Patent Publication Number: US-7225248-B1

Title: Integrated automation system with publisher interface

Description:
The present application is a continuation-in-part application, which claims priority to patent application Ser. No. 09/826,578 filed in the U.S. Patent and Trademark Office on Apr. 5, 2001 now U.S. Pat. No. 6,950,851. 

   FIELD 
   The present embodiments relate generally to an integrated automation system that has utility in the refining, petrochemical and chemical processing industries as well as the oil and gas production industry, metal manufacturing industry, maritime drilling businesses and environmental monitoring. 
   BACKGROUND 
   The automation industry has had major developments in the implementation of SCADA monitoring and control systems. A need has long existed for an integrated system, which uses small PC&#39;s to run factory lines, and other large manufacturing facilities. 
   The automation industry has had major developments in the implementation of SCADA monitoring and control systems. A need has long existed for an integrated system, which uses small PC&#39;s to run factory lines, and other large manufacturing facilities. 
   The integration problems were rampant in the industry. Either, hosts were inadequate or defective. A unique RTU was developed to facilitate the integration of software. 
   1. A need has long exists for a less expensive RTU 
   2. A new board has been desired to reduce the costs of RTU by at least 25% 
   3. A need has existed for a system, which works faster than traditional host systems 
   4. A need has existed for an improved SCADA system and method of communication, which can talk to more systems as host more than traditional systems. 
   A vital part of any process control system is the initial communication and periodic point-to-point communication of the system, including the process input values, the database, the displays and the like. Such a communication procedure is associated with a SCADA system, which in its most generic definition is essentially a process control system. The components of a typical SCADA system comprise a SCADA device and one or more remotely connected Intelligent Electronic Devices. As used herein, the term SCADA device is used as a convenient shorthand for what may be a collection of electronic equipment, including a computer based controller, which can be a server, also termed the “enterprise server” that is used to remotely monitor communication and/or control the operation of one or more remote RTUs such as relays, meters, transducers and the like. In general, the enterprise server is located miles away from the RTUs presenting many SCADA system communication difficulties. However, such a definition should not preclude an enterprise server being located much closer, even in the same plant as the RTU or RTUs. 
   Communication for a SCADA system traditionally has been very time and labor intensive. The initial set up of the RTU required an expensive technician to go into the field to configure the RTU. Subsequent maintenance communication has also been particularly time and labor intensive where the RTU is in an extremely remote location, such as on a mountain top or under snow on a pipeline in Alaska with respect to the enterprise server. In such a case, transportation and communication problems have been abundant. Therefore, reducing the time and effort required to run communication of a SCADA system while insuring that the SCADA device database and overall SCADA system operation meets the highest possible accuracy standards would provide substantial cost advantages over current communication procedures. 
   Traditionally, RTU configuration has involved steps of: 
   1. Assembling and transporting to the RTU location a collection of complex and expensive test equipment and signal generators that are required to produce the needed configuration 
   2. Requiring an expensive technician at the remote location to inject the data into the RTU&#39;s inputs. 
   3. Requiring a second expensive technician at the central location(s) to verify the RTU is correctly processing according to the new configuration. 
   4. Such a system presents many drawbacks. For example, two technicians at disparate locations are required to perform the service. One of the technicians may be required to travel long distances. Moreover, in most SCADA systems, the RTU can be disconnected from the process that it is monitoring and/or controlling, which may affect the process under control. 
   5. There is a need for method and apparatus that address the shortcomings of present communication of a SCADA system. These needs are now met by the present invention. 
   The present embodiments meet these needs. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The detailed description will be better understood in conjunction with the accompanying drawings as follows: 
       FIG. 1  depicts a SCADA system according to the present invention. 
       FIG. 2  provides a detail of an RTU of the present invention. 
       FIG. 3  is a detail of a user interface with an enterprise. 
       FIG. 4  a diagram of international with external systems. 
       FIG. 5  depicts representation of a screen shot of the publish interface according to the invention. 
       FIG. 6  depicts representation of a screen shot of the publish interface according to the invention. 
       FIG. 7  depicts representation of a screen shot of the publish interface according to the invention. 
   

