2012 06 22 Implementasi Teknologi Scada Di Dunia Industri

� Nama : Handy Wicaksono

� S1 & S2 di Teknik Elektro, ITS

� DosenTeknik Elektro, UK Petra

� Trainer Industrial Automation TC, UK Petra

� Meminati otomasi industri (PLC, SCADA) danrobot cerdas

Just an introductionJust an introduction

OverviewOverview

1. SCADA, What and Why?

2. SCADA Architecture

3. SCADA Application

4. SCADA Trend 4. SCADA Trend

Suggestion : what can we do at campus?

What is SCADA? (1)What is SCADA? (1)

Monitoring Akuisisidata

Kontrolsekunder

Database

Report Grafik, trend

What is SCADA? (2)What is SCADA? (2)

� “Teknologi yang memampukan penggunauntukmengumpulkan data dari satuatau lebih fasilitas jarak jauh

dan/ataumengirim instruksi kontroldan/ataumengirim instruksi kontrolterbatas ke fasilitas – fasilitas tersebut”

5

Sumber : National Institute of Standards and Technology, USA

What is SCADA? (3)What is SCADA? (3)

Sumber : http://www.millennas.force9.co.uk/

Why Why SCADA is important? SCADA is important? (1)(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? Why SCADA is important? (2)(2)

PLC

Directors

Aliran data perusahaan

Plant

PLC

ManualRecord

EnteringThe data

Why SCADA is important? Why SCADA is important? (3)(3)

Directors

Aliran data perusahaan

Plant

PLC

Why data is important?• Data yang direkam dan dianalisamemberi nilai tambah bagi perusahaan• Database � report � optimasi produksi

� Apakah ada SCADA?

History : “Primitive” SCADA

10

History : “ModernHistory : “Modern” ” SCADA (1)SCADA (1)

11Sumber : Control Magazine, May 2012

History : “Modern” SCADA (2)History : “Modern” SCADA (2)

12

Sumber : http://www.controlmicrosystems.com/

SCADA Basic Components (1)SCADA Basic Components (1)

Komunikasi

SCADA

Software

SCADA

Software

13

Komunikasi

Field Devices Field Devices

Komunikasi

SCADA Basic Components (2)SCADA Basic Components (2)

1. Field Devices (Sensor dan aktuator)

2. PLC atau RTU (controller)

3. Sistem Komunikasi

4. Komputer (Master Terminal Unit)4. Komputer (Master Terminal Unit)

14

Programmable Logic ControllerProgrammable Logic Controller

� Komputer industri khusus untuk mengawasi dan mengendalikan proses industri.

� menggunakan bahasa pemrograman khususuntuk kontrol industri (ladder diagram)

Didesain untuk tahan terhadap lingkungan� Didesain untuk tahan terhadap lingkunganindustri yang banyak gangguan

◦ noise, vibration, shock, temperature, humidity

15

Remote Terminal UnitRemote Terminal Unit

� Alat pengendali dan pengumpul data di industri

� Beroperasi pada lokasi yang jauh,

dimana data dikirim pada sistem utamadimana data dikirim pada sistem utamamelalui telemetry (radio, dial-up telephone, atau leased lines)

16

SistemSistem KomunikasiKomunikasi (1)(1)Sangat bervariasi!

Contoh KomunikasiPC- PLC

17

Sumber : http://www.controlmicrosystems.com/

SistemSistem KomunikasiKomunikasi (2)(2)

1. Dari PLC ke field device

2. Dari PLC ke PLC

3. Dari PLC ke PC

4. Dari PC ke PC lainnya (jaringan)4. Dari PC ke PC lainnya (jaringan)

18

SistemSistem KomunikasiKomunikasi (3)(3)

Pengumpulan danpemeliharaan data

Hirarki Industrial Networks

DeviceNetwork

ControlNetwork

Information Network

mengintegrasikan peralatan di lapangan dengan perusahaan

pengendalian I/O real time, messaging - interlocking antarpengendali

pemeliharaan data plant keseluruhan

SistemSistemKomunikasiKomunikasi (4)(4)

Hirarki Industrial Networks

KomputerKomputer sebagaisebagai MTUMTU

� Master Terminal Unit :

◦ Komputer dengan SCADA software

◦ Merupakan “otak” dari sistem SCADA

� Demo flash!

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SCADA Software in the marketSCADA Software in the market

�Wonderware

� Intellution (GE)

� Citect (Schneider)

� Factory Talk, RS View (Rockwell � Factory Talk, RS View (Rockwell Automation)

�WinCC (Siemens)

� Iconics

� Dll

DT AnalystDT AnalystDT AnalystDT Analyst

ActiveFactoryActiveFactoryActiveFactoryActiveFactory

InSQLInSQL / /

HistorianHistorian

InSQLInSQL / /

HistorianHistorian

QI AnalystQI AnalystQI AnalystQI Analyst

StudiStudi kasuskasus : : WonderwareWonderware (1)(1)

HistorianHistorianHistorianHistorian

SuiteVoyagerSuiteVoyagerSuiteVoyagerSuiteVoyagerAppServerAppServerAppServerAppServer

Plant Data Sources

InTouchInTouchInTouchInTouch

StudiStudi kasuskasus : : WonderwareWonderware (2)(2)

SCADA software function :

� Interfacing with field device

� Control and monitoring

� Alarm, trend� Alarm, trend

� Database, report

� Statistical analysis : Key Performance Index, Statistical Process Chart, Quality, Downtime

�Web visualization, etc

StudiStudi kasuskasus : : WonderwareWonderware (3)(3)

