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

ANAV Ascó I (PWR) 1032,5 MVtAscóII (PWR) 1027,2 MVt

Vandellós II (PWR) 1087MVt

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

data, radiation.

CNAT Альмарас I (PWR) 1049,4 МВтАльмарас II (PWR) 1044,5 МВтТрильо PWR) 1066 МВт

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 Garoña

Nuclenor is a company which expoits

the nuclear plant of Garoña situated

in Burgos, Spain. The staff of the

administrative office located in

Santadner, 150 far from Garoña,

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 Almaráz I,

Almaráz 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 of

Renewable Energy of Iberdrola Ingeniería y Construcción, 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, the

developed 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 high

range”, “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 м (PRI-DAT) Specific driver UDP EGD 2 s

Meteo RX3i GE Fanuc

RX3i

Wind direction 100 м (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 Garoña (the owner –

Nuclenor).

Architecture – secure data transference

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Architecture – Example 1

Process Net

DRVGIPNET2DRVGIPNET1

TOPGIPNET

3D MONICORE ELITELMETEOROLOGÍA

FTP FTPFTP

Re

d d

e a

qu

isic

ión

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 the

acquired 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

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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

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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, 20

ms…)) during a certain period of time.

Data Base: for storage of historical data of each parameter with less

resolution or averages, for scallability and effective quieries resolution.

CALCULATION

STORAGE

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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 certain

frequency, intermediate data are excluded.

Average values: average values are stored at a

certain frequency.

Polynomial: polynomials which organize

dispersion 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 losing

image 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 Web

Client 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 graph

functionalities.

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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.

• Newton’s 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 operator’s response to the received alarms information and

use 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 system’s 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

100ºC, 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 from

which data stored in IDbox will be controlled.

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

information 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

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E

R

EXTERNAL ANALYSIS OF REMOTE ACCESS

DATA

DIODE

PLANT 3

PLANT 2

PLANT1

PLANT«N»

OTHER SYSTEMS

PE Management

Information for Citizens

Portal …

PWAN

CALCULATION

The information is

available throughany device in any

place.DATA

DIODE

F07.02.01.00.22.r01

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 Científico Tecnológico de Cantabria, C/ Isabel Torres nº 3 · 39011 SantanderSede Madrid · Paseo de la Castellana nº123 · Esc. Izq. 1ºA · 28046 Madrid· Tlf.:91 417 44 63buzon@cic.es Tel.: 902 269 017 Fax: 902 269 117