB Group April 11, 2023 | Slide 2
Overview of Today’s Presentation
Water Automation projects with ABB India
Lift Irrigation projects under execution
Overview of SCADA system in Lift Irrigation projects
Product overview
Operation & Maintenance
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Your Partner in turnkey solution for:
Motor Pump
Motor PumpMotor Pump
Motor Pump
Motor PumpMotor Pump
Motor PumpMotor Pump
Motor PumpMotor Pump
Motor PumpMotor Pump
Motor Pump
Motor Pump
Motor Pump
Motor Pump Irrigation
Substation & pumping station automation.
Water Transport and Supply
Water / Wastewater Treatment
Seawater Desalination
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One stop shop solutions from ABB
Motors and Drives
Energy distributionEnergy supply
Actuators
Networks and controls
SCADA and Automation
Instrumentation
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Network Management System
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SCADA Defined
What is SCADA ?
SCADA stands for Supervisory Control and Data Acquisition
SCADA is a type of application
Not an off- the-shelf product or technology
Used in a wide range of industrial processes
Provide monitoring and control of remote equipment and facilities
Primary functions of SCADA system:
Data acquisition
Data communication
Data presentation
Control
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Various protocols supported by SCADA
IEC 61850 Master Protocol for relay communicatios LONWORKS Devices DNP V3.00 Master Protocol DNP V3.00 Slave Protocol IEC 60870-5-101 Master/Slave Protocol IEC 60870-5-103 Master Protocol IEC 60870-5-104 Master/slave Protocol Modbus Master/slave Protocol OPC DA client for PLC communication
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Data Acquisition Redundant Data Processing Calculations Supervisory Control Tagging Flexible Operator Authority Map board / Video Wall Alarm Handling & Presentation Historical and Planning data handling One-line and Tabular Presentation Trend Presentation Load Shed and Restore On-line Context Sensitive Help Disturbance Data handling Control System Supervision Full graphic HMI Network Topology Hot / standby redundant support Colour Setting tools Zooming, panning and de-cluttering Data storage into open databases like Ms-SQL server, Oracle etc.,
SCADA Features
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SCADA User Benefits
User Benefits Always up-to-date and reliable information about network state
Secure operation of the network
Manual dressing of network operational state
Sorting of essential information at disturbances
Easy to define calculations and reports
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Graphical User Interface
Operator Station based on Microsoft Component
Features
On-line Configurable Menus and Toolbars
Microsoft Excel for Report presentation
Trend and instantaneous curves based on ActiveX components
Support for large screen display walls
Support for Remote Workstations on many medias
WEB based system
User Benefits
Intuitive usage – less risk for operational errors
Reduced operator training costs
Advanced integration possibilities with minimal costs
“Future proof” - easy adaptation to new requirements
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A4 Colour Printer
A4 B/W Laser Printer
SCADA Architecture for Master Control Center
GPS Antenna
HOPF
Engineering W/S
LAN A (Main)
LAN B (Hot SB)
Router/Firewall Main and Redundant HIS(UDW) Server
Main and Redundant SCADA/DMS Server
Workstation -1 Workstation -2 Workstation -3
Ethernet Switch
Ethernet Switch
To Backup Control Centre
Router
Redundant FEP For RTU’s & FRTU’s
Fiber Optic Network
Substation RTU’s
(220KV/132KV/66/11 KV)
For GIS services
Pumping station PLCs
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Water Automation projects with ABB India
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Water Projects with ABB India
Kerala Water Distribution System.
HNSS Lift Irrigation Project.
Indra Sagar Lift Irrigation Project.
PADA Lift Irrigation Project.
Sripada Sagar Lift Irrigation Project .
Rajiv Sagar Lift irrigation Project .
Dhummagudem Lift Irrigation Project Pkg-1 & Pkg-4.
Bhima Lift Irrigation Project .
Kalwakurty Lift Irrigation Project.
Pranahita Chevalla LIS Pkg-5, Pkg-7 and Pkg-12
Thotapalli Lift Irrigation Project.
