Technical Survey for the Development of a SCADA System.
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A technical survey for a SCADA (Supervisory Control and Data Acquisition) project is the audit and field data collection stage necessary to define the scope, design, and required hardware/software. It consists of documenting in detail the current state of the processes, machines, communication networks, and operator needs to avoid misunderstandings and ensure system compatibility.
This process is divided into the following key areas:
- 1. Asset Survey and Field (Level 0-1).
- • Identification of sensors and actuators: Locate and list transmitters (temperature, pressure, level, flow), motors, valves and frequency converters.
- • Instrumentation Review: Verify the status, calibration, output signal (4-20mA, 0-10V) and location of the instruments.
- • Existing control equipment (PLCs/RTUs): Document brand, model, memory capacity, available I/O modules (inputs/outputs) and communication protocols of the PLCs.
- • Safety: Check electrical cabinets, protection systems, emergency stops and power supply.
- 2. Survey of Networks and Communications.
- • Network infrastructure: Identify the type of cabling (fiber optic, twisted pair, coaxial) and network equipment (switches, routers) installed.
- • Communication protocols: Determine the active protocols for integrating devices (Modbus TCP/RTU, Profinet, Profibus, OPC).
- • Network architecture: Map the connectivity between PLCs, RTUs, HMIs and the corporate network.
- 3. Functional and Operational Survey.
- • Identification of critical variables: Define which data should be monitored, graphed, or controlled in real time.
- • Storage Requirements (Historian): Determine the data sampling rate and the historical storage time required.
- • Alarm Management: Identify critical events, machine failures, and process alarms that require immediate operator attention.
- • HMI Interfaces: Review operator experience and graphical display needs.
- 4. Deliverables of the Technical Survey.
At the end of the survey, a document must be available that includes:
- • Updated P&ID (Piping and Instrumentation) diagrams.
- • Proposed Network and Control Architecture.
- • Complete I/O (inputs and outputs) list.
- • Detailed scope of the project (scope of work, limitations, risks).
In summary, a successful SCADA survey ensures that the system design accurately reflects the reality of the plant, optimizing costs and ensuring the reliability of monitoring and control.
- DATA:
To implement an efficient SCADA (Supervisory Control and Data Acquisition) system, it is necessary to collect detailed data about the physical process, field devices, communication network, and visualization requirements.
Here are the key data points divided by categories:
- 1. Field and Process Data (Inputs/Outputs).
- • Signal Identification (Tags): Complete list of analog signals (temperature, pressure, level, flow rate) and digital signals (start/stop, alarms, switch states).
- • Measurement Ranges (Scaling): Minimum and maximum physical values and their equivalent in the electrical signal (e.g., 4-20mA = 0-100 bar).
- • Location of Sensors/Actuators: Where the measurement points are physically located in the plant.
- 2. Control Infrastructure and Hardware.
- • Controllers (PLC/RTU): Brand, model, IP addresses and memory capacity of the controllers that will handle the process.
- • Communication Protocols: Identify which protocol the devices use (Modbus TCP/RTU, OPC UA, DNP3, Siemens S7, Ethernet/IP).
- • Network Topology: Network structure (switches, routers, fiber optics, VPN) to ensure connectivity between field devices and the SCADA server.
- 3. Data for the Human-Machine Interface (HMI).
- • Screens and Graphics: Plant layouts, P&ID diagrams (piping and instrumentation) or other necessary visual representations.
- • Control Operations: Define what actions the operator can take from the screen (e.g., change a setpoint value, start a motor).
- • User Hierarchy: Define access profiles (operator, supervisor, engineer, administrator) and passwords.
- 4. Operational and Management Data (Historical Data and Alarms).
- • Alarm Strategy: Define critical alarms, levels (high, low, critical) and priorities to prevent operator fatigue.
- • Historical Variables: What data should be stored in the historian (database) for future analysis and reports (historical temperatures, downtime, production).
- • Reports: Frequency and format of production or failure reports needed by management.
- Summary of key steps for collection.
- 1. Conduct a floor plan survey: Identify existing hardware.
- 2. Create a signal list (I/O List): Define the tag name, data type, and address in the PLC.
- 3. Define the communication: Establish the IP addresses and protocols (e.g., Modbus).
- 4. Design the information flow: Decide how each piece of data will be displayed and stored.
- Additional Requirements:
- List of processes.
- List of procedures.
- List of machinery.
- List of machines.
- List of systems.
- List of departments.
- List of personnel.
- Customer list.
- List of roles.
- List of production lines.
- List of production plans.
- List of main faults.
- List of current problems.
- List of losses.
- List of kpi's main departments.
- If you are not yet convinced about purchasing our product, service, or course, we can conduct a technical assessment at your facility to provide greater clarity and precision regarding the scope of the report we deliver. This assessment costs USD $60,000.00 and will be carried out over two weeks at your location. This fee will be refunded upon purchase of the product, service, or course; otherwise, it will not apply.
- Technical Assessments: Service Description.
- We offer these options to clarify the technologies.
- Courses for:
- Executives.
- Beginners.