Wonderware System Platform

SCADA ApplicationSCADA Application

� Chemicals manufacturing

� Electric power generation

� Petroleum refining

� Pharmaceutical & life science

� Plastic & rubber � Food & beverage manufacturing

� Metals, minerals, & mining

� Oil and gas extraction

manufacturing

� Pulp & paper manufacturing

� Water & wastewater processing

AplikasiAplikasi flow monitoring flow monitoring padapadaperusahaanperusahaan gas (1)gas (1)

Sumber : PT. Sukses Bersama Nusantara

AplikasiAplikasi power metering power metering padapadaperusahaanperusahaan gas (2)gas (2)

Sumber : PT. Sukses Bersama Nusantara

AplikasiAplikasi padapada pabrikpabrik pakanpakan ternakternak

AplkasiAplkasi PembuatanPembuatan SusuSusu

Sumber : PT. Sukses Bersama NusantaraBerdasar recipe

AplikasiAplikasi padapada perusahaanperusahaanpembangkitpembangkit –– flow meteringflow metering

Sumber : PT. Sukses Bersama Nusantara

AplikasiAplikasi padapada perusahaanperusahaan pembangkitpembangkit ––Trend of lead & raw meteringTrend of lead & raw metering

Sumber : PT. Sukses Bersama Nusantara

AplikasiAplikasi padapada perusahaanperusahaan minyakminyak --PLC PLC diagnostic diagnostic

Sumber : PT. Sukses Bersama Nusantara

SCADA Trend SCADA Trend

� Electrical and informatics integration

� Ethernet as industrial network

� Open standard communication (OPC)

� Security issue� Security issue

� Mobile device application for SCADA

� Integration with business software (SAP, MES, OEE Report, etc.)

� Etc.

Must have a

Special Card

Modbus +

DH +

InTouch

Ethernet as Industrial Network (1)Ethernet as Industrial Network (1)

35

PLC PLC PLC PLCPLC

Profibus

Sumber : Wonderware Seminar Material

TCP/IP

InTouch InTouch InTouch InTouch

Ethernet as Industrial Network (2)Ethernet as Industrial Network (2)

36

Must have a

Special Card

PLC PLC PLC PLCPLC

Modbus +

DH +

Profibus

Sumber : Wonderware Seminar Material

Use Ethernet Card

InTouch InTouch InTouch InTouch

Ethernet as Industrial Network (3)Ethernet as Industrial Network (3)

37

PLC

With Ethernet

module

TCP/IP

PLC

With Ethernet

module

PLC

With Ethernet

module

PLC

With Ethernet

module

PLC

With Ethernet

module

Sumber : Wonderware Seminar Material

OPC Definition (1)OPC Definition (1)

� OLE for Process Control (OPC)

� A software interface technology used to facilitate the transfer of data

between industrial control systems, between industrial control systems, Human Machine Interfaces (HMI),

supervisory systems and enterprise systems such as historical databases

Sumber : OPC Foundation

OPC Definition (2)OPC Definition (2)

� Contoh implementasi OPC

Sumber : Kepware

OPC Server

Primary Value of OPC (1)Primary Value of OPC (1)

� OPC provides a common interface for communicating with diverse industrial control products,

regardless of the software or 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)Primary Value of OPC (2)

OPC ArchitectureOPC Architecture

� OPC is based on a client-server architecture

Sumber : OPC Foundation

OPC Application in the marketOPC Application in the market

� KepServerEx from Kepware

� OPC Data Hub from Cogent� OPC Data Hub from Cogent

� OPC Systems.NET from Open Automation

Future of OPCFuture of OPC

StudiStudi KasusKasus OPC OPC sederhanasederhana padapadaperusahaanperusahaan gas (1)gas (1)

� Menyimpan data dariflow computer unit diberbagai area keberbagai area kedatabase � OPC team

� Membuat aplikasi websecara real time yang menampilkan data tersebut� IT team

StudiStudi KasusKasus OPC OPC sederhanasederhana padapadaperusahaanperusahaan gas (2)gas (2)

� Konfigurasi KepServerEx(OPC server) yang membaca data alat

� Konfigurasi DataLogger� Konfigurasi DataLogger(add-ons KepServerEx)

StudiStudi KasusKasus OPC OPC sederhanasederhana padapadaperusahaanperusahaan gas (3)gas (3)� Konfigurasi DataLogger (add-ons

KepServerEx)

◦ Ambil tag name dari OPC Server

◦ Atur koneksi ke database (DSN)◦ 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)Security Issue (1)

� “Lobang keamanan” pada SCADA

Sumber : Control Magazine, May 2012

Security Issue Security Issue (2)(2)

� SeranganWorm Stuxnet ke komputer denganSCADA software & PLC (Siemens)

Sumber : www.threatinfo.trendmicro.com

SCADA SCADA Mobile Device ApplicationMobile Device Application

SCADA application on tablet and Smartphone

Sumber : SCADAVisor, mySCADA

Suggestion :Suggestion :What What can we do now (at campus)?can we do now (at campus)?� Learning Information Technology aspect

◦ Network, database, OOP, dll

� Self experiment on SCADA system with freeware (if existed)with freeware (if existed)

� Part time job at automation system integrator

� Following student competition (lombaPLC, HMI, Gemastik)

Suggestion :Suggestion :What can we do now (at campus)?What can we do now (at campus)?� Self experiment example

WonderwareInTouch / VB.Net

OPC Client (OPC Link)(OPC Link)

OPC Server(KepServerEx 5)

PLC Omron PLC Siemens

Please visit : http://learnautomation.wordpress.com

Thanks to : Tonny Leonard (PT. Sukses Bersama Nusantara)