Troubleshooting Of SCADA & Data Acquisition Systems Rev4

Engineering Institute of Technology (EIT)Nuts and Bolts ofTroubleshooting of SCADA andData Acquisition SystemsbySteve MackayDean of Engineeringwww.eit.edu.auTopics Background to SCADA A Simple SCADA & Data AcquisitionSystem Typical SCADA Communication Structures Troubleshooting Techniques for SCADAwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar1

Engineering Institute of Technology (EIT)20/11/2017EIT Micro-Course Series Every two weeks we present a 35to 45 minute interactive coursePractical, useful with Q & AthroughoutPID loop Tuning / Arc FlashProtection, Functional Safety,Troubleshooting conveyorspresented so farUpcoming:– Electrical Troubleshooting andmuch much more . Go to http://www.eit.edu.au/freecoursesYou get the recording and slideswww.eit.edu.auBackground to SCADAwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar2

Engineering Institute of Technology (EIT)20/11/2017SCADASupervisory Control And Data Acquisition– SCADA is not just Software or Hardware– But a complete control system includingcommunications systemswww.eit.edu.auSCADASupervisory Control and Data Acquisitionwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar3

Engineering Institute of Technology (EIT)20/11/2017Remote Terminal Unit The complete assembly of equipment atan end point of the control system in thefield, factory or industrial site. This can be a Programmable LogicController (PLC).www.eit.edu.auTypical SCADA Systemwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar4

20/11/2017Engineering Institute of Technology (EIT)Local Area Networks High speed access Ethernet Industrial Ethernetwww.eit.edu.auSCADA Systems Softwarewww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar105

20/11/2017Engineering Institute of Technology (EIT)Components of a SCADA SystemDisplayServer #1DisplayServer #2PrinterI/ODatabaseRS-232Trend Server TaskReport Server TaskInput / Output Server TaskRadioModemRadioModemInstrumentation& ControlIn OutIn OutAnalogDigital11www.eit.edu.auKey Features User InterfaceGraphics DisplaysAlarmsTrendsRTU (and PLC) InterfaceScalabilityAccess to dataDatabaseNetworkingFault Tolerance and RedundancyClient/Server distributed processingwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar126

20/11/2017Engineering Institute of Technology (EIT)SCADA Software Package Centralized– Central Control Room– Distance Between RTU’s and Control Room Distributed– De-Centralized Control– Multiple Operators Proprietary– Produced by a single company Open Standard– Interoperability13www.eit.edu.auClient Server for SCADA ksTaskReportsDisplayDatabaseDatabasesServer NodeI/ODatabaseDisplay NodeDisplay NodeDisplay NodePrinterLocal Area du.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar147

20/11/2017Engineering Institute of Technology rtServerI/OServerRadioModemRTU#1LANRTU#2LANPLC #1PLC #2PLC #3PLC #4PLC #5PLC #6www.eit.edu.au15Industrial ng of SCADA and Data Acquisition Systems Free Webinar8

Engineering Institute of Technology (EIT)20/11/2017Topics EIA-232 Interface StandardEIA-485 Interface StandardMODBUS ProtocolDNP 3.0 Protocolwww.eit.edu.auRS-232 Connections (DB25)www.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar9

Engineering Institute of Technology (EIT)20/11/2017RS-232 Breakout Boxwww.eit.edu.auProtocol Analyzer ooting of SCADA and Data Acquisition Systems Free Webinar10

Engineering Institute of Technology (EIT)20/11/2017RS-485 Reviewwww.eit.edu.auEIA-485 interface standard Distances of up to 1200mData Rates of up to 10Mbps32 Line Drivers32 Line ReceiversNOTE : Total of 32 devices on same linewww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar11

20/11/2017Engineering Institute of Technology (EIT)RS 485 RS-485 Is the Most Common VoltageStandard in Use Today for Multi-dropCommunication Systems. This Is Because It Is Very Resistant to Noise It Can Send Data at HighSpeeds And Can Go Long Distanceswww.eit.edu.auTwo Wire Multidrop RS-4851200M (4000 FT)TERMINATION RESISTORS AT BOTH ENDS WGAARXBRGWGB- Generator- Receiver- Circuit ground orcircuit common- Protective ground orframe groundGWG - Green wire ground orpower system groundNote: The RS-485 standard documentationleaves out the invertes for the receiverwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar12

