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MicroSCADA Pro in demanding Industrial Applications

MicroSCADA Pro in demanding Industrial Applications. John Tsao Eric Chuang Anders Brokvist. Contents. About Nanya Technology Corporation (NTC) NTC Fab 3 MicroSCADA Pro Installation System Layout & Components Process Devices Applications Engineering. Contents.

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MicroSCADA Pro in demanding Industrial Applications

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  1. MicroSCADA Proin demandingIndustrial Applications John Tsao Eric Chuang Anders Brokvist

  2. Contents • About Nanya Technology Corporation (NTC) • NTC Fab 3 • MicroSCADA Pro Installation • System Layout & Components • Process Devices • Applications • Engineering

  3. Contents • About Nanya Technology Corporation (NTC) • NTC Fab 3 • MicroSCADA Pro Installation • System Layout & Components • Process Devices • Applications • Engineering

  4. About Nanya Technology Corp. • Founded on March 4, 1995 • Main shareholder: Nanya Plastics Corporations of the Formosa Plastics Group • Headquarters in Taoyuan, Taiwan • 5,275 employees (Oct 2007)

  5. About Nanya Technology Corp. • Conduct research and development, design, manufacturing and sales of DRAM products • Two factories producing 8-inch (200mm) wafers and one factory producing 12-inch (300mm) wafers

  6. Contents • About Nanya Technology Corporation (NTC) • NTC Fab 3 • MicroSCADA Pro Installation • System Layout & Components • Process Devices • Applications • Engineering

  7. NTC Fab 3 • 12-inch wafers with 70 and 60nm technology • Planned max. capacity/month 62,000 wafers • Constructed in two phases: • Fab 3A: 70nm 30,000 wafers/month • Fab 3B: 60nm

  8. NTC Fab 3A (phase 1) • Milestones: • 3 / 2006 : Ground-breaking ceremony • 3 / 2007: Clean room construction • 5 / 2007: Equipment move-in • 10 / 2007: Successful Pilot run • 3Q / 2007: 70nm wafers production started Customer: NanYa Technology Corporation (NTC) Year of commissioning: 2007

  9. Contents • About Nanya Technology Corporation (NTC) • NTC Fab 3 • MicroSCADA Pro Installation • System Layout & Components • Process Devices • Applications • Engineering

  10. MicroSCADA Installation Customer’s need • EPC contractor NanYa Switchgear Unit builds six (6)new “Fab3A” substations • Reliable partner for SA to support the project from tender clarification to turnkey implementation ABB’s response • SAS650 IEC61850-based system with fully redundant hot-standby station servers • Various ABB IEDs (REX521 * 197 pcs, REF541 * 66 pcs, RET541 * 13 pcs, & REB670 * 3 pcs) integrated in MicroSCADA Pro HMI with new GUI • Integration of 3rd party meters & D-UPS, DC charger, MIMIC controllers via MODbus and Allen- Bradley PLCs via OPC connection Customer’s benefits • Close cooperation resulting in optimized solution • Safeguarded investment and optimized life cycle cost through future-proof IEC61850 based systems • Excellent local competence and support Customer: NanYa Technology Corporation (NTC) Year of commissioning: 2007

  11. Contents • About Nanya Technology Corporation (NTC) • NTC Fab 3 • MicroSCADA Pro Installation • System Layout & Components • Process Devices • Applications • Engineering

  12. System Layout • System level

  13. System Layout • System level • 2 pcs Hot Standby Servers • 4 pcs Workstations • 7 pcs Front-end computers: • 3 pcs with local database & workplace (Mirroring to Servers) • 4 pcs without local database (“COM530”) • Front-ends contain IEC61850 OPC Server and External OPC DA Clients • Redundant Ethernet (Tree)

