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DATA ACQUISITION AND MONITORING ON-LINE SYSTEM
JUST ONE SYSTEM FOR DATA ACQUISITION, INTEGRATION, PROCESSING
AND ANALYSIS
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1. Introduction
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CIC Consulting – Company Profile
The Central Office, Santander (Cantabria region)
˃ SOFT AND TELECOMMUNICATION ENGINEERING COMPANY
˃ More than170 employees,
˃ Offices in Santander and Madrid
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as an integration solution
Energy, cooling, power…
Electric systems, turbine,
substations...
Production llines,Alarms, KPIs,
indicators ...
Environment,fuel, gas emissions...
Production, pumps, valves...
Metheorological,chemical, seismic data,
radiation...
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KPIs, indicators, dashboards…
Real-time data
Cumulated historical data
Mnemonics
Calculations
Alarms and Notifications
etc. …
as - an integration solution
BPM ENGINE (calculation)
STORAGE SERVICES
ANALISYS
SERVICESMIDDLEWARE AGENTS
CONNECTORS
AND DRIVERS
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Owner Nuclear plantTags, acquisitionfrequency
Integrated Systems
Nuclenor Garoña (BWR-3) 466 MVt 4.000 / 20 ms Of the active zone, cooling, emission, environment, metheorological and seismicdata, radiation.
ANAV Ascó I (PWR) 1032,5 MVtAscóII (PWR) 1027,2 MVt
Vandellós II (PWR) 1087MVt
40.000 / 1 sec Of the active zone, cooling, metheorological and seismic
data, radiation.
CNAT Альмарас I (PWR) 1049,4 МВтАльмарас II (PWR) 1044,5 МВтТрильо PWR) 1066 МВт
20.000 / 10 sec The Scada system OVATION (of the active zone)
CSN (Nuclear
Security Counsil)
CSN receives the most important parameters from each nuclear plant – 124 signalseach 30 sec.
Examples of imlementation
More information: http://es.wikipedia.org/wiki/Energ%C3%ADa_nuclear_en_Espa%C3%B1a
Monitoring experience in Spanish Nuclear plants
˃ Currently the IDbox system moniors signals and explotation parameters in almost all Spanishnuclear plants. Examples:
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1. Example. Nuclenor: NP Garoña
Nuclenor is a company which expoits
the nuclear plant of Garoña situated
in Burgos, Spain. The staff of the
administrative office located in
Santadner, 150 far from Garoña,
monitors all the signals of the plant in
remote and use for this the same
system - IDbox.
Madri
d
Santander
CNAT has 2 nuclear plants with 2
reactors. The information from each
plant is sent to the Administrative
Center of Engineering and
Maintenace, from where it is possible to
query data of each reactor. At the
same time it is possible to do this type
of quiery from each plant.
2. Example. CNAT : NP Almaráz I,
Almaráz II and Trillo
Monitoring experience in Spanish nuclear plants
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Visualization of different indicators and KPIs at NP CNAT Trillo
Monitoring experience in Spanish nuclear plants
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Examples of implementation
CMEX, wind farm monitoring – this project, carried out by the Department of
Renewable Energy of Iberdrola Ingeniería y Construcción, implemented thesoftware solution IDbox, which is the main tool for trend analysis and data storage to
improve management of the wind turbines, located worldwide.
The first stage of the project includes monitoring in real time and storage at
maximum resolution of the main parameters of each plant. It includes the values
captured from the sensors, installed in each generator WTG (Wind Turbine
Generator) and parameters of substations and meteorological tower.
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CMEX, wind farm monitoring
IDbox shares the acquired from WTG information with the original SCADA
system, Vestas, and substation monitoring tool GEPower, integrating all
information in a single client and making easier the analysis of variables
from different sources.
Graph picture of the generator motor with dynamic data (on-
line data)
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IDbox at Robert Bosch is responsible for analysis and monitoring of sensors and PLCs, which are connected for supervision of the Department of Maintenance and Repair
of the machinery and equipments of the plant.
