Mikon Systems Companie Publicatii Sisteme complexe de monitorizare a proceselor industriale utilizand LabVIEW
Sisteme complexe de monitorizare a proceselor industriale utilizand LabVIEW
Luni, 18 Iulie 2005 13:12

Constantin Alexandru, Cristian Patrulea, Andrei Gusti, Dragos Brezoi

S.C. Mikon Systems S.R.L.

 

Key words : Remote engineering, real-time monitoring, Labview specialized language

 

Abstract :

The monitoring of the industrial processes is the main source of information for the technological and economical management. Based on a performant SCADA system, a real-time mathematical model provides a permanent updated image of the efficient working status of the process, providing beside the direct acquired information complex calculations of specific consumptions, estimated and real outturns or other aggregate parameters.

The challenge to achieve this objective consists in solving the multi-level integration of different sources of data in a range stating with various types of equipment and ending with complex ERP systems.

Using LabVIEW together with its add-ons it was our solution for development and implementation of complex monitoring systems for industrial processes. LabVIEW as a high-level and specialized programming language have allowed us to provide our clients with the state-of-the-art solutions that meet their performance, value and timeline expectations.

 

General Presentation

Most of the industrial plants in Romania have been subjected in the last decade to a continuous step-by-step modernization process. In many cases this process ended with the purchasement and installation of a variety of equipment and software applications, which was satisfactory for a certain level of development of the plant.

The new competitional level on the Romanian market rised in the last years a new challange for the technological and economical management of the industrial plants - to obtain aggregate information about the efficiency of the plant in an effective time so that to be able to take the necessary decisions needed to improve the production while reducing the costs.

Obviously, this challanging goal can only be acheived, at a reasonable level of investment, by integration of the all already existing sources of information on the plant - equipment and software applications.

Trying to provide our clients the best solutions for their next development stage, MIKON SYSTEMS is using the LabVIEW programming environment to develop custom-taylored software applications fully compliant with the standard SCADA requirements at the process level, but in the same time able to integrate database information provided by ERPs, laboratory applications, environmental applications etc.

The final result of our software system is to ensure the plant management with on-line real-time or syntethic reports, created by running a specific mathematical model over the entire collection of the technological and economical information.

 

System Description

The general system's architecture is presented in the following diagram. Basically the entire system is a multilayer client-server application, providing the necessary mechanism to obtain the integration of the various sources of information.

 

 

The first level of integration is acheived at the equipment level. At this point it is typical to find in operation equipment using either standard or propertary communication protocols, also using communication media like RS232, RS485, current loop, Ethernet, radio, GSM

For the standard protocols, in the most cases OPC servers can be used but for the propertary protocols it is neccessary to develop specific communication drivers. Because LabVIEW is a high-level programming language it ensures native handling of the OPC standard using user-friendly wizards to link process variables to internal tags. In the same time LabVIEW is providing low-level access to communication ports and powerful functions for bit-level processing of the specific protocol telegrams.

In some cases, the client has under operation specific applications that also acquire information from the process. These applications can be either standard HMI/SCADA systems or other owner applications like laboratory or environmental data aquisition systems. In the fist case the typical mechanism can be either an OPC client or a NetDDE client while in the former case ODBC drivers can be used to apply repetitive SQL interogations upon application's database. Again LabVIEW has been proved to be an appropriate tool to realise the needed connectivities.

Once the raw data collection process is completed, the application's server automatically applies a real-time mathematical model upon the acquired data to obtain more technological information like energetic balances, heat and volume calculation, including Vukalovik corrections, etc. Raw data together with derived information are published for the application's clients by a LabVIEW NetDDE server.

Further processing of the real-time information is usually an off-line process and involves integration with other software systems like ERPs. Typically the SCADA system provides input data for the Operation & Maintenace module of the ERP, while the ERP provides information about the production costs and costs distribution between the plant products, using also complex technological mathematical model.

The final integration level is provided by the system's client application. Under the same interface, the user can obtain information about the entire process at the real-time level, at the technological management level (plant synthetic parameters) and at the economical management level (production costs per products).

Being an assembly of client modules for NetDDE and database servers, the client application can be used by a relatively big number of users either in the local area network or remotely, over a virtual private network (VPN). The client application includes also an enhanced reporting mechanism based on the integration of MS-Excel at the client level.

The system's client application is developed using LabVIEW advanced graphical features. Typical screens of the client application are presented in the following pictures.

 

System Implementations

The SCADA system described in the former chapters already has a number of implementations from which the most representative are PALAS and BRAZI power plants.

The characteristics of the PALAS power plant implementation are:

•  Total number of system tags: 10,000

•  Integrated equipment:

•  National Instruments data acquisition system for analogic and binary parameters

•  ABB Alpha AIN500 for electrical energy meters

•  Lovato DMK electrical multimeters

•  ACK MULTICALC heat integrators

•  ACK MULTICALC gas volume integrators

•  Communication protocols and media:

•  IFLAG - current loop

•  MODBUS - RS485

•  ACK proprietory protocol - M-BUS

 

 

 

 

•  Integrated applications:

•  Techno Instruments - combustion emissions analyzer

•  Laboratory fuel samples analyzer

•  Integrated databases:

•  MS SQL 7

•  Siveco Applications - ORACLE 8i

•  MySQL

•  dBASE V

 

The characteristics of the BRAZI power plant implementation are:

•  total numer of systems tags: 2,000

•  integrated equipment:

•  Felix - DAS 9000 data acquisition system for analogic and binary parameters

•  ABB Alpha AIN500 for electrical energy meters

•  Endress & Hauser - MegaLog 1

•  Advantech - 4011, 4017

•  ACK C ALEC heat integrators

•  Koyo - DL205, DL06 PLCs

•  Communication protocols and media:

•  IFLAG - current loop

•  MODBUS - RS485

•  M-BUS

•  Felix propertary protocol on QNX

•  Integrated databases

•  MS Access

 

References :

•  Mikon Systems, Sistem informatic integrat de management pentru productia de energie electrica si termica - Sucursala Electrocentrale Constanta

•  Dumitru Popescu, Sisteme de conducere a proceselor continue

•  National Instruments, Graphical programming for engineers and scientists

 

Author(s) :

Constantin, Alexandru, General Manager

Cristian, Patrulea, Technical Manager

Andrei, Gusti, Chief Operating Officer

Dragos, Brezoi, Software Programmer