   The present embodiments are detailed below with reference to the listed Figures. 
   DETAILED DESCRIPTION OF THE EMBODIMENTS 
   Before explaining the present embodiments in detail, it is to be understood that the embodiments are not limited to the particular embodiments and that it can be practiced or carried out in various ways. 
   The embodiment of the current invention saves lives through automated collection of data from devices such as gas meters that might be located on a transcontinental pipeline or on a residence. The data that is collected from these geographically dispersed locations is collected automatically through available means of communication such as the public switched telephone network and is published through the AES Publish interface to data analysis systems thereby eliminating the risks for personnel who otherwise would be required to travel to each meter at these distant locations. 
   The embodiment of the current invention saves the environment by eliminating the necessity for personnel to travel to distant locations to get data from remote devices such as gas meters and RTUs. The polluting hydrocarbon exhausts that result from traveling by automobile or another vehicle to these locations will not be created. 
   The embodiment of the current invention saves energy by eliminating the requirement for personnel to routinely travel to the location of each remote device to gather information. Traveling to these locations which can be spread over thousands of miles by automobile or other means of transportation would utilize valuable energy resources. Instead the AES can automatically gather the information over commonly available means of communication such as the world wide global network. Finally, the critical data read from control and metering devices on assets such as a transcontinental gas pipeline can be passed through the AES Publish interface to leak detection systems to determine the size and location of a possible leak. Leak mitigation on pipelines such as this can greatly reduce the potential for loss of life, environmental damage and loss of valuable energy resources. 
   The embodiments of this invention allows for the automatic collection of data such as residential gas meter data and can automatically format and publish this data for delivery to data validation and accounting systems. This automation greatly reduces manpower requirements by eliminating the need to manually collect and key-in the data one data item at a time. 
   The embodiments of this invention eliminate the possibility of human error when data from remote devices such as residential gas meters are manually collected and manually entered into data validation or accounting systems. Instead the AES automatically collects the meter data over available means of communication, reformats the data to a compatible format and publishes the data to a data validation and accounting system without human intervention. 
   The embodiment of the current invention reduces the time to collect critical data from remote devices such as RTUs or utility meters, and to subsequently reformat and publish the collected data to data validation, analysis and accounting systems. This data would otherwise be manually collected and entered by personnel one data item at a time. The elimination of human intervention in the process of data collection, reformatting and publishing to data validation, analysis and accounting systems can be done by a computer which saves time and makes the business much more efficient. 
   An embodiment of the invention can be for an enterprise server for communication between data centers, control centers and remote devices. The enterprise server includes, a configurable server software (AES) running on memory in a computer. The AES can be adapted to cache the status and measurement data on the memory of the computer. The configurable server software can comprise an ability to request the status and the measurement data from the RTU at defined time intervals. 
   Server control commands can be added to allow client initiated modifications to server software during enterprise server operation. The server can be a component of a SCADA system. The server can also be a component of a control system, an automatic meter reading system, another utility monitoring system, another sensor monitoring system, an alarm detection system, an alarm notification system, a data measurement system or combinations thereof. 
   The server also includes a configurable server interface adapted to receive a client request from a client application requesting status and measurement data from a remote terminal unit (RTU) and wherein the configurable server interface provides the status and the measurement data to a client application. A configurable protocol interface is in communication with the configurable server software for building a message for the RTU using a device protocol. A plurality of device protocols are supported simultaneously by the configurable protocol interface. 
   A configurable connection interface is used for connecting the AES to the RTU and enabling a second message to be transmitted to the RTU, and a third message to be received from the RTU. The third message can contain the status and the measurement data. The configurable connection interface can also be used for transmitting the status and the measurement data to the configurable server interface using the configurable protocol interface. 
   A configurable publish interface is integrated in the AES. The configurable publish interface includes a first option to reformat the status and the measurement data to be compatible with a second software system. The second software system can be data validation software. 
   The configurable publish interface also has a second option to publish to a designation in a variety of formats. The formats include, a location specific file format, a location specific database, a location specific message queue, a data stream on the world wide network, a file format at an internet URL, a specific database at an internet URL, a message queue at an internet URL. The publish interface can publish at a frequency ranging from one minute to one year. 
   The publish interface handles from 1 to a maximum number of records which can be carried over a communication bandwidth. The communication bandwidth can be a connection from 9600 baud to 100 megabaud. 
   Device protocols can be used to facilitate the operation of the SCADA system. The device protocols are selected from the group Modbus, BSAP, AINet, DF1, or Mercor. 
   There can be Interface diagnostics for one or more of the configurable interfaces to identify a frequency of software errors, communication errors or other types of errors occurring with one or more configurable interfaces as the interface communicates with a specific device, and other errors. A barometer can be added to a RTU for totalizing errors in communication. The errors can include, framing errors, CRC errors, communication time outs and combinations thereof. 
   A configurable logging interface can be added to run on the configurable server software. The logging interface communicates with a software logging program for tracking and viewing errors occurring in a channel or with the RTU and then storing tracked errors. The configurable logging interface can communicate over a global communication network with a second computer hosting the software logging program or the software logging program can reside on the enterprise server. 
   An embodiment of the invention can be a method for obtaining and publishing a dataset from an RTU using configurable server software. The steps can be first building a dataset request into a message through a protocol interface and then transmitting the message to an RTU through a connection interface. After that receiving a message including the dataset from the RTU through the connection interface. After receiving the message interpreting the dataset using the protocol interface and publishing the dataset to a designation in a various formats. The formats can be, a location specific file format, a location specific database, a location specific message queue, a data stream on the world wide network, a file format at an internet URL, a specific database at an internet URL, and data into a message queue at an internet URL. 
   Referring now to  FIG. 1 , there is shown a SCADA system  10  of the present invention. As shown, the SCADA system  10  comprises an enterprise server  12  and has a display device  14  for displaying data to a human operator (not shown in the figure). A second enterprise server (not shown) can optionally be connected to the SCADA system  10  which may have a second display device connected to the second enterprise server. 
   An RTU  20  such as a microprocessor-based relay, connects to the system. The RTU can monitors and/or control a physical process  22 , and an optional local computer  24  can be used for configuring RTU  20  locally. 
   RTU  20  communicates with enterprise server  12 , via a connection called OPC messenger  26 . OPC messenger  26  can reside on server  12  as shown in  FIG. 1 . In another embodiment, the OPC messenger  26  can reside on the local computer  24 . In fact, OPC messenger  26 , or AES  28  can be on either of the two computers,  12 , and  24  shown and there can be less or more than two computers  12  and  24  for the AES  28  to reside on. 
