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Seeing is Believing:
Visual management for SCADA/HMI applications
Sure, your SCADA system lets you to automate complex industrial processes where human control is impractical. Sensors and actuators can be placed at each managed processes' critical points to provide a detailed view of operations as they occur. But even with all of these real-time updates and raw data pouring in, it can still be difficult to diagnose a problem and take proper action. Was the security alarm triggered by an actual intruder or accidentally set off by a new technician on his first day on the job? Or maybe it was that darn stray cat again. All the numbers on your screen, flashing lights, and blaring alarms still leave you in the dark. So what's missing from this picture? Well, it's the picture.
IP video technology has become one
of the hottest trends in industrial automation today. More
than just a surveillance tool, IP video technology can enhance
your SCADA/HMI systems with visual management. According to
Control
Engineering, "more cost-effective and intelligent
digital technology, ubiquitous Ethernet and other networks,
and plant engineers having to do more with less are all enabling
the 'automation' of human sight and visual analysis for process
control." So how exactly does visual management enhance
your SCADA/HMI applications?
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Video surveillance benefits
Real-time video surveillance offers automatic monitoring and control capabilities, enhancing remote monitoring applications with visual management. These capabilities not only save management costs for manpower, but also achieve complete network automation.
Supervisory Control and Data Acquisition (SCADA) systems installed in industrial automation and process control systems provide data about the system's status and can be easily integrated with video surveillance technology. By installing a real-time video monitoring system, system administrators are able to receive visual data to complement the raw SCADA data. Real-time video monitoring can help ensure normal operations for power equipment, protect against intrusion and tampering by unauthorized personnel, and prevent accidents. For example, intruders, physical obstructions, or smoke indicating a fire can be seen via video so engineers no longer need to visit the site in-person each time to diagnose an anomaly, saving both time and costs.
Integrating real-time video surveillance into SCADA systems gives system operators a more powerful tool for managing their processes. The main goals of including real-time video are:
- Be able to see what's happening onsite in real-time, even if no one is at the field site.
- Save time and labor by being able to view equipment and the environment from off-site.
- Give engineers better information about dangers at the site before sending them to the field site.
- Record events in real-time, even when it is not possible to check in person.
- Prevent sabotage and theft.
Video display in Citect SCADA software once an alarm is triggered.
Integrating video surveillance into a SCADA system
Networks for modern SCADA systems are migrating to Ethernet-based TCP/IP to provide better remote accessibility, integration capability, and easier deployment and management. Following this trend, many I/O devices can now connect directly to an Ethernet network for greater data transmission versatility.
This Ethernet-ready trend also applies to video surveillance devices. However, due to the complexities of video digitization and compression technologies, and the variety of video networking solutions on the market, system integrators may have trouble selecting and integrating suitable video networking solutions into their SCADA system. In addition, system integrators must consider how environmental conditions may affect the system, and then choose products accordingly.
Thanks to advances in video digitization and compression technologies, video networking surveillance is becoming the mainstream of video surveillance systems. Many video networking solutions, such as IP cameras, video servers, and NVRs (network video recorders) are being developed to implement networked video surveillance systems. By using such devices, system integrators can easily integrate video surveillance applications into their SCADA system. Four factors must be considered when choosing which video networking solution to use for your SCADA system:
- Applicability
- Reliability
- Integration
- User-friendliness
Why IP video?
In the past, video surveillance systems such as CCTV networks relied upon analog video cameras. Due to advances in video digitization and compression technologies, high quality digital video images can now be sent over Ethernet TCP/IP networks. By using such devices, system integrators can easily integrate video surveillance applications into their SCADA system. As a result, IP video technology is the current trend in video surveillance systems. The benefits of IP video surveillance include:
- One network—Using the existing IP network saves cabling costs and increases installation flexibility, especially for widely distributed substations. Ethernet TCP/IP networks can accommodate a variety of I/O monitoring and control devices in addition to transmitting data, video, voice, and even power (PoE) over a single network.
- One system—Integration with SCADA or alarm systems (such as fire, intrusion, etc.) increases monitoring efficiency and creates an event-driven video surveillance system. This means the video images can be displayed and recorded and real-time responses can be received when an event or alarm occurs.
Industrial IP video
But everyday run-of-the-mill IP cameras and equipment generally aren't tough enough to withstand the harsh conditions in industrial environments. As Eddie Lee, product manager for Moxa USA Inc., explained in the January 2009 issue of Control Engineering, "a video encoder, also commonly referred to as a video server, is not required if a video over IP camera (webcam) is used. The problem is that most IP cameras today are built for light consumer use." As a result, Siemens Taiwan has decided to use Moxa's industrial-grade VPort solutions in their I/O system for building automation, DESIGO INSIGHT. By integrating Moxa's IP video technology with a SCADA system, Siemens Taiwan is able to provide customers with visual management for enhanced remote monitoring and control capabilities.
SCADA systems offer a real-time and comprehensive view of all events, even for very complex manufacturing processes and large electrical plants, and provide the information needed to correct errors and improve efficiency. As helpful as the raw data are, they still don't provide the entire picture. Fortunately, visual management via IP video has become a viable and affordable solution for system integrators to consider.
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