Monitoring experience in automobile industry
Monitoring of data in real time 1000 signals;
monitoring of temperatures, pressures, humidity of boilers, compressors, etc.;
option to add calculations of equipment reliability and fatigue.
Notifications of alarming status centralization in a Control Room for security supervision of the plant;
alarms generation in IDbox (digital signals with limiting values), more than 100
types.
Graph schemes of the industrial areas for monitoring of equipment performance: real-time data, alarm status indicators
for critical parameters.
Examples of implementation
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Examples of graph schemes at
Boiler Room
Compressors
Monitoring experience in automobile industry
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Examples of implementation
IDbox was implemented in metallurgy for monitoring, management and analysis of
parameters of electric ovens.
Monitoring in real time: acquiring and processing of more than 10.000 signals;
monitoring through mnemonics (graph pictures).
Classification of captured and processed information:
control dashboard and reporting
on-line data
historical data
interactive graph schemes
calculations, alarms and notifications
analysis: trend graph, comparison and statistics
Monitoring experience in metalworking industry
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Control dashboards
a graph picture (mnemonic) of general status with LED indicators of ovens and produced power
Monitoring experience in metalworking industry
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Mnemonics: examples of maximum presentation of information
Monitoring experience in metalworking industry
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Data and processes monitoring in real time Control over the raw material delivery
Monitoring experience in metalworking industry
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Mnemonics
Reproduction of the same scheme in the IDbox system.
Monitoring experience in metalworking industry
Schneider
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Monitoring experience in metalworking industry
Schneider
Mnemonics
Reproduction of the same scheme in the IDbox system.
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2. Data Acquisition and Monitoring in
Real Time
CALCULATION
STORAGE
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Data acquisition, Monitoring in real time and options for visualization
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Data acquisition and Monitoring in Real Time
A quality data acquisition is provided through highly effective
drivers that allow setting up of certain parameters for a
correct data introduction into the system.
CALCULATION
STORAGE
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Latency and data quality:
Possibility to obtain data with different frequency (1 min, 30 sec, 10 sec, 1 sec, 20 ms…).
Specific drivers development for connection to data sources of different manufacturers, the
developed drivers for the following technologies: Siemens, Bosch, GEfanuc, Schneider, Honeywell,
ABB, Beckoff...
Etc...
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Data Latency
Quality of information:
Characteristics of each acquired signal:
CALCULATION
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code,
description,
type (digital or analog),
acquisition moment (date and time),
value,
measure units
status (set up from the catalogue: 32 non excluded status, for example, “normal”, “alarm high
range”, “introduced manually”, “out of range”, etc.).
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Used data:Analog and digital
Connection to the industrial data Connection to different PLCs and sensors, using specific drivers or OPC, for example:
PLC - Sensors Supervised Signals Used driver Fequencyof
acquisition
MBC GeFanuc Position of control bars Specific driver 1 s
RTP2000 RTP Corporation Nuclear fuel waste, waste FW Tren A,
reactor pressure
Specific driver 20 ms
RTPSOE RTP Corporation Pump A status LPCI, Isolation of Group 1
A1, Low level of the Reactor A1
Specific driver Up to 1 ms
OPC TEMP2 GeFanuc Oil temperature Pump M2-10A Driver OPC 1 s
OPC TEMP1 GeFanuc Air temperature Toro E514 Azi.110 Driver OPC 1 s
Meteo Campbell
Datalogger CR3000
Wind direction 100 м (PRI-DAT) Specific driver UDP EGD 2 s
Meteo RX3i GE Fanuc
RX3i
Wind direction 100 м (PRI-DAT) Specific driver UDP EGD 2 s
Data Latency – Exmaple of Nuclenor
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Security within the adopted standard in the corporation:
The system allows to work in UDP mode, that makes possible to support
structures of physical security, for example, through data-diod.