20/11/2017Engineering Institute of Technology (EIT)Four Wire Network1200M (4000 aveSlaveABGTXGTXARXAGBR- Generator- Receiver- Circuit ground orcircuit commonARXRBRGWGB- Protective ground orframe groundGWG - Green wire ground orpower system groundGWGNote: The RS-485 standard documentationleaves out the invertes for the receiverwww.eit.edu.auInstallation of Bias Resistorsto Minimize leshooting of SCADA and Data Acquisition Systems Free Webinar13

Engineering Institute of Technology (EIT)20/11/2017MODBUSwww.eit.edu.auModbus Message Formatwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar14

Engineering Institute of Technology (EIT)20/11/2017Modbus PLC Notationwww.eit.edu.auMessages & 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 ordeposit the data e.g. Coil Status, Input Status, Input Register,Holding Registerwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar15

Engineering Institute of Technology (EIT)20/11/2017What 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 UtilityIndustrywww.eit.edu.auDesigned for SCADA Features– Time stamping– Optimised use ofbandwidth– Reporting byexception– Variety of operatingmodes Data Structure– Analogs– Binary– Counterswww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar16

Engineering Institute of Technology (EIT)20/11/2017Why use DNP3? It is an open protocol It is optimised for SCADA communications It provides interoperability between different vendor’sequipment It is supported by a substantial number of SCADAequipment manufacturers It will provide immediate and long-term benefits touserswww.eit.edu.auFeatures of DNP3 Supports time stamped messages for Sequence of Event (SOE)recording Breaks messages into multiple frames to provide optimum errorcontrol 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 bymaster 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 confirmationwww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar17

Engineering Institute of Technology (EIT)20/11/2017Troubleshooting hooting of SCADA and Data Acquisition Systems Free Webinar18

Engineering Institute of Technology (EIT)20/11/2017Troubleshooting the telemetry system Ensure that components are not removed online whilst the system is powered up unless themanufacturer specifically indicates that this ispermissible. Damage to components and modules can occurwhen removing whilst the system is still poweredup. Ensure that the antenna system is notdisconnected from the system unless a dummyload has been installed, otherwise the radiopower amplifier may be damaged.www.eit.edu.auThe RTU and component modulesCheck: 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 linkswww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar19

Engineering Institute of Technology (EIT)20/11/2017The master sites The master sites will generally consist of amore complete telemetry unit and higherquality radio equipment. The same troubleshooting techniques canbe applied to the master site as are usedat the RTUs. Additional equipment would include linksto other master sites, to the central siteand computer control facilitieswww.eit.edu.auThe central site The operator stations The software for the system The communications network for theoperator stationswww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar20

Engineering Institute of Technology (EIT)20/11/2017The operator station and softwareThere is not much that can be done here if asystem fails or has intermittent problems exceptto systematically replace each connected unit toidentify the faulty module Operator terminal (normally a personalcomputer) Local area network card(s) Bridge unit to radio, microwave or landlinesystem Printer connected to operator terminalwww.eit.edu.auThere are however a few problems whichcan be examined: Operator terminal locks upintermittently Throughput of the operator station andassociated system drops offdramaticallywww.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar21

Engineering Institute of Technology (EIT)20/11/2017Maintenance tasks Whether the maintenance tasks are to beundertaken internally by your company oroutsourced to a maintenance contractor, itis vital that there is a comprehensive andplanned approach to maintenance Tasks should be broken down in to thosethings done daily, weekly, monthly andannually.www.eit.edu.auThe maintenance unit system In industry today there is an increasingtendency for companies to reducepermanent staff to cover only the corebusiness of the company and to contractout peripheral activities to specialistmaintenance companies.www.eit.edu.auTroubleshooting of SCADA and Data Acquisition Systems Free Webinar22

Engineering Institute of Technology (EIT)20/11/2017Thank You For Your InterestIf you are interested in further training, please visit:The Engineering Institute of Technologieswww.eit.edu.auIDC eshooting of SCADA and Data Acquisition Systems Free Webinar23

Data Acquisition Systems by Steve Mackay Dean of Engineering www.eit.edu.au Topics Background to SCADA A Simple SCADA & Data Acquisition . Management Quality Control Display Client Display Client Display Client Display Client Alarm Server I/O Server PLC #1 PLC #2 PLC #3 PLC #4 PLC #5 PLC #6 Trends Server Report Server