Trouble Shoot SCADA

The Engineering Institute of Technology (EIT) & IDC Technologies - Free Online Course
Troubleshooting of SCADA
and Data Acquisition
Systems
by
Steve Mackay
Dean of Engineering
www.eit.edu.au
Topics
Background to SCADA
A Simple SCADA & Data Acquisition
System
Typical SCADA Communication Structures
Troubleshooting Techniques for SCADA
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Troubleshooting of SCADA and Data Acquisition Systems
EIT Micro-Course Series
Every two weeks we present a 35

to 45 minute interactive course
Practical, useful with Q & A
throughout
PID loop Tuning / Arc Flash
Protection, Functional Safety,
Troubleshooting conveyors
presented so far
Upcoming:
Electrical Troubleshooting and
much much more..
Go to http://www.eit.edu.au/freecourses
You get the recording and slides
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Background to SCADA
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SCADA
Supervisory Control And Data Acquisition
SCADA is not just Software or Hardware
But a complete control system including
communications systems
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SCADA
Supervisory Control and Data Acquisition
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Remote Terminal Unit

The complete assembly of equipment at
an end point of the control system in the
field, factory or industrial site.
This can be a Programmable Logic
Controller (PLC).
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Typical SCADA System
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Local Area Networks

High speed access
Ethernet
Industrial Ethernet
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SCADA Systems Software
10
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Components of a SCADA System

Display
Server #1
Display
Server #2
Printer
I/O
Database
RS-232
Trend Server Task

Report Server Task
Input / Output Server Task
Radio
Modem
Radio
Modem
Instrumentation
& Control
In Out
In Out
Analog
Digital
11
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Key Features
User Interface
Graphics Displays
Alarms
Trends
RTU (and PLC) Interface
Scalability
Access to data
Database
Networking
Fault Tolerance and Redundancy
Client/Server distributed processing
12
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SCADA Software Package

Centralized
Central Control Room
Distance Between RTUs and Control Room
Distributed
De-Centralized Control
Multiple Operators
Proprietary
Produced by a single company
Open Standard
Interoperability
13
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Client Server for SCADA Systems

Trends
Alarms
Trends
Alarms
I/O
Report
Display
Tasks
Task
Reports
Display
Database
Databases
Server Node
I/O
Database
Display Node
Display Node
Display Node
Printer
Local Area Network
Bridge
Programmable
Logic
Controllers
14
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Management
Quality
Control
Engineering
Mainframe
LAN
Bridge
Display
Client
Display
Client
Display
Client
File
Server
Display
Client
LAN
Trends
Server
Alarm
Server
Report
Server
I/O
Server
Radio
Modem
RTU
#1
LAN
RTU
#2
LAN
PLC #1
PLC #2
PLC #3
PLC #4
PLC #5
PLC #6
15
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Industrial Communications
Protocols
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Topics
EIA-232 Interface Standard

EIA-485 Interface Standard
MODBUS Protocol
DNP 3.0 Protocol
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RS-232 Connections (DB25)
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Protocol Analyzer Connections
Protocol
Analyzer
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10
RS-485 Review
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EIA-485 interface standard
Distances of up to 1200m
Data Rates of up to 10Mbps
32 Line Drivers
32 Line Receivers
NOTE : Total of 32 devices on same line
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11
RS 485
RS-485 Is the Most Common Voltage
Standard in Use Today for Multi-drop
Communication Systems.
This Is Because
It Is Very Resistant to Noise

It Can Send Data at High Speeds
And Can Go Long Distances
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Two Wire Multidrop RS-485

1200M (4000 FT)
TERMINATION RESISTORS AT BOTH ENDS ONLY
A
G
Rt
A
B
Rt
TX
TX
RX
R
RX
G
GWG
GWG
A
G
TX
- Generator
- Receiver
TX
A
RX
R
GWG
RX
GWG
- Circuit ground or
circuit common
- Protective ground or
frame ground
GWG - Green wire ground or
power system ground
Note: The RS-485 standard documentation
leaves out the invertes for the receiver
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12
Four Wire Network

