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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 Garoa (BWR-3) 466 MVt 4.000 / 20 ms Of the active zone, cooling, emission, environment, metheorological and seismicdata, radiation.

    ANAV Asc I (PWR) 1032,5 MVtAscII (PWR) 1027,2 MVt

    Vandells II (PWR) 1087MVt

    40.000 / 1 sec Of the active zone, cooling, metheorological and seismic

    data, radiation.

    CNAT I (PWR) 1049,4 II (PWR) 1044,5 PWR) 1066

    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 Garoa

    Nuclenor is a company which expoits

    the nuclear plant of Garoa situated

    in Burgos, Spain. The staff of the

    administrative office located in

    Santadner, 150 far from Garoa,

    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 Almarz I,

    Almarz 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 ofRenewable Energy of Iberdrola Ingeniera y Construccin, 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, thedeveloped 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

    STORAGE

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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 highrange, 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 (PRI-DAT) Specific driver UDP EGD 2 s

    Meteo RX3i GE Fanuc

    RX3i

    Wind direction 100 (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 Garoa (the owner

    Nuclenor).

    Architecture secure data transference

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    Architecture Example 1

    Process Net

    DRVGIPNET2DRVGIPNET1

    TOPGIPNET

    3D MONICORE ELITELMETEOROLOGA

    FTP FTPFTP

    Red d

    e a

    quis

    ici

    n

    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

    STORAGE

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    Calculation Module

    Possibility to make arithmetic calculations, complex logics and create new signals on the basis of theacquired 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

    STORAGE

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    AGENTS

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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

    STORAGE

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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

    STORAGE

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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, 20ms)) during a certain period of time.

    Data Base: for storage of historical data of each parameter with lessresolution or averages, for scallability and effective quieries resolution.

    CALCULATION

    STORAGE

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    AGENTS

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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 certainfrequency, intermediate data are excluded.

    Average values: average values are stored at acertain frequency.

    Polynomial: polynomials which organizedispersion 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 losingimage 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 WebClient 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 graphfunctionalities.

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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. Newtons 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 operators response to the received alarms information anduse 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 systems 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

    100C, 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 fromwhich data stored in IDbox will be controlled.

    Control room monitors, regardless of the user, are means of visualizinginformation 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

    D

    A

    T

    A

    R

    E

    C

    E

    I

    V

    E

    R

    EXTERNAL ANALYSIS OF REMOTE ACCESS

    DATA

    DIODE

    PLANT 3

    PLANT 2

    PLANT1

    PLANTN

    OTHER SYSTEMS

    PE Management

    Information for Citizens

    Portal

    PWAN

    CALCULATION

    The information is

    available throughany device in any

    place.DATA

    DIODE

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    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 Cientfico Tecnolgico de Cantabria, C/ Isabel Torres n 3 39011 SantanderSede Madrid Paseo de la Castellana n123 Esc. Izq. 1A 28046 Madrid Tlf.:91 417 44 [email protected] Tel.: 902 269 017 Fax: 902 269 117