  14. System Layout • Substation level

  15. System Components • Server computers: IBM eServer X236 • Xeon 3.2GHz*2 CPU • 4GB RAM • 4*80GB SCSI RAID • Matrox P650 VGA Dual Graphics card • Windows 2003 Server • SYS 600 9.2 • Front-end computers: Advantech IPC-610 • Pentium P4 3.0GHz, 2GB RAM • Windows XP Pro • SYS 600 9.2

  16. System Components • Ethernet switches: Ruggedcom RSG-2100 (28 pcs) • Serial Device Servers: Moxa Nport 16-port (7 pcs) • For Modbus, RP570 protocols • Meinberg Lantime GPS receiver • Report printer • Event printer

  17. Contents • About Nanya Technology Corporation (NTC) • NTC Fab 3 • MicroSCADA Pro Installation • System Layout & Components • Process Devices • Applications • Engineering

  18. Process Devices ABB IED’s: • REX 521 (197 pcs) • REF 541 (66 pcs) • RET 541 (13 pcs) • REB 670 (3 pcs) 3rd party devices: • RTU 211 (7 pcs, General I/O) • Allen Bradley PLC (Generator controller) • Modicon PLC (DUPS controller) • Siemens S7 PLC (Mimic controller) • Siemens P650 (Meters)

  19. Contents • About Nanya Technology Corporation (NTC) • NTC Fab 3 • MicroSCADA Pro Installation • System Layout & Components • Devices • Applications • Engineering

  20. Applications • Connected to FMCS (Facility Maintenance Control System) using OPC DA Server • DUPS interface (Dynamic Uninterruptible Power Supply) • Mimic controller • Generator controller interface (Synchronization control) • Internal billing function • Geographical layouts • System supervision

  21. Applications • DUPS interface (Dynamic Uninterruptible Power Supply) • Modbus interface to Modicon PLC

  22. Applications • DUPS interface (Dynamic Uninterruptible Power Supply)

  23. Applications • Mimic controller • Control room mimic controlled from MicroSCADA • Using Siemens S7 PLC connected on Modbus

  24. Applications • Generator controller • Connection realized by using AB RSLinx as OPC Server SYS 600 OPC DA Client Front-end computer RSLinx OPC DA Server Ethernet Allen-Bradley PLC SLC503 Allen-Bradley PLC SLC503 Redundant PLC

  25. Applications • Internal billing function • Creates energy consumption reports • Exports information to MS Excel

  26. Applications • Geographical layouts • Helps operators locate alarms in factory

  27. Applications • System supervision – main system devices

  28. Applications • System supervision – IED displays

  29. Applications • System supervision • IED supervision uses two signals: 1. System – SPA-ZC40x adapter using “Device connection status” item 2. SPA-ZC40x – IED using “ComStatus\stVal” (SPS)

  30. Contents • About Nanya Technology Corporation (NTC) • NTC Fab 3 • MicroSCADA Pro Installation • System Layout & Components • Devices • Applications • Engineering

  31. Engineering • Engineering tools: • CET for SPA-ZC40x • CET for IEC 61850 OPC Server • SCL Importer • OPC PO list • External OPC DA Client Conf. Tool • Object Navigator • Display Builder

  32. Engineering Problems encountered in MicroSCADA • Trends with Chinese OX characters crashes Trend Basket • Busbar coloring not support multiple displays • SCL Importer OX texts for protection signals • Device naming (IEC61346) used in SCL not accepted by customer Problems encountered with adapters SPA-ZC40x • MMI alarms not in connectivity packages, requires manual entering • Supervision signals not in connectivity packages, requires manual entering • Time synch problem with OPC Server-> SPA-ZC40x, required update of firmware

  33. Engineering Lessons learned: • Complete SPA-ZC40x configuration before downloading to all adapters • We downloaded new configurations (and firmware) several times (to over 250 adapters)! • IED time synchronization to be done directly from GPS receiver • IEDs are now synchronized from Front-end OPC Server • Consider to have one large Ethernet network for whole system • Now the process devices are on a separate network

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