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Lift Irrigation Projects Under Execution
HNSS Lift Irrigation Project –12 pumping stations.
Indra Sagar Lift Irrigation Project – 3 pumping stations
PADA Lift Irrigation Project – 5 pumping stations
Bhima Lift Irrigation Project – 2 pumping stations
Kalwakurty Lift Irrigation Project – 1 pumping station
Kerala Water Distribution System.
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Overview of SCADA system in Lift Irrigation
projects
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SCADA In Lift Irrigation Schemes
Functionalities Requirements
Remote operation and management
Operation on Unmanned location
Data collection, storage, retrieval and archive
Alarm and events management
Reports generating
Process monitoring and control
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Lift Irrigation Scheme Requirement
The details of four levels of automation such as
Local equipment panel (Level 1)
Local PLC control (Level 2)
Regional Control through network and Local PC (Level 3)
Central Control through PCs and network of entire system (Level 4)
Benefits in terms of
Extent of control
Performance
Reliability
Reduction in manpower, etc
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Automation in Pumping Station
Programmable Logic Controller
Field Instrumentation :
Pressure Measuring Instruments
Flow Measuring Instruments
Level Measuring Instruments
Temperature Measuring Instruments
Vibration Monitoring System
SCADA Equipments
Communication Equipments
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Components of SCADA System
Larger computers( Servers & workstations) running various software
Provide Human-machine Interface( HMI) for operators
Accept, process and store data from RTU ( substation automation) and PLC ( pumping system automation).
Regulate the controlled system
Distribute data to other systems
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Components of SCADA System
Communication Network
Connect Central Control Station and RTU/RPU/PLC
Types of Networks
Direct connection (Fiber Optic Backbone)
Telephone (leased or dial-up line)
Radio
Satellite (GPRS/CDMA)
VSAT
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Technology Innovation and Future Trends
Integration of SCADA with corporate IT system
Integration of SCADA with GIS
Integration of advanced process control technologies
Standardization
More open system and interoperability
Wider use of wireless network
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Application Example
Remote Access and Control
Provide continued operational control of the facilities in the event of a facility evacuation from any other facility.
Provide support staff with remote access to process control system for troubleshooting and maintenance.
Provide view-only access to process monitoring system for external end-users.
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Radio Link
SCADA Workstation
Radio Equipment
Operator Workstation
Ethernet Switch
PLC Controller
SCADA Workstation
Radio Equipment
Operator Workstation
Ethernet Switch
SCADA Workstation
Radio Equipment
Operator Workstation
Ethernet Switch
SCADA Workstation
Radio Equipment
Operation Workstation
Ethernet Switch
SCAD Workstation
Radio Equipment
Operator Workstation
Ethernet Switch
SCADA Workstation
Radio Equipment
Operator Workstation
SCADA Workstation
Radio Equipment
Operator Workstation
Ethernet Switch
SCADA Workstation
Radio Equipment
Operator Workstation
Ethernet Switch
SCADA Workstation
Radio Equipment
Operator Workstation
Ethernet Switch
SCADA Workstation
Radio Equipment
Operator Workstation
Ethernet Switch
Main Server
Radio Equipment
Standby Server
Ethernet Switch
PLC Controller
PLC Controller PLC Controller PLC Controller PLC Controllerv PLC Controller PLC Controller
PLC Controller
PLC Controller
PLC ControllerPS-1
PS-2
PS-6 PS-7 PS-8 PS-9 PS-10
PS-11
PS-12
PS-4 (Main Control Center)
Note:-
Operating Workstations
PS-5
Overview Of HNSS Pumping Stations & Master Control Centre
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11KV Switchyard
PLC Controller
Ethernet Switch-1
Standby Server
Dot Matrix printer
Main Server
Ethernet Switch-2
PRINT SERVER
Hardw
ires signals from field instrum
ents
DI, D
O, A
I & A
O
Unit Control Board, Synchronizing
Equipment
DI, D
O, A
I & A
O
Field Instruments
Dot Matrix printer
Workstation -3 Workstation -4 Workstation -5
Laser Jet printer
SCADA Architecture for Pump House in Kalwakurity LIS
Workstation -2Workstation -1
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KWA : Reservoir Monitoring Through SCADA
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KWA Process Layout
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KWA : Overview of Control Center
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Service
Trouble Shooting Experts, Consultancy SparesService Contracts
Modernization, Extension Remote service, Maintenance System Training
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Product Overview
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Automation Hardware & Software
Hardware
Remote Terminal Unit – RTU 560, RTU211. ( for substation automation)
Programmable Logic Controller – AC800, AC500, AC31 ( pumping station automation)
Software
SCADA – Network Manager, Micro SCADA Pro, 800xa
GIS – Facilplus.