Example of the conceptual architecture scheme, applied in NP Garoña (the owner –
Nuclenor).
Architecture – secure data transference
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Architecture – Example 1
Process Net
DRVGIPNET2DRVGIPNET1
TOPGIPNET
3D MONICORE ELITELMETEOROLOGÍA
FTP FTPFTP
Re
d d
e a
qu
isic
ión
RTP
MVD
WEBGIPNET1
(SidpWeb + WS)
WEBGIPNET2
SidpWeb + WS,
Sql Server Express
Client
Clients SC
MBC
OPC
Meteo
Plant
Data
Management Net
Data
Recorder
Data
Agent
Cyclic
queue
Data
RecorderData
Agent
SIDP_Conf
SIDP_Hist
Cyclic
queue
SIDP_Conf
SQLGIPNET
SQL Server
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Architecture – Example 2
HMI PLCs ERP ...
AspenTechIP.21.Archive
AspenTechIP.21.Archive
AspenTechIP.21 OPC SERVER
Storage
IDbox ODBC Connector
IDbox Middleware
IDbox Notification ManagerSignal
Historic Data
IDbox Analisys Services
IDbox Clients (Web, Mobile…)Setup
Notification
eMail SMS PhoneCall Push
IDbox OPC Connector
IDbox DataAgent
IDbox DataRecorder
RT DataIDbox
Web ServicesReq. / Resp
Option #2. IP.21 - IDbox Integration
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Architecture – Example 3
Customer
Customer
Customer
Marzewo (Poland)
Chirnogeni (Romania)
Cerro de Hula (Honduras)
Noblesfontein(South Africa)
Klipheuwel(South Africa)
0101001
0101001
0101001
0101001
0101001
IDbox FTP
Connector
IDbox Data Recorder
IDboxData Agent
Storage
IDbox BackEnd IDbox FrontEnd
IDbox Notification
Manager
IDbox Analysis Services
(Web client, Mobile,
Notification Setup)
eMail SMS PhoneCall Push
RequestResponse
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Scalability
Vertical scalability
DTO (Data Transfer Objects) transmission among
modules enables a suitable distribution of
elements on various PCs for maximum use of
power of each of them.
Balancing
Server Server Server
scalability
Balancing
Server Server Server Server
Horizontal scalability
By adding new concurrent users, it is suggested a
horizontal scalability through new servers addiition to
increase the system capacity.
ServerServer
CPU
1 GB RAM
CPU CPU
1 GB RAM 1 GB RAMscalability
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3. Integration and data processing
CALCULATION
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Calculation Module
Possibility to make arithmetic calculations, complex logics and create new signals on the basis of the
acquired ones.
Specific application (“Administrator”) to manage calculations in IDbox:
A set of related components (logical, arithmetic, filters, etc.)
A great number of oeprators to carry out different mathematical calculations.
Components for data sending through TCP/IP, UDP, FTP, etc., to other systems.
CALCULATION
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Characteristics
Example of operators for a calculation and identifying the new aggregated signal
Receiver X
Receiver Y
Calculation
Historical data Recorder 1
Historical data Recorder 2
Sender “ftp” type
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Calculations
The Calculation tool initially was thought only for calucation generation. Now it is a real
BPM (Business process management), since this module contains the actions algorithms,
focused on oeprating physical equipment, itegration with other systems, notification and
etc. The Calculation tool recently has been migrated to Web Client for optimisation fo
the work of the system.
Calculation Module
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Calculation tool - User Interface
The unique development for aggregating new calculation, algorithms and
logic for support and optimization of processes of the organization
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4. Data Agent
CALCULATION
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Core – Data Agent
A communication core for smart data sending tot he user:
The IDbox Data Agent is an IDbox component responsible for classification and service
of current and historical data to necessary modules for further work.
The inner architecture of the system consists of independent and configurable
components, the same way as the module of IDbox.
