Integrating Power
Monitoring Data into SCADA
Michael S. Watkins, CAP
CDM Smith
May 23, 2012
Overview
What types of Power Monitoring Data is
available
How is the data integrated with SCADA
systems
How is the data utilized
Examples of Integration and Usage of Power
Monitoring Data
Questions
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Power Monitoring Data – What types
of data are available?
Depends on the Equipment / Devices on your
system!
Typically large rotating equipment includes
basic power data
– Amperage
– Voltage
Dedicated Power Monitoring Devices
– Overwhelming amount of data available
Power Monitoring Data – What types
of data are available?
Power monitoring devices (Cutler Hammer,
Allen-Bradley, GE, Schneider Electric, etc.)
offer an extensive list of variables depending
on the device.
Schneider Electric PowerLogic PM 1000
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Power Monitoring Data – What types
are often collected?
Typical Power Monitoring Data:
–
–
–
–
–
–
–
–
Real Power
Apparent Power
Current per Phase
Voltage per Phase
Power Factor
Energy usage (KWh)
Equipment Safeties (temperature)
Mains breaker status
Integrating the data with SCADA
Various methods utilized to integrate the
devices into a SCADA system (hardwired,
serial communication, Ethernet
communication).
Communication technology utilized in the
Power Monitors follows the SCADA hardware
technology.
– Transition to Ethernet communication
and standard protocols
– Implementation of OPC when needed to
enable data availability
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Trends in SCADA Communication
1990s – Discussion on implementing
standard Ethernet (Would it be
deterministic?)
2000s – Wide spread implementation of
Ethernet networks on control systems for
HMI / PLC communication
Current Trends – Ethernet continues to push
down into the SCADA network
– Device level communication
Trends in SCADA Communication
Ethernet standardized the physical hardware.
– Fiber Optic / Copper (CAT5 / CAT6)
– Network Hardware
Various protocols implemented on the
networks
Push toward open protocols and standard
communication methods
– Modbus TCP/IP
– Ethernet IP
– Development of OPC
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Ethernet Protocols
Protocol – Set of rules devices use to
transmit and receive data.
Standard Ethernet (Office Network) uses
TCP/IP.
– TCP – Transmission Control Protocol
– IP – Internet Protocol
Widely used industrial protocols have been
built upon the standard Ethernet protocol.
– Modbus TCP/IP
– Ethernet IP
– PROFINET
Bridging Between Protocols
Protocol Converters
– Communication modules in PLC rack for
translating serial protocols
– Gateways connected to the network for
translation
OPC (OLE for Process Control)
– Attempts to provide universal
connectivity
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Integrating the data with an HMI
Serial Protocols
– Modbus, DeviceNet
Typical Use:
– Collect data in PLC
for transfer to HMI
graphics / historian.
Serial Communication Control
System Architecture
Integrating the data with an HMI
Ethernet Connectivity
– Uses Standard
Protocols
(Ethernet/IP,
Modbus TCP/IP)
Advantages
– HMI Connection for
graphic displays
– Peer-to-Peer
Communication
with PLCs
Ethernet Control System Architecture
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Reminder for Questions
Questions can be asked at the end of the
presentation.
How is Power Monitoring Data used?
All installations add value in some fashion.
Most do not use the abundance of data to
fullest extent.
Some use data in unique ways.
Coupling OPERATIONAL decisions to DATA
requires analysis, engineering effort, and
planning in addition to the step of acquiring
the hardware and software components
themselves.
Systems and use can be simple or complex
(low or high maintenance).
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How is it used?
Tacoma, Washington Area WWTP
– Dedicated PMCS
– Monitor Power Quality and Reliability from
Power Utility
DFW Area WTP
– Dedicated PMCS
– Instantaneous Power / Motor & pump
safeties (bearing temperatures)
Coastal Virginia area WWTP
– Data brought into SCADA
– Instantaneous Power and Manual Load
Shedding…featuring big LED display
How is it used?
Cincinnati, OH MSD
– Data brought into SCADA
– Power Usage and Peak Monitoring
Cleveland, OH Water Department
– Dedicated PMCS
– Power Monitor and Wire-to-Water
calculations
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Example Configuration using PLCs
Metropolitan Sewer District of Greater
Cincinnati
Integration with SCADA:
– PLCs communicate via Ethernet/IP to Power
Monitoring Devices
– Calculations for Power Usage in PLC Logic
HMI Graphic Displays:
– Power Usage (KW) / Power Factor
– On Peak / Off Peak (Time Sensitive)
Example Configuration – Cincinnati, OH
Device looks the
same as a PLC
on network.
Ethernet network contains PLCs and the Power Monitors. HMI
software is utilized to communicate from the HMI Servers to the
devices on the Ethernet network.
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Example Configuration – Cincinnati, OH
PLC logic polls the power monitors for data
PLCs read data directly from the Power Monitors via polling
logic in the PLC program.
Example Configuration – Cincinnati, OH
PLC logic calculates usage for each unit process
PLC logic sums the KW for each piece of equipment to
calculate a total for each process area of the plant.
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Example Configuration – Cincinnati, OH
HMI Graphic displays
Graphic displays power monitoring data directly from power
monitors and from PLCs.
Example Configuration using PMCS
Cleveland Water Department
Integration with SCADA:
– OPC utilized to communicate to power
monitoring system server.
– Calculations for Wire-to-Water in PLC Logic
HMI Graphic Displays:
– Multiple power monitoring readings from
motor management relays
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Example Configuration – Cleveland, OH
OPC Communication to dedicated power
monitoring server provides data-rich source.
Example Configuration – Overview
HMI Graphic Display
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Example Configuration, Equipment
Power
HMI Graphic Display
Example Configuration “Wire to Water”
HMI Graphic Display
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Summary
Utilities consider Power Monitoring valuable
Display of acquired data is a standard feature
in all systems.
Only one plant explicitly uses power
monitoring to load shed on a regular basis
(Coastal Virginia WWTP).
Columbus and Cleveland display custom
information and leave at operations discretion
how to use.
Applications beyond display of metered data
require detailed analysis and planning, with
provision for ongoing maintenance.
Questions
Contact Information
Mike Watkins
Email: watkinsms@cdmsmith.com
Phone: (312) 780-7747
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