Nama : Handy Wicaksono S1 & S2 di Teknik Elektro, ITS Dosen Teknik Elektro, UK Petra Trainer Industrial Automation TC, UK Petra Meminati otomasi industri (PLC, SCADA) dan robot cerdas
Just an introduction
Overview SCADA, What and Why? 2. SCADA Architecture 3. SCADA Application 4. SCADA Trend Suggestion : what can we do at campus? 1.
What is SCADA? (1) Monitoring
Kontrol sekunder
Akuisisi data
Database
Report
Grafik, trend
What is SCADA? (2)
“Teknologi yang memampukan pengguna untuk mengumpulkan data dari satu atau lebih fasilitas jarak jauh dan/atau mengirim instruksi kontrol terbatas ke fasilitas – fasilitas tersebut”
Sumber : National Institute of Standards and Technology, USA 5
What is SCADA? (3)
Sumber : http://www.millennas.force9.co.uk/
Why SCADA is important? (1) PLC
Input Devices
Output Devices
Plant
Why PLC is not enough? • Operator tidak dapat “melihat” proses • PLC tidak hanya hasilkan produk, namun data
Why SCADA is important? (2) Aliran data perusahaan Directors
PLC
Manual Record Plant
Entering The data
Why SCADA is important? (3) Aliran data perusahaan Directors
PLC
Why data is important? • Data yang direkam dan dianalisa Plant memberi nilai tambah bagi perusahaan • Database report optimasi produksi
History : “Primitive” SCADA
Apakah ada SCADA?
10
History : “Modern” “Modern” SCADA (1)
Sumber : Control Magazine, May 2012
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History : “Modern” SCADA (2)
Sumber : http://www.controlmicrosystems.com/ 12
SCADA Basic Components (1) Komunikasi SCADA Software
SCADA Software
Komunikasi
Komunikasi Field Devices
Field Devices 13
SCADA Basic Components (2) Field Devices (Sensor dan aktuator) 2. PLC atau RTU (controller) 3. Sistem Komunikasi 4. Komputer (Master Terminal Unit) 1.
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Programmable Logic Controller
Komputer industri khusus untuk mengawasi dan mengendalikan proses industri. menggunakan bahasa pemrograman khusus untuk kontrol industri (ladder diagram) Didesain untuk tahan terhadap lingkungan industri yang banyak gangguan ◦ noise, vibration, shock, temperature, humidity
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Remote Terminal Unit Alat pengendali dan pengumpul data di industri Beroperasi pada lokasi yang jauh, dimana data dikirim pada sistem utama melalui telemetry (radio, dial-up telephone, atau leased lines)
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Sistem Komunikasi (1) Sangat bervariasi! Contoh Komunikasi PC- PLC
Sumber : http://www.controlmicrosystems.com/ 17
Sistem Komunikasi (2) Dari PLC ke field device 2. Dari PLC ke PLC 3. Dari PLC ke PC 4. Dari PC ke PC lainnya (jaringan) 1.
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Sistem Komunikasi (3) Hirarki Industrial Networks
Information Network
Control Network Device Network
Pengumpulan dan pemeliharaan data plant keseluruhan pengendalian I/O real time, messaging - interlocking antar pengendali mengintegrasikan peralatan di lapangan dengan perusahaan
Sistem Komunikasi (4) Hirarki Industrial Networks
Komputer sebagai MTU
Master Terminal Unit : ◦ Komputer dengan SCADA software ◦ Merupakan “otak” dari sistem SCADA
Demo flash!
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SCADA Software in the market Wonderware Intellution (GE) Citect (Schneider) Factory Talk, RS View (Rockwell Automation) WinCC (Siemens) Iconics Dll
Studi kasus : Wonderware (1) QI Analyst
ActiveFactory DT Analyst
InSQL / Historian
AppServer
SuiteVoyager
InTouch
Plant Data Sources
Studi kasus : Wonderware (2) SCADA software function : Interfacing with field device Control and monitoring Alarm, trend Database, report Statistical analysis : Key Performance Index, Statistical Process Chart, Quality, Downtime Web visualization, etc
Studi kasus : Wonderware (3)
Wonderware System Platform
SCADA Application
Chemicals manufacturing Electric power generation Food & beverage manufacturing Metals, minerals, & mining Oil and gas extraction
Petroleum refining Pharmaceutical & life science Plastic & rubber manufacturing Pulp & paper manufacturing Water & wastewater processing
Aplikasi flow monitoring pada perusahaan gas (1)
Sumber : PT. Sukses Bersama Nusantara
Aplikasi power metering pada perusahaan gas (2)
Sumber : PT. Sukses Bersama Nusantara
Aplikasi pada pabrik pakan ternak
Aplkasi Pembuatan Susu
Berdasar recipe
Sumber : PT. Sukses Bersama Nusantara
Aplikasi pada perusahaan pembangkit – flow metering
Sumber : PT. Sukses Bersama Nusantara
Aplikasi pada perusahaan pembangkit – Trend of lead & raw metering
Sumber : PT. Sukses Bersama Nusantara
Aplikasi pada perusahaan minyak PLC diagnostic
Sumber : PT. Sukses Bersama Nusantara
SCADA Trend Electrical and informatics integration Ethernet as industrial network Open standard communication (OPC) Security issue Mobile device application for SCADA Integration with business software (SAP, MES, OEE Report, etc.) Etc.
Ethernet as Industrial Network (1) InTouch
Must have a
Modbus +
Special Card
DH + Profibus
PLC
PLC
PLC
PLC
PLC
Sumber : Wonderware Seminar Material 35
Ethernet as Industrial Network (2) TCP/IP
InTouch
InTouch
InTouch
InTouch
Modbus +
Must have a
DH +
Special Card
Profibus
PLC
PLC
PLC
PLC
PLC
Sumber : Wonderware Seminar Material 36
Ethernet as Industrial Network (3) Use Ethernet Card InTouch
InTouch
InTouch
InTouch
TCP/IP
PLC
PLC
PLC
PLC
PLC
With Ethernet
With Ethernet
With Ethernet
With Ethernet
With Ethernet
module
module
module
module
module
Sumber : Wonderware Seminar Material
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OPC Definition (1) OLE for Process Control (OPC) A software interface technology used to facilitate the transfer of data between industrial control systems, Human Machine Interfaces (HMI), supervisory systems and enterprise systems such as historical databases
Sumber : OPC Foundation
OPC Definition (2)
Contoh implementasi OPC
OPC Server
Sumber : Kepware
Primary Value of OPC (1) OPC provides a common interface for communicating with diverse industrial control products, regardless of the software or hardware used in the process OPC is open connectivity through the creation and maintenance of open standards specifications
Sumber : OPC Foundation
Primary Value of OPC (2)
OPC Architecture
OPC is based on a client-server architecture
Sumber : OPC Foundation
OPC Application in the market
KepServerEx from Kepware
OPC Data Hub from Cogent
OPC Systems.NET from Open Automation
Future of OPC
Studi Kasus OPC sederhana pada perusahaan gas (1)
Menyimpan data dari flow computer unit di berbagai area ke database OPC team Membuat aplikasi web secara real time yang menampilkan data tersebut IT team
Studi Kasus OPC sederhana pada perusahaan gas (2) Konfigurasi KepServerEx (OPC server) yang membaca data alat Konfigurasi DataLogger (add-ons KepServerEx)
Studi Kasus OPC sederhana pada perusahaan gas (3)
Konfigurasi DataLogger (add-ons KepServerEx) ◦ ◦ ◦ ◦
Ambil tag name dari OPC Server Atur koneksi ke database (DSN) Menyimpan ke tabel baru/existing Konfigurasi durasi penyimpanan ke database
Konfigurasi (sederhana) SQL Server 2008 ◦ Desain tabel, tipe data ◦ Remote connection for SQL (test :VM Ware)
Security Issue (1)
“Lobang keamanan” pada SCADA
Sumber : Control Magazine, May 2012
Security Issue (2)
Serangan Worm Stuxnet ke komputer dengan SCADA software & PLC (Siemens)
Sumber : www.threatinfo.trendmicro.com
SCADA Mobile Device Application SCADA application on tablet and Smartphone
Sumber : SCADAVisor, mySCADA
Suggestion : What can we do now (at campus)?
Learning Information Technology aspect ◦ Network, database, OOP, dll
Self experiment on SCADA system with freeware (if existed) Part time job at automation system integrator Following student competition (lomba PLC, HMI, Gemastik)
Suggestion : What can we do now (at campus)?
Self experiment example
Wonderware InTouch / VB.Net OPC Client (OPC Link) OPC Server (KepServerEx 5)
PLC Omron
PLC Siemens
Please visit : http://learnautomation.wordpress.com
Thanks to : Tonny Leonard (PT. Sukses Bersama Nusantara)