Inner architecture of the IDbox Data Agent
CALCULATION
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DataAgent
Provider of Real Time
Provider of Historical DataEntry Data Points
(UDP, FTP, files,
etc…)
Historical Data
and Events
Cyclic QueueAnalog UDPs
with Inserted
Points
Time
MarkerDigital UDPs
with Inserted
Points
Cyclic
Queues
maximum
resolution
Cyclic
Queues
marked data
Real
Time
Map
Provider
Chain
Provider
Duplicated
Data
Control
(optionl)
Reciever
UDP
Receiver
UDP
Files
Reading
Remoting
Historical Data
Remoting TR
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5. Storage
CALCULATION
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Storage - Flow
The Storage module consists of:
Cyclic queues: for storage of data with maximum resolution (e.g., 5 s,1 s, 20
ms…)) during a certain period of time.
Data Base: for storage of historical data of each parameter with less
resolution or averages, for scallability and effective quieries resolution.
CALCULATION
STORAGE
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DataRecorderEntry Data Points
(UDP, FTP, files,
etc…)
Historical Data
And Events
Cyclic
Queues
Time
Marker
Duplicated
Data
Control
(optional)
Reciever
UDP
Reciever
UDP
Files
Reading
Disc
Recorder
DataBase
Recorder Factory
DataBase
Recorder
Analog UDPs
with Inserted
Points
Digital UDPs
with Inserted
Points
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Data Bases supported by
IDbox does not have its own Data Base – storage can be done in any Data Base (MongoDB
as default data base, SQLServer, Oracle, etc.).
Types of Data Base accepted by IDbox:
Non-relational: MongoDB
Advantages:
a more flexible architectural structure,
suitable for high scalability,
fast return of historical data (Ad hoc queries),
easier and faster integration of data in API,
open software (free).
Relational: SQLServer, Oracle
Advantages :
well known database, installed in large corporations,
suitable for high scalability,
fast.
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Storage: compression and optimization
IDbox accepts different storage strategies in order to optimize space and provide
faster query execution. In general, the higher compression the less efficiency and vice
versa. All the historical data are not consulted at the same frequency, so the storage
strategy will vary depending on data age. We are talking about data division, which
are prioritized for compression or allocation in a database or cluster.
Types of data compression:
Decimation: data is stored at a certain
frequency, intermediate data are excluded.
Average values: average values are stored at a
certain frequency.
Polynomial: polynomials which organize
dispersion are stored.
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6. IDbox signal organization
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Signal classification in the main menu
Signal classification in hierarchical manner. Classification is proposed (1) by each
production area subsystem or (2) by specifics of the issues that should be studied and
analyzed.
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Signal searcher
IDbox system offers a quick signals or synoptics searcher: in the main menu
there is a Searcher in which the user can enter the whole or part of the keyword
related to the signal o synoptic description (for example, “temp” for temperature) or
code (for example, “AGITMP”), then the system will provide all available information
according to the search criteria.
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Signals in My favorites
IDbox Web Client offers the opportunity to select any signals from the directory and
incorporate them into “Favorites” signals with which the user usually works with.
"My Favorites" visualizes historical data for the past 24 hours by default with the
option to visualize other periods (for the past 8 hours and the last week or month).
Different options to access to “My Favorites”
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Signals in My Favorites
Simultaneous presentation of the data list and the chart in “My favorites”
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Adding new parameters
To add new parameters to a specific folder, the user must select the
appropriate signals from the general list and add them to the desired folder,
for example, to “My favorites".
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Create a new folder is also easy, the user must click the right mouse
button on the section, in which the folder will be created, and select the
desired option.
Adding new parameters
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7. Real-time and historical data operation
(Analysis)
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7. Real-time and historical data operation (Analysis)
IDbox offers different data monitoring and analysis tools
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Real-time monitoring
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Real-time monitoring
Real-time options
Real-time signals can be visualized as data list and graphic presentation all
together.
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Real-time monitoring
Mnemonics (Dynamic graph pictures)
• Real-time values represented by images, drawings or schematics.
• Application of SVG (Scalable Vector Graphics) technology which allows unlimited scaling without losing
image quality.
Some examples of mnemonics created by IDbox:
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Analysis
Historical data of the past 24 hours.Visualization of data list and graphic presentation all together.
Types of analysis
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Analysis
Provides Historical data to the Web
Client and allows exporting data to PDF
or Excel formats.
Trend analysis for a personalized time
period:
• quick selection of the time period in
the same screen,
• statistic options for selected time
period,
• possibility to export graphics to
different formats.
Types of analysis
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Analysis
Types of analysis
Trend Graph- Statistic options of selected data on the trend graph
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Analysis
Trend Graph
Trend Graph full details view
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Analysis
Types of analysis
Comparison chart Prediction
XY (correlative analysis)
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Analysis
Comparison chart
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Analysis
XY (correlative analysis)
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Analysis
XY (correlative analysis)
Selection of correlative graph functionalities.
Additional information about selected correlative graph
functionalities.
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Analysis
Prediction
Inside the regression graph there are the
following options:
• Deviation, based on typical deviation.
• Trend.
• Pending.
There are three types of interpolation
analysis:
• Linear.
• Lagrange.
• Newton’s Divided Difference.
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Analysis
Prediction
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Analysis
Allows exporting one or several signals of Historical data
to Microsoft Excel.
Use of Excel analysis tools.
Integration with Microsoft Excel
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Reports
Example of specially created balance-report:
Daily Nuclenor data acquisition
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IDbox has predefined reports which allow:
• Exporting graphs to other formats.
• Exporting data to text files, Excel o CSV.
• Reports from «Reporting» service (Microsoft Visual Studio customized reports)
Reports
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This IDbox module consists of menu from which changes related to the application and
functional characteristics can be applied. The user access is configured according to the
predefined roles.
Administration module
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Access statistics – this option shows graphically visit statistics, connections to the system,
used browsers and signals receiving frequency.
Audit
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Monitoring is a customizable feature.
Monitoring can be applied to all relevant events which take place in the system:
User acces,
Forcing signal values (manual introduction o change the value of certain situations),
Delivery of notifications,
Alarms confirmation as operator’s response to the received alarms information and
use of appropriate actions,
...
Audit
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Parameterization
Alarms
Every signal connected to the system has a defined value which determinates the alarm.
Additionally, it is possible to generate complex signals and bind actions to these alarms through
logic and calculation component, which allows configuring system’s behavior in emergency
situations.
Notifications
Notifications allow users to have the access to “private” information. Notifications can be
sent by events, created signals. For example, send SMS when the temperature exceeds
100ºC, or susribe to, for example, daily email with temperature average values.
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Parameterization - Notifications
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Parameterization
Alarms and Notifications visualization
An example of alarms and notifications in IDbox
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Parameterization
Synoptics: designer
The designer allows creating, adding or importing vectorial pictures in order to add
them dinamic data. Thus, more appropriate information is shown to the operator
when monitoring the picture.
Vector technology
guarantees image quality
when working with them,
or when extending a specific work area.
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Parameterization
Security: access and log
IDbox security system relies on MSR
(Model Security Role) or security
module, based on user roles, with which
they can work or have permission to
realize actions or visualize information.
IDbox Administration module provides
administration and safe multiclient
management.
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8.Access to the acquired information
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Requirements for data access in IDbox
Access to IDbox is possible through different devices, the only condition is the
availability of a Web browser in order to have access to the IDbox Web Client.
Recomended versions:
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Interface of the system access
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Interface
Example of the main user interface (signals list)
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Access types to the collected information
Through a personal computer;users can use computers with which they are used to work.
Through the corporate desk;
Through the monitor in the production area;usually there are several monitors monitoring various operations, both critical and supporting
ones, and also real-time data.