1200M (4000 FT)
Master
Slave
Rt
G
TX
Rt
R
TX
RX
RX
R
Rt
Rt
GWG
GWG
Slave
Slave
A
B
G
TX
G
TX
RX
- Generator
- Receiver
- Circuit ground or
circuit common
RX
R
GWG
- Protective ground or
frame ground
GWG - Green wire ground or
power system ground
GWG
Note: The RS-485 standard documentation

leaves out the invertes for the receiver
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Installation of Bias Resistors

to Minimize Noise
560
A
120
560
120
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13
MODBUS
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Modbus Message Format
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14
Modbus PLC Notation
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Messages & Functions

Two types of messages:
Query/response - specific slave addressd
Broadcast - address 00, no response required
Function codes specify:

what the slave is to do
what section of the memory map to find or
deposit the data
e.g. Coil Status, Input Status, Input Register,
Holding Register
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15
What is DNP3?
Distributed Network Protocol Version 3.0
Defines communications between:
Master Stations
Remote Telemetry Units (RTUs)
Intelligent Electronic Devices (IEDs)
More than just communications

Originally developed in Electrical Utility
Industry
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Designed for SCADA

Features
Time stamping
Optimised use of
bandwidth
Reporting by
exception
Variety of operating
modes
Data Structure
Analogs
Binary
Counters
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16
Why use DNP3?

It is an open protocol
It is optimised for SCADA communications
It provides interoperability between different vendors
equipment
It is supported by a substantial number of SCADA
equipment manufacturers
It will provide immediate and long-term benefits to
users
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Features of DNP3
Supports time stamped messages for Sequence of Event (SOE)

recording
Breaks messages into multiple frames to provide optimum error
control and rapid communication sequences
Allows peer-peer topology as well as master-slave
Allows multiple master topology
Provides user definable objects
Provides for reporting by exception / event without polling by
master
Provides for changed data only responses
Broadcast messages
Secure configuration/file transfers
Addressing for over 65,000 devices on a single link
Provides Time synchronisation and time-stamped events
Data link and application layer confirmation
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17
Troubleshooting and
Maintenance
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18
Troubleshooting the telemetry system

Ensure that components are not removed on
line whilst the system is powered up unless the
manufacturer specifically indicates that this is
permissible.
Damage to components and modules can occur
when removing whilst the system is still powered
up.
Ensure that the antenna system is not
disconnected from the system unless a dummy
load has been installed, otherwise the radio
power amplifier may be damaged.
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The RTU and component modules

Check:
Analog input modules
Digital input module
Interface from RTU to PLC (RS-232 /

RS-485)
Privately owned cable
Switched telephone line
Analog or digital data links

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19
The master sites

The master sites will generally consist of a
more complete telemetry unit and higher
quality radio equipment.
The same troubleshooting techniques can
be applied to the master site as are used
at the RTUs.
Additional equipment would include links
to other master sites, to the central site
and computer control facilities
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The central site

The operator stations
The software for the system
The communications network for the
operator stations
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20
The operator station and software

There is not much that can be done here if a
system fails or has intermittent problems except
to systematically replace each connected unit to
identify the faulty module
Operator terminal (normally a personal
computer)
Local area network card(s)
Bridge unit to radio, microwave or landline
system
Printer connected to operator terminal
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There are however a few problems which

can be examined:
Operator terminal locks up
intermittently
Throughput of the operator station and
associated system drops off
dramatically
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21
Maintenance tasks
Whether the maintenance tasks are to be
undertaken internally by your company or
outsourced to a maintenance contractor, it
is vital that there is a comprehensive and
planned approach to maintenance
Tasks should be broken down in to those
things done daily, weekly, monthly and
annually.
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The maintenance unit system

In industry today there is an increasing
tendency for companies to reduce
permanent staff to cover only the core
business of the company and to contract
out peripheral activities to specialist
maintenance companies.
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22
THANK YOU FOR ATTENDING

If you are interested in further training please visit;
IDC Technologies
Two-day practical workshops available to the public:
www.idc-online.com/course_schedule/
On-site customised workshops:
www.idc-online.com/training/
Technical Manuals:
www.idc-online.com/products/
Conferences:
www.idc-online.com/cons/
The Engineering Institute of Technologies

Practical online Certificate, Advanced Diploma and Graduate Certificate programs:
www.eit.edu.au
www.eit.edu.au
If you are interested in further training in the area visit:

www.idc-online.com
Practical SCADA Systems for Industry
CITY
COUNTRY
DATE
Dublin
Ireland
08-Mar-12
DAYS
2
Auckland
New Zealand
16-Apr-12
Practical Boiler Control and Instrumentation for Engineers and Technicians