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Market Requirements for Modern RTUs
NCC Process
Commands
MonitoringDirection
+serial
interfacingof
IEDsStation HMI
Integrated HMI PLC functions Data archives
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Maintenance
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Maintenance Overview
Maintenance, which has been a non-core area for a pumping Stations, is an integral area, which has to be looked in for better performance. Maintenance of equipment is of primary importance for every plant.
Maintenance procedures should be given a high priority in the daily work schedule, because making sure that the plant equipment functions properly is an important factor in achieving the proper water quality discharge.
By proper Maintaining the Plant Equipment, an operator can extend its Plant Life by at least 25 %.
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Maintenance in LIS
Proper Maintenance is required for all the systems in the Pumping Stations.
Electrical Systems
Mechanical Equipments
Automation Equipments
Instrumentation
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Maintenance Overview
Types of Maintenance:
Preventive Maintenance.
Predictive Maintenance.
Breakdown maintenance.
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Preventive Maintenance It should be considered as a part of your normal daily work routine
and something that is necessary to keep the plant operation at full capacity.
Preventive Maintenance is the form of Inspection and tests that are performed every day.
Types of Preventive Maintenance
Planned Maintenance:
Planned Maintenance is defined as the periodic scheduled
removal of equipment from service for the disassembly and
inspection of Internal working parts.
Routine Maintenance:
Routine maintenance is best described as the daily general
Inspections and test including regular lubrication, that are
performed as a part of regular operation of the Plant.
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Predictive Maintenance
Predictive Maintenance is regular monitoring of the actual mechanical condition, operating efficiency, and other indicators of the operating Condition of process systems will provide the data required to ensure the maximum interval between repairs and minimize the number and cost of unscheduled outages created by failures.
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Key points for Predictive Maintenance:
Based on the Criticality of the Process Value & Instruments Value the Checking and Calibration should be done.
Improper Functioning of Instruments.
SCADA Value is not matching with the Field Values.
Based on the Alarm Generated.
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Breakdown Maintenance
During the Shut Down Operation Breakdown Maintenance should be done.
Breakdowns in industrial manufacturing systems can have significant impact on the profitability of a business. Expensive production equipment is idled, labor is no longer optimized, and the ratio of fixed costs to product output is negatively affected. Rapid repair of down equipment is critical to business success; and this can be overcome by proper Preventive and Predictive maintenance.
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Key Points for Breakdown Maintenance:
Before shutdown Collect the required data for preparing shutdown procedures.
During Shut down Clean all the Instruments and Equipments by dismantling.
Critical Instruments can be Calibrated during this Time.
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Self-diagnostics
Hot swap maintenance
On-line changes of application program and configuration
Compact Flash memory for storage of application and data
Search & Navigation
Comprehensive maintenance features reduce down-time
Cost Effective Maintenance
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Steps to Deploy SCADA System
Analyze process requirements
System design
Hardware selection and procurement
Control system programming
HMI development
Installation
Testing
Startup system
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Calibration:
Calibration is the process of establishing the relationship between a measuring device and the units of measure. This is done by comparing a device or the output of an instrument to a standard having known measurement characteristics.
Calibration can be called for:
with a new instrument
when a specified time period is elapsed. For example PG,PS,PT etc
when a specified usage (operating hours) has elapsed.
when an instrument has had a shock or Vibration which potentially may have put it out of calibration
whenever observations appear questionable
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