Through a tablet;particularly suitable for staff who are often on business trips.
Through a smartphone;Access to the IDbox system through a mobile phone or smartphone which runs through a mobile
app.
Through Microsoft Excel;Client, developed for MS Excel in order to use the full potential of this Microsoft calculation tool.
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Channeling of information to the Control Room
There is no need to install any specific program on each workplace from
which data stored in IDbox will be controlled.
Control room monitors, regardless of the user, are means of visualizing
information obtained by IDbox.
What can be displayed on the control room monitors?
• Real-time data monitoring,
• Trend over the past 24 hours,
• Comparative analysis of critical parameters,
• KPI (Key Performance Indicators),
• Graphic pictures with dynamic real-time data,
• Alarms and notifications viewer,
• Prediction analysis of critical parameters,
• etc.
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9. Integration with other systems.
Application scenarios
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Integration with other systems.
IDbox allows multiple integrations. These possible scenarios can be divided into two
groups:
Input integration: IDbox itself is integration and signals receiver system from
physical devices, but beyond that, the system has a number of connectors and tools
for integration with other systems both on technical and software side.
Output integration: the information managed by IDbox could be sent to other
systems (hardware or software), i.e. the system is able to send data previously
processed through:
1. Web service applications: such a system makes possible the integration
with any technology and environment.
2. Logic in motor calculation: calculation components and BPM allow you
to integrate data from other systems, for example, ERP (SAP,
Dynamics, ...)
The question of security access from third systems and applications in Web services
IDbox solves through hush.
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IDbox system is built on independent components using web 2.0 technologies
Meteorology, chemical,
seismic data,
fuel, emissions...
All the data and
systems just in one the
platform
SCENARIO 1 – Monitring single plantThis scenario allows the integration of all existing systems at the plant.
Possible application scenarios
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CENTRAL REGULATORY AUTHORITY
Data subset
Data subset
Data subset
Data subset
SCENARIO 2 – Centralized Monitoring
This scenario implies monitoring in one direction: plants, regardless of used systems, send somedata to the Central Regulatory Authority (the top level of the project) through IDbox collectors.Possible start variant at the power unit is through IDbox collector. It is not necessary to havea complete IDbox system installation.
Possible application scenarios
SCADA
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SCENARIO 2 – Centralized Monitoring
IntegratedMonitoring
2
IntegratedMonitoring
3IntegratedMonitoring
N
IntegratedMonitoring
As for centralized monitoring it is
recommended to have a plant
integration software.
IDbox collector will be needed to send
data to the centralized monitoring
system.
Integrated Monitoring
1
Monitoring systemsFor example: monitoring of key prosseses, analysis of equipment diagnostic…
Control and measuring devices
For example: Sensors, PLC...
Other systems
For example: SCADA, ERP, systems maintenance,…
Control of received data
For example: Mobile devices, modeling, …
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10. Conclusions
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Conclusions
Scheme
ANALYSISSOURCES
STORAGE
ACQUISITION AND
RECORDING AGENTS
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V
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EXTERNAL ANALYSIS OF REMOTE ACCESS
DATA
DIODE
PLANT 3
PLANT 2
PLANT1
PLANT«N»
OTHER SYSTEMS
PE Management
Information for Citizens
Portal …
PWAN
CALCULATION
The information is
available throughany device in any
place.DATA
DIODE
F07.02.01.00.22.r01
Main characteristics of
Modular, scalable and configurable system
Data acquisition, integration, on-line monitoring, processing and
analysis system
Just one system for the entire organization
Sede Santander PCTCAN Parque Científico Tecnológico de Cantabria, C/ Isabel Torres nº 3 · 39011 SantanderSede Madrid · Paseo de la Castellana nº123 · Esc. Izq. 1ºA · 28046 Madrid· Tlf.:91 417 44 [email protected] Tel.: 902 269 017 Fax: 902 269 117