   Configuration of the RTU  20  occurs by use of a configuration tool ARME  17  which can reside on either of the computers  12 , and  24  but is shown on enterprise server  12 . The ARME  17  configures the RTU  20  through the AES  28 . The OPC messenger  26  and the ARME  17  can be on their own enterprise servers and separate from the enterprise server the AES  28  is installed on. The OPC messenger  26  and the ARME  17  can still connect to the AES  28  to communicate with the RTU  20   
   Software termed the “AES”  28  is the communication tool, which can communicate with the RTUs  20 . 
   The ARME provides a client interface. The client interface can be a window on a computer screen and the client can adjust configuration setting using the ARME software. The ARME can transmit RTU reconfiguration commands to the AES server interface. 
   Generally, in this system, the RTU  20  measures physical properties and monitors status and can measure various physical indicators, such as flow through a pipeline. Additionally, the RTU&#39;s can run simulations, and provide data to the enterprise server  12  or  14  based on instruction via the AES. 
   For a simulation, a, SCADA system  10  requires communication with RTU  20  using at least the enterprise server  12  and/or  14 , or even others. 
   The AES provides the RTU  20  with simulation instructions so the RTU can run tests without the need for an operator or expensive test equipment to inject a new configuration of an RTU into system  10 . Moreover, RTU  20  can continue to monitor and/or control process  12 , while the simulation is running. 
   A configurable publish interface can be integrated into the AES. The publish interface receives data from the RTU, and publishes to a local designation in a file format, database, message queue or XML data stream. The published data is then reformatted to a proprietary output in a file format, database, message queue, or XML datastream. The proprietary output file can be in a Flow-Cal CFX format, if a database is a Flow-Cal Transaction Queue, an XML datastream is an ABB Win CCU XML, and SonicMQ would be the message queue. Then the data is published to an internet designation in a file format, database, message queue or XLM datastream. The data can be reformatted and published to an internet designation in a file format, database, message queue, or XML datastream. 
   Referring to  FIG. 2 , an exemplary RTU  20  is shown in further detail. As shown, the essential parts of RTU  20  comprise a microprocessor  30 , an analog-to-digital converter (ADC)  32 , a digital signal processor  34 , a communication interface  36 , such as a bi-directional port or one or more directional input ports or output ports. A user interface  40  provides displace and command entry features. The microprocessor  30  has a memory area  42 . Memory area  42  can comprise both Read-Only Memory (ROM) and Random Access Memory (RAM). Computers  12 ,  16 , and  24  can connect to the communication interface  36  of the RTU  20 . 
   The input ports can be an Ethernet adapter, a serial communication port, or a modem. The output ports can be an Ethernet adapter, a serial communication port, or a modem. 
   The watchdog timer can also be used with the SCADA device. The watchdog timer is a relay that is reset during every cycle of the AES software. If the relay is not reset for a preset period of time the processor of the RTU can be restarted. 
   As with many standard RTUs such as the microprocessor-based relay, RTU  20  measures aspects of a physical process  22  such as currents and voltages and converts the measured values into a digital equivalent via an analog to digital converter. Microprocessor  30  moves the digital representation of the measured values into memory area  42  where the data can be accessed by programs and external devices such as an enterprise server. Moreover, microprocessor  30  can perform various predetermined functions on the data, such as fault detection as in the case of a relay, or control the process. Microprocessor  30  is also in communication with communication interface  36 , the AES so that data (i.e., digital representative data) can be transferred to an external device such as enterprise server  12  or  16  or both, or even more servers. 
   An Input/output interface  36  is coupled to microprocessor  30  and provides binary input signals from a controlling device. Moreover, RTU  20  provides control signals to the controlling device such as a breaker close or open signal if the controlling device is a circuit breaker. 
   User interface  40  provides a local mechanism for gaining access to the data in memory  42 . In this way, a local operator can provide initial configuration data to RTU  20  or check the status of data within memory  42 . 
     FIG. 3  shows the detail of the reconfiguration process. For reconfiguration while an RTU is on line, a user interface  46  provides input parameters to the RTU via an input device such as a keyboard or a keypad at the server  12  through the AES  28  to the RTU  20 . Additionally, interface  46  may display communication data from the RTU allow a user to change the values for the data stored in the RTU. Alternatively, this same user interface  46 , can initiate steps to place RTU  20  is in a simulation or test mode. 
   Significantly, user interface  46  provides another mechanism to command RTU  20  and place RTU  20  either “off line” or into a “sleep mode”. Specifically, user interface  46  can be used to remove specific tasks by interval or entirely from the task list initially installed in the RTU. This same interface permits additional tasks to be added to the RTU. If a task is deleted from the RTU, or if the RTU is put into periodic “wake up” mode, the RTU does not store data in memory, or transmit. This feature is particularly useful for a system to be used on long space flights, where the Houston Johnson Space Center needs to only “wake up” certain RTU&#39;s at periodic times. 
   Additionally, user interface  46 , which interacts with the AES program  28  permits a user to request internal diagnostics from the RTU to determines the internal status of RTU  20  such as memory failure or processor failure while all other RTU and servers remain on line. 
   Referring now to  FIG. 4 , a flow chart is shown that depicts the interaction of an RTU for metering electricity with a SCADA system of the invention. During normal operation, a metering module  46  writes metered values to register memory  42 . Moreover, input/output task  48  writes binary status values to register memory  42 . The register memory values written by metering module  46  and input/output task  48  are, then transmitted to the enterprise server  12  for further processing. As described above, the communication port communicates with the AES and controls the interaction between RTU  20  and enterprise server  12 . For clarity and brevity, the communication process is described in reference to communication interface  36 . 
   During a typical communication sequence (i.e., normal mode) three steps are performed. First, a command is received via communication interface  36  requesting the transmission of data values from memory  42 . The data values are then retrieved from memory  42 , and prepared for transmission via the AES, for example, properly formatting the data. Finally, the prepared response is transferred to the external device via the AES. An encapsulation layer (GEL) is also used. 
     FIG. 5  depicts a screen shot of an embodiment of the publisher interface. This figure is of the EFM setup window. EFM stands for electronic flow measurement. 
   With these selections, the user can go to a file, database, message queue, or data stream. Element  50  is and example of a file which can be published and this file can include Hourly, Daily, and Events. Element  52  represents a reformatted data set which can be published according to the invention. The box  54  can be expanded to accommodate a multitude of configuration settings. Once the setup is acceptable the “OK” button  51  is clicked on and the EFM output selection window appears Alternatively the “Cancel button” can be depressed. 
     FIG. 6  shows the EMF output formats that can be used according to the invention under element  56 . A user can select one of the EMF outlets and then only publish the reformatted selected data. Once the output format is selected the “OK” button  51  is clicked on and the next window appears. 
     FIG. 7  shows an XML as element  58  which can be published to a data stream according to the invention. Data items  60  are shown which can optionally be included in the XML. In this embodiment once the “OK” button  51  is clicked on the publisher software closes all the windows and continues to publish based on the files selected. 
   The following terms are used here in.
     a. The term “SCADA” means Supervisory Control and Data Acquisition Systems.   b. The term “ARME” means the RTU configuration or maintenance tool for the SCADA system. ARME is an OPC Client that communicates through the AES that allows RTU&#39;s to be remotely reconfigured after deployment. OPC MESSENGER combines with AES to provide a data acquisition front-end for relational databases.   c. The term “GEL” means Generic Encapsulation Layer.   