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COUNTRY
DATE
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South Africa
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Canada
15-Mar-12
Edmonton
Canada
19-Mar-12
Toronto
Canada
22-Mar-12
London
United Kingdom
12-Apr-12
Birmingham
United Kingdom
16-Apr-12
Edinburgh
United Kingdom
19-Apr-12
Auckland
New Zealand
14-Jun-12
www.eit.edu.au
23

www.idc-online.com
Practical Distributed Control Systems (DCS) for Engineers & Technicians
CITY
COUNTRY
DATE
Johannesburg
South Africa
10-May-12
DAYS
2
Vancouver
Canada
24-May-12
Edmonton
Canada
28-May-12
Montreal
Canada
31-May-12
Practical Industrial Flow Measurement for Engineers and Technicians

CITY
COUNTRY
DATE
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United Kingdom
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DAYS
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United Kingdom
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Cardiff
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DATE
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Practical Intrinsic Safety for Engineers and Technicians
CITY
COUNTRY
DATE
Sydney
Australia
12-Apr-12
DAYS
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Perth
Australia
16-Apr-12
Melbourne
Australia
19-Apr-12
Practical Tuning of Industrial Control Loops

CITY
COUNTRY
DATE
Johannesburg
South Africa
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CITY
COUNTRY
DATE
Johannesburg
South Africa
04-Jun-12
DAYS
2
Practical Process Control

DAYS
2
Practical Control Valve Sizing, Selection and Maintenance

CITY
COUNTRY
DATE
Edmonton
Canada
21-Jun-12
DAYS
2
Winnipeg
Canada
25-Jun-12
Halifax
Canada
28-Jun-12
www.eit.edu.au
24

Trouble Shoot SCADA

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The Engineering Institute of Technology (EIT) & IDC Technologies - Free Online Course

Troubleshooting of SCADA and Data Acquisition Systems

EIT Micro-Course Series

Every two weeks we present a 35

Troubleshooting of SCADA and Data Acquisition Systems

Troubleshooting of SCADA and Data Acquisition Systems

Remote Terminal Unit

Typical SCADA System

Troubleshooting of SCADA and Data Acquisition Systems

Local Area Networks

SCADA Systems Software

Troubleshooting of SCADA and Data Acquisition Systems

Components of a SCADA System

Trend Server Task

Troubleshooting of SCADA and Data Acquisition Systems

SCADA Software Package

Client Server for SCADA Systems

Troubleshooting of SCADA and Data Acquisition Systems

Troubleshooting of SCADA and Data Acquisition Systems

EIA-232 Interface Standard

RS-232 Connections (DB25)

Troubleshooting of SCADA and Data Acquisition Systems

Protocol Analyzer Connections

Troubleshooting of SCADA and Data Acquisition Systems

EIA-485 interface standard

NOTE : Total of 32 devices on same line

Troubleshooting of SCADA and Data Acquisition Systems

It Is Very Resistant to Noise

Two Wire Multidrop RS-485

Troubleshooting of SCADA and Data Acquisition Systems

Four Wire Network

Note: The RS-485 standard documentation

Installation of Bias Resistors

Troubleshooting of SCADA and Data Acquisition Systems

Modbus Message Format

Troubleshooting of SCADA and Data Acquisition Systems

Modbus PLC Notation

Messages & Functions

Function codes specify:

Troubleshooting of SCADA and Data Acquisition Systems

More than just communications

Designed for SCADA

Troubleshooting of SCADA and Data Acquisition Systems

Why use DNP3?

Supports time stamped messages for Sequence of Event (SOE)

Troubleshooting of SCADA and Data Acquisition Systems

Troubleshooting of SCADA and Data Acquisition Systems

Troubleshooting the telemetry system

The RTU and component modules

Analog input modules

Digital input module

Interface from RTU to PLC (RS-232 /

Privately owned cable

Switched telephone line

Analog or digital data links

Troubleshooting of SCADA and Data Acquisition Systems

The master sites

The central site

Troubleshooting of SCADA and Data Acquisition Systems

The operator station and software

There are however a few problems which

Troubleshooting of SCADA and Data Acquisition Systems

The maintenance unit system

Troubleshooting of SCADA and Data Acquisition Systems