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Application of SCADA in Valve Testing Automation flotek.g 2017‐ “Innovative Solutions in Flow Measurement and Control - Oil, Water and Gas” August 28-30, 2017, FCRI, Palakkad, Kerala, India. Application of SCADA in Valve Testing Automation Muthukumar. V McWANE India Private Limited Coimbatore, INDIA. [email protected] ABSTRACT INTRODUCTION The Industrial Control System (ICS) Recently SCADA has arisen as one of for valve testing includes the use of the best solutions for industrial automation. Programmable Logic Controller (PLC), The SCADA system plays a vital role in Distributed Control system (DCS) and industrial automation, since it helps to Supervisory Control and Data Acquisition maintain efficiency, process data for smarter (SCADA). The SCADA system plays major decisions and communicate system issues to role in implementation of automation in help mitigate downtime. industrial automation, distribution network and Implementing the SCADA system product testing. enables the user to timely monitor and This paper explains the use of a remotely controls the valve testing operation. SCADA system in an automated valve testing The field instruments and devices are linked environment. This environment will be to the SCADA engine and PLCs allowing us illustrated with data acquired from a SCADA to trigger and control any instruments or system. The automation is enhanced by devices connected to the system. Monitoring constant monitoring of the process using a live data and system status via the SCADA SCADA screen which is connected to the screens is also easily accomplished. This PLC with communication cables. The SCADA system has proven especially for type-test / screen monitors the entire process, which is cyclic-test of the valves. It benefits both the in turn controlled by setting the tag values of operator and supervisor to run the process various variables in the SCADA system. automatically, which significantly reducing the Usage of SCADA in the valve testing labor cost and human errors. line has increase the reliability, control and efficiency of the testing operation. By using ARCHITECTURE SCADA we not only automate the valve The basic SCADA architecture begins testing but also record all testing parameters with a human machine interface (HMI), and store them in the system for easy programmable logic controllers (PLC) and/or retrieval and analysis. remote terminal units (RTU) as well as field A case study is presented herein instruments and control systems. PLCs are where the SCADA is effectively utilized in a microcomputers that communicate with an valve testing facility. This study illustrates the array of objects such as factory machines, automation of the valve testing process with HMIs, sensors, and end devices, and then SCADA and the auto recording of the valve route the information from those objects to test details. computers with SCADA software. The architecture of SCADA system is KEY WORDS explained in Fig.1 SCADA, Automation, Valve Testing, Type Test. Page | 1 Data logging and reporting: Required live data can be selected and logged into a database. Based on the requirements this data can be plotted into graphs or charts, and reports generated automatically. Alarming: Get alerted instantly by alarm notification from any minor unwanted events to critical incidents. You can monitor these alarms all the time on HMI screens, or configure your SCADA to send you notifications via phone calls or messages. Figure 1 - Architecture of SCADA system. Scripting / Calculation: The HMI processes the data from There are times where your process each tag and sends the information to the operation requires the calculation of some SCADA screen, where the operator can parameters. This can be easily achieved with monitor and control the system. The a SCADA system. Most of the SCADA supervisory system gathers the data sent engines and software comes with the from each tag and sending commands or automatic scripts that enables the operator to operations to the process. The RTUs configure the system required logics and connects the sensors and also convert the calculations. sensor’s signals to digital data. This data are transferred to the supervisory system, where VALVE TESTING it can be stored in a distributed database. As per EN / ISO / BIS standards PLCs are used as field devices because they guideline, the valve type test requirements are much more versatile and economical than are automated by using the SCADA system process-specific RTUs. Finally, the for the following valve types, communication infrastructure delivers Gate Valve connectivity to the supervisory system and Butterfly Valve then to the RTUs and PLCs for the user to Check Valve command. The communication infrastructure Air Release Valve is necessary to relay data from remote Control Valve RTU/PLCs, which run along electric grids, The valve type tests are not only water supplies and other testing devices. limited to the following tests, as it may vary In the specific terms of using a based on the product types, SCADA system in the valve testing operation, Shell Test Seat / Leak Test you also get the following functions: Obturator Strength Test Control and monitor the process remotely: Torque Test SCADA software enables remote Endurance / Cyclic Test monitoring and control of process operations Test Results: in real time and it eliminates the need for site Based on the test requirement and visits by personnel for inspection, adjustments inputs set into the SCADA system, the test and data collection. progresses and outcomes are monitored through SCADA screen and the entire test Page | 2 results are stored in the system and can CONCLUSION retrieve the test data easily at any time for SCADA systems are designed for web review and analytical purpose. based connectivity eliminating cumbersome cable connection systems. THE BENEFITS OF SCADA While SCADA platforms provide a vast When applied properly a SCADA system number of benefits and reduce the cost and can help us to save time, cost and reduces downtime of the system, there are still the human errors. Some of the major benefits security threats that need to be addressed. of a SCADA automation system are listed The goal of SCADA platforms is to below. provide users with quick access to Safety of workers and equipment are PLCs/RTUs and provide simplistic integration increased through predefined of this equipment control to user interfaces. processes managed by a SCADA system. ACKNOWLEDGEMENT Engineering costs, time and risks are Author extended their gratitude to reduced through easy integration with McWANE India Pvt. Ltd. colleagues and Mr. all your plant devices. Saravanan, Manager of Mansco Fluidtek Pvt. Resources, such as people and plant Ltd. for their supports provided for this paper assets, are optimized as SCADA presentation. promises high level control over the plant environment. NOMENCLATURES Productivity is increased via analysis SCADA : Supervisory control and Data of processes used to improve plant Acquisition. and production efficiencies. PLC : Programmable Logic Controllers Maintenance costs are reduced ICS : Industrial Control Systems through centralized control and RTU : Remote Terminal Units monitoring, that minimizes downtime. HMI : Human Machine Interface Quality is improved because the FI : Field Instruments, which are analysis of process data can result in includes Actuator, Sensor and preventing errors before they occur. other Electronic devices Operators are more effective using EN : European Standard SCADA because it consolidates the ISO : International Organization for various plant processes and provides Standardization. them with a comprehensive overview of operations. REFERENCES Alarms are centrally managed which a. https://inductiveautomation.com improves operational effectiveness by b. www.allaboutcircuits.com not overwhelming operators c. www.scadalink.com unnecessarily. Integrating SCADA with a historian package and other business systems will connect the plant floor to the boardroom by sharing real-time and historical data. Mobility solutions provide operators with the freedom to observe operations first hand, no matter where they are. Page | 3 .
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