   The invention relates to communication technology which can simultaneously handle multiple types of telemetry and different protocols from various remote terminal units, such as custody control computers for pipelines, pump off controllers, non-specific controllers, and water meters. 
   The invention is a server-based system that can provide information to a wide variety of client server interfaces, with the only limitation on capacity being bandwidth and processing power. 
   The invention works with lease line, radio, public switched telephone networks, cellular phones, and satellite and Internet telemetry reception. 
   For example, this invention can handle the communication for utility metering for an entire city. Multiple servers of the invention can be used, and the servers can be used in parallel to each other, and enable millions of terminals to receive and transmit communications to a central server and enables the utility to configure millions of RTU&#39;s at once. 
   The invention involves several features, an AES communication tool which has as the new benefits, a publisher interface as well as the ability to conserve resources within an operating system including, memory, and the number of threads, which can be run through Microsoft NT. This new SCADA system was developed to handle these and other objects, including an ability of the user to assign threads to specific ports to conserve thread. 
   The AES communication system is capable of handling communication systems with over 100,000 RTU&#39;s while continuing non-stop communication with no downtime. The AES component enables the user to add or delete RTU while continuing to operate and function on line. This AES component also enables the user to add additional servers to the AES while the user is on line, without downtime. 
   The AES, is essentially a windows-based OPC server, (object linking and embedding for process control), which communicates with a plurality of RTU&#39;s simultaneously. The present invention relates to a window based communication server that permits digital communication to a field device, and enables the user to digitally connect or disconnect any one or more of the RTU while the system is operating on line. There can be at least 1000 RTU&#39;s engageable and disengageable while the system is on line. The system includes hardened computers suitable for performing remote automation in environmentally exposed locations using software compatible with the Windows 98™, NT™ and 2000™ operating systems. 
   The hardware of the invention is capable of performing remote control, alarm detection, data acquisition, and data management functions. The software provides communication to RTU&#39;s via telemetry systems, acquired data management via commercially available databases, such as Oracle, Microsoft Access, Microsoft SQL server, and Cybase and RTU status and performance values and parameters to data centers. 
   The AES can run as an NT server and the AES has: 
   a. Connection modules, which are connected from a standard port, and include: 
   
       
       
         
           i. TCPIP 
           ii. Dialup 
           iii. Serial 
         
       
     
  
   Other modules can be added depending on the hardware interface, such as an ARC NET connection module; and 
   Protocol Modules—the messaging language 
   
       
       
         
           a. Enron Modbus protocol module 
           b. ABB total flow module 
         
       
     
  
   SCADA system hardware usable in this invention includes a such as the RTU 3000, 4000E or 5000E. These models have different I/O capability, with the 3000 unit being the smallest and only communication ports to meet different application requirements and budgets. 
   The inventive SCADA system includes: 
   1. ARME; 
   2. AES, 
   
       
       
         
           a. Communication Software that is an NT Service 
           b. Configuration Software which is an ActiveX Control, and
 
3. OPC MESSENGER.
 
         
       
     
  
   The ARME is the RTU configuration or maintenance tool for the SCADA system. ARME is an OPC Client that communicates through the AES that allows RTU&#39;s to be remotely reconfigured after deployment. OPC MESSENGER combines with AES to provide a data acquisition front-end for relational databases. 
   OPC MESSENGER not only is an OPC Client but also has an ODBC interface that is compatible with all leading relational database products. 
   The ActiveX AES Configuration Software merges with any other software that is an Active X container to allow modification of the AES Communication Software. The AES Configuration Software has specific features that allow the remote configuration of the AES Communication Software, such as over the Internet. The AES Configuration Software provides a set of windows that allows the end user to define the communication desired with the RTU. For example, if a client wants to communicate with a “Totalflow” instrument, a window allows the user to set up the connection type, and then set up a virtual port associated with that connection type. A Windows Interface allows the user to select a serial connection type or serial port, and define multiple virtual ports, which are associated with an actual port, such as a COM Port  1 . Next, the user selects a protocol, such as Modbus. The user then defines a device, which is to be communicated with via the Modbus protocol. All communication parameters are then selected and then the AES Communication Software is setup for communication with the device through the port. 
   The AES Configuration Software can modify an offline database where the interface is OLE DB. This feature allows the invention to be compatible with any relational database. When a new device is selected, or new parameters are entered, the changes that are made to the offline database are automatically assimilated by the AES Communication Software. 
   AES and ARME and OPC MESSENGER run on Microsoft Windows 98™, NT™ or 2000™. The host system (personal computer) requires a minimum of 66 MHz processor speed and a minimum of 16 Megabytes of RAM. The system can be a 500 MHz process with at least 125K of Ram. 
   The host system&#39;s operating environment can be Microsoft Windows 98™, NT™ or 2000™. The invention can be compatible with Win32API. The modular design, based on COM Objects, a Microsoft standard, allows the present invention to be extended to support different connection types and protocols. 
   Communication can be established between a Microsoft Windows base computer and an RTU immediately upon powering the RTU and without RTU configuring or programming. 
   Automation functionality in the RTU can setup through the following method:
     1. Step 1: Select a automation function to be executed in the RTU from the functions available in an ARME program.   2. Step 2. Select additional parameters associated with the specific function.   3. Step 3: Communicate the function from ARME through the AES to the RTU.   4. Step 4: Optionally functions can be added to a function map and portions or all of the function map can be communicated from ARME through the AES to the RTU.   5. Step 5: Optionally functions can be added to a function map and communicated from ARME through AES simultaneously to many RTU&#39;s.   6. Step 6: Reconfigures existing RTU&#39;s via the AES with new function maps simultaneously.   7. Exemplary function blocks that solve data processing application problems include:
       a. Staging function block,   b. Analog alarm function block,   c. Gas metering calculation block,   d. Digital alarm blocks,   e. Archive blocks containing historical measurement or data records with date stamps, and   f. The ARME consists of function maps.   
       

   A library of function blocks that can be included in each map. The ARME has customizable function block ability; enabling end users to self develop and customize function blocks with a VB language. The ARME overwrites a Simulation Environment to simulate a function map in a host computer prior to loading the function map in an RTU. The ARME can download function maps to RTU; upload function maps from RTU&#39;s; and synchronize to one or more RTU&#39;s with the internal computer clock. 
   The RTU has a software component termed “the soft RTU” which is loaded on the hardware, the “RTU hardware.” The soft RTU has a special operating system, which executes on the function maps, which are downloaded to the RTU. 
   The hardware interface layer is called the Generic Encapsulation Layer or GEL. This hardware interface contains all the low-level communication programs, which enable the soft RTU to communicate with the Enterprise server. Some of these programs include, timing programs, communication buffers, I/O scanners, memory management, real time clock, power management routines. 
   To operate the soft RTU, controls in individual function blocks indicate to the operating system of the soft RTU when they should execute. The default configuration of the soft RTU enables immediate communication of the RTU with SCADA system at the moment of power up. Access to all I/O points on the RTU is also granted at the moment of power up. 
   RTU 4000 of the present invention is designed so that all hardware features can be configures from ARME. This means the user no longer has to have dipswitches, plug in modules, or jumpers. This saves time so that all hardware options with regard to I/O and communication are set in software only. There is only one reason to open the box of the RTU of the invention that is to activate the lithium battery, which is good for at least 10 years. 
   Features of the novel RTU include the ability of the RTU to put itself to sleep, based on change of status. It can be set to wake up periodically, or be woken up by telephone. It can be put to sleep periodically as well. 
   The invention contemplates using 8 analog inputs, which can be current, or voltage inputs and the input that are desired, can be picked by the software of the soft RTU. 
   A multifunction I/O point can be set up as (a) a digital input, a digital output, initializing off, initializing on, a low speed counter and a low speed counter of 0–10 kilohertz, a high speed counter of 125 Kilohertz to 400 kilohertz, a pulse output, a quadrature decoder. 
   It should be noted that Com Port  1  is always, 232, Com Port  2  and  3 , can be RS 232 or RS 485 and be software configurable. 
   Very little power is required by the RTU when it is asleep. It can be powered for 10 years on the one battery. 
   In an embodiment, a 12 VDC power supply can power the RTU 4000E. While terminating power supply wires to the RTU be sure to the power supply is off. A 12 VDC power supply or battery can be connected to the (+) 12 VDC terminal and the (−) 12 VDC (The power supply common should be terminated here. After connecting the power supply wires to the RTU, Turn-On the supply. Power-up should be indicated by the 12 VDC pilot light, which can be used as an indicator to check power connections. 
   Once the RTU is powered the next step is to establish communications between the RTU and can be an Intel computer equipped with Windows 2000™ or Windows NT™. The RTU initially, permits direct wiring of the RTU, however, just after power up with RTU may be configured to communicate via radio, lease line, internet or public telephone, however the following procedure can enable a user to use a default configuration to connect. 
   For direct communication a standard Null Modem cable should be connected to one of the three RTU 4000E serial ports (DB9 Male serial connectors) and to COM2, the second serial port on the Intel computer. If COM2 is not available, other COM Ports may be used. To use other COM Ports, attach the serial cable to the desired COM Port&#39;s; Configuring Ports. 
   The AES is compatible with Window 2000™ or Windows NT™. AES supports communication with various RTU&#39;s and other vendor products through a computer serial port or network card. Other software packages can communicate with the RTU through AES and its DDE (Dynamic Data Exchange) or OPC (OLE for Process Control) Server interface. 
   AES is installed by running an SETUP.EXE program as follows:
     1. Start Windows 2000™ Windows NT™,   2. Insert the distribution diskette into a floppy drive,   3. From the Windows Program Manager, invoke the File/Run&amp;#8230 command, and   4. Enter A:\SETUP (or B:\SETUP.EXE if the diskette is in drive B) and click on the OK or press &lt;ENTER&gt; key. The Setup dialog box appears.   

   The RTU 4000E1 is a hardened industrial controller suitable for installation in environmentally exposed locations. The RTU&#39;s 32-bit Motorola 68332 processor, 256 Kbytes of battery backed Static RAM and 16 Mbytes of Flash RAM provide strong computing power to perform complex control and data management activities. The RTU 4000E1 has three serial ports that can be used for communication with host computers, pagers, subordinate RTU&#39;s, I/O, analyzers and/or other vendor PLC&#39;s and RTU&#39;s. Lastly, the RTU 4000E1 has 53 I/O points that can be interfaced to instruments and actuators to measure and effect changes to process or equipment status and conditions. 
   When power is initially applied to an RTU 4000E1 the Factory Default; configuration retained in the RTU&#39;s flash memory is loaded to static RAM where it is executed. (The active configuration in static RAM is the On-line configuration.) This configuration allows immediate access to the RTU&#39;s I/O through the serial ports and the Modbus protocol on power-up. To setup the unit for an automation purpose the user can develop a configuration from a library of Function Blocks embedded in the RTU 4000E1 with the ARME configuration tool. Once loaded, this new configuration replaces the Factory Default and is called the User Default configuration. 
   The RTU 4000E1 can be packaged with a metal mounting plate and cover. This packaging provides RFI protection but does not provide environmental protection from moisture, dust, corrosive chemicals and atmospheres. In addition, the RTU is not suitable for installation in industrial areas that have a hazardous classification. Additional packaging however, can often meet these requirements. 
   The RTU 4000E1 has Power Input terminations and Battery Input terminations as shown in  FIG. 3 . These power inputs are OR&#39;ed in the RTU power circuitry such that if one source is removed, the RTU can draw from the remaining power source. The Power Input terminations are the primary power source and can accept from 11 to 30 VDC. The Battery Input terminations are intended for a system back-up battery and can accept from 9 to 14 VDC. Circuits associated with the Battery Input can also trickle charge the back-up battery as long as 11 to 30 VDC is applied to the Power Input terminations. Should the Power Input voltage fall below 11 VDC the RTU can automatically draw from the Battery Input power source. When the Power Input voltage returns to a level between 11 and 30 VDC the RTU again draw power from the Power Input terminations and trickle charge the backup battery. When input voltages fall below 9 VDC, a low voltage cutout can protect the RTU from indeterminate states that can occur. 
   LED indication of the status of power at the Power Input terminations and the Battery Input terminations are provided on the face of the RTU above the Reset button. When power is applied to either the Power Input or the Battery Input terminations the LED can be visible. When power is only applied to the Battery Input the LED can also be visible. 
   RTU 4000E1 has two grounds, which serve different purposes and can not be connected during the installation process. Transients, radio frequency interference (RFI) and over-voltage protection circuitry in the RTU are designed to transfer these disruptive or destructive signals to earth ground. The protection circuits connect to the mounting plate through mounting pads on the RTU circuit board. The installer should take care to insure that the mounting plate is also connected to a reliable earth ground. In addition the installer should collect all of the shields associated with instrument cables/wiring to RTU I/O at the RTU end and should connect these shields to earth ground. 
   The digital grounds associated with Digital I/O, Multifunction I/O and Analog I/O is connected within the RTU to Power Input and Battery Input grounds. As indicated in the Power and Battery Backup section above these grounds should be connected to the Common terminal of the power supply and/or to the Negative Terminal of the Back-up Battery. 
   An internal lithium back-up battery is provided in the RTU 4000E1 to maintain static RAM and the Real Time Clock when power is removed from the Power Input and Battery Input terminals. Current control set-points or targets, accumulated values and alarm thresholds that are being executed in static RAM may be different from those of the initial configuration maintained in flash RAM. The lithium battery, with a nominal life of 10 years, can maintain all of these settings in static RAM. It is necessary however, to install a jumper on the RTU circuit board to activate the internal back-up battery. To install, remove the RTU cover and locate the jumper next to the lithium battery in the upper right hand corner of the RTU circuit board. Press the jumper on the two pens and replace the RTU cover. 
   The user can control power consumption in the RTU to a large extent. Under normal operating modes the RTU nominally draws 115 mA at 14 VDC from the Power Input source. This does not include the additional power draws of instrumentation, telemetry hardware or other devices that may be included in an RTU installation. The user can reduce this power consumption by putting the RTU in a sleep mode on an interval or on an event. This capability can be configured through the ARME. In the Sleep Mode the RTU draws 13 mA at 14 VDC from the Power Input Source. Finally, further reductions can be made by selectively or completely deactivating LED indications on the face of the RTU. Again this feature is configured through ARME. 
   The RTU&#39;s are designed to monitor and control assets in environmentally exposed installations and to receive supervision regarding that mission from a remotely located data center. As a result, flexible communication to data center computers is a key capability. The RTU 4000E1 has three serial ports that can be individually configured for Master or Slave communications, different Modbus Slave IDs, communication parameters, hardware handshaking, password protection, privileges, and telemetry methods. 
   On initial power-up RTU 4000E1 I/O is accessible through any of the three serial communication ports and the Factory Default serial port values. The default settings for the serial ports are given in Table 1 below. 
   The RTU I/O is also accessible through the Modbus addressing provided in Table 2 below. Note that the address of some points is dependent on the configuration. The address for the default configuration of a particular I/O point is indicated in bold. As indicated in Table 2, all of the I/O in the RTU 4000E1 have pre-assigned Modbus addresses with the exception of the two analog outputs for whom holding addresses are assigned by ARME. 
   In addition to the default configuration detailed in Table 1, RTU 4000E1 serial ports default to the RS-232 electrical standard. COM Ports  2  and  3  however, can be configured by ARME to support RS-485.  FIG. 4  shows the locations of the COM Ports and associated LED&#39;s. LED&#39;s are provided to indicate the status of serial communication lines. In addition, the indicators located to the left of the Port  2  and  3  LED&#39;s; indicate whether these ports are configured for RS-232 or RS-485. The RTU 4000E1, which is a DTE device, is connected to computers and modems through standard serial cables. When connecting to computer serial ports a Null Modem cable should be used. When connecting to a modem or a radio modem a Straight-through cable should be used. Additionally, when communicating through modems that require hardware handshaking the cable can require the RTS, CTS and DCD lines in addition to TX, RX and GND. 
   In an embodiment, the CPU can be a Motorola 68332 16 MHz having 512 KB Static RAM and 4 MB Flash RAM. 
   The temperature range for operation of the SCADA system can be −40 deg C. to 85 deg C. 
   The Analog Inputs Software are Selectable 0 to 5 VDC or 4 to 20 mA. 
   The Analog Output Software Selectable 0 to 5 VDC or 4 to 20 mA. 
   The Multifunction I/O&#39;s can be configured in the software as: 
   1. Digital Inputs (DI), 
   2. Digital Outputs (DO), 
   3. Low Speed Counters/Accumulator (LSC), 
   4. High Speed Counters (HSC), 
   5. Pulse Outputs (PO), 
   6. Quadrature Decoder (QD), 
   7. Pulse Width Modulation (PWM), 
   8. DI Mode—5/12/24 VDC Sink, 
   9. DO Mode—5/12/24 VDC Sink, 
   10. HSC Mode—125 Hz to 100 KHz @ 5 DC to 36 VDC, 
   11. LSC Mode—0 Hz to 10 kHz @ 5 VDC to 36 VDC, 
   12. PO Mode 125 Hz to 100 kHz @ 5 VDC, 
   13. PWM Mode 125 Hz to 100 kHz Duty Cycle. 
   Add-on modules can convert any of these 11 points to additional Analog Inputs, Thermocouples Inputs, RTD Inputs, or Analog Outputs. 
   There are 32 Digital Points in the software that include: 
   1. Digital Inputs (DI) 5/12/24 VDC Sink 
   2. Digital Outputs (DO) 5/12/24 VDC Sink 
   3. LED indication for all Digital Points 
   4. Transient Protection 
   5. Compliant with IEEE 472 and ANSI 37.90. 
   The Serial Communication Ports can be: 
   1. Port  1  EIA-232, full handshaking, DB-9 Male. 
   2. Port  2  EIA-232/485, software selectable, full handshaking, DB-9 Male. 
   3. Port  3  EIA-232/485, software selectable, full handshaking, DB-9 Male. 
   4. LED indication of Port  2 / 3  EIA-485 mode. 
   5. LED indication of DTR, TX, RX, DCD, RTS, and CTS for each port. 
   The Power Supply can be set with:
     1. Three power modes: Un-powered, Sleep, Operational   2. Primary Power Input   3. Power Requirement 11–30 VDC   4. Operational Mode: Minimum power draw is 115 mA @ 14 VDC plus @ 1.8 mA/LED   5. Sleep Mode: Minimum power draw is 13 mA @ 14 VDC   6. LED indication when powered by Primary Power source   7. Back-up Battery Input   8. Power Requirement 9–30 VDC   

   In the Operational Mode, the minimum power draw is 102 mA @ 12 VDC plus @ 1.8 mA/LED 
   In the Sleep Mode: 
   1. The RTU is configured to enter Sleep mode by software logic. 
   2. The RTU awakens upon: 
   
       
       
         
           i. Return of power 
           ii. Alarm Clock setting 
           iii. Modem ring indication 
         
       
     
  
   The overall dimension of the RTU can be 6.14W×11.5L×1.35H with mounting plate. 
   The firmware of the RTU&#39;s control, data acquisition, alarm and event, and data logging capabilities are configured with the RTU Maintenance Environment (ARME). In addition all hardware options are configured from ARME. No hardware jumpers, switches or plug-ins are required. 
   The RTU 4000E supports the Modbus protocol standard, and can monitor 17 million RTU Addresses, provide: 
   1. Exception Reporting, 
   2. Scatter Reads (Registers do not have to be contiguous), 
   3. Mixed Data Type Messaging, and 
   4. Security/Access privileges configurable per port, which are 
   
       
       
         
           a. Read Only, 
           b. Read/Write, or 
           c. Read/Write/Configure. 
         
       
     
  
   The master protocols supported by the invention include: 
   1. Modbus ASCII and RTU. 
   2. Daniels Modbus ASCII and RTU. 
   3. Enron Modbus. 
   4. Rosemount 3095 Modbus. 
   5. Extended Modbus. 
   6. Yokagawa Power Quality Monitor 
   Slave protocols supported include: 
   1. Modbus ASCII and RTU, 
   2. Daniels Modbus ASCII and RTU, 
   3. Enron Modbus, 
   4. Extended Modbus. 
   For Data Acquisition, on power-up all RTU I/O is accessible via EIA-232 and Modbus addressing, no programming required. In addition,
     1. Data archival sampling rates are configurable from seconds to hours.   2. RTU flash RAM that is available for data archival can store 365 days of hourly data for 24 points. Over 250,000 records available for storage.   

   The invention allows up to 100 function blocks can be configured to address control, data acquisition, data logging or alarm applications. The function blocks can be: 
   1. Accumulator/Totalizer Block 
   2. AGA Block Compressible Fluid 
   3. Incompressible Fluid 
   4. AGA 3 
   5. AGA 8 Detailed 
   6. AGA 8 Gross 1 
   7. AGA 8 Gross 2 
   8. AGA 7 
   9. Alternate Block 
   10. Analog Alarm Block 
   11. Analog Input Block 
   12. Archive Block 
   13. Boolean/Math Block 
   14. Cryout Block 
   15. Digital Alarm Block 
   16. LCD Block 
   17. Mapping Block 
   18. Momentary Block 
   19. On/Off Control Block 
   20. PID Control Block 
   21. Scale Block 
   22. Staging Block 
   23. Sleep Block 
   24. Stop Watch Block 
   25. System Block 
   26. Timer Block Valve Block 
   27. User definable Function Blocks via Soft RTU Toolkit 
   The Enterprise Server includes:
     1. On-line configuration supports non-stop communication with field devices.   2. Communication Server runs as a Service in Windows NT 4.0 and 2000.   3. Communication support includes,   4. Real-time data polling,   5. Archival data uploads from field devices,   6. Exception reports or Cryouts from field devices,   7. Configuration tools are ActiveX controls that can be run in an OLE,   8. Container Compliant HMI or Browser.   9. Remote Administration Supported,   10. Embedded diagnostics logs performance information and forensics data to,   11. ASI Viewer and/or Log File,   12. Most communication functions and controls are accessible to external applications through the OPC Server interface,   13. Embedded Client triggers,   14. Enables real-time data caching for OPC Client applications,   15. Automatic archived data uploads from field devices without OPC Client application,   16. Item aliases supported for protocol independent HMI/Client Application development,   17. Browsing supports protocol specific data types/items and Aliases,   18. Multiple protocols can be supported on a single communication channel,   

   Telemetry methods, which are usable in this invention, include: 
   1. Serial Cable, Leased-line or Serial Multi-drop, 
   2. PSTN and PPP via Modem, 
   3. Radio (Conventional, Trunking, and Spread-Spectrum Radio), 
   4. VSAT, 
   5. TCP/IP Ethernet, TCP/IP Ethernet Terminal Servers, and IP. 
   The Protocols Modules can include:
     1. Modbus Module   2. Modbus RTU and ASCII   3. Omni 3000/6000 Modbus (Real-time Data, and History and Report Uploads)   4. Daniels Modbus RTU and ASCII (Real-time Data and History Uploads)   5. Enron Modbus (Real-time Data and History Uploads)   6. Flow Automation Modbus (Real-time Data and History Uploads)   7. ABB TotalFlow Modbus (Real-time Data and History Uploads)   8. Motorola MOSCAD Modbus   9. Delta X Modbus (Real-time Data and Dynagraph Cards)   10. Baker CAC Modbus (Real-Time Data and Dynagraph Cards)   11. Bristol Babcock BSAP Module   12. ABB TotalFlow Packet (Native) Protocol Module (Real-time Data and History Uploads)   13. ABB HCI-A Module (AAI Analyzers)   14. Allen Bradley DF1 Module
       i. Master-Slave (Half Duplex)   ii. Point-To-Point (Full Duplex)   
       15. Fisher ROC Module (ROC 300 Series, FloBoss 407, 500 Series) (Real-time Data and History Uploads)   16. GE SNP Module   17. GE 90 Series PLC Ethernet Module   18. HP48000 Module (Real-time Data and History Uploads)   19. Cutler Hammer—IMPACC System Communications Module   20. Detroit Diesel DDEC Module (Detroit Diesel Electronic Controller)   21. General Motors EMD MDEC Module (Marine Diesel Electronic Controller)   22. Caterpillar ECM Module (Electronic Controller Module)   23. Nautronix ASK Module   24. Mercury ECAT, ER Module (Real-time Data and History Uploads)   25. Teledyne CA, TGP Module   

   Server Interface Formats include: 
   1. OPC (OLETM for Process Control) 
   2. Microsoft CF_TEXT, XITable 
   3. Rockwell Software AdvanceDDETM 
   4. Wonderware FastDDETM 
   The types of communication transactions include:
     1. Real-time Data   2. Interval Polling at 15 different intervals (Periodic Timer Triggered)   3. Slow Polls at 15 Intervals are a percentage of Polling Interval (Faster and Slower rates are supported.)   4. Synchronous Polling (Clock or Calendar Triggered)   5. Demand Polling (DDE/OPC Client Triggered)   6. History/Archived data Uploads   7. Interval Uploads at 15 different intervals (Periodic Timer Triggered)   8. Slow Uploads at 15 Intervals are a percentage of Polling Interval (Faster and Slower rates are supported.)   9. Synchronous Uploads (Clock or Calendar Triggered)   

   The AES can communication without an OPC request from an external Client. It provides more deterministic performances as real-time data items are constantly active. The data collected is cached for delivered to external Client applications via the Server interface. Provides standalone history/archived data uploads from field devices for storage in database or audit files without the requirement of an external Client. 
   Documentation and Configuration, the invention permits the following:
     1. OLE DB interface support for all leading relational databases.   2. Database driven external configuration tools to ease maintenance of large applications.   3. Database driven reports to document AES configuration.   4. Database tools to support simultaneous configuration of HMI/Client Application and AES.   5. SCADA Capabilities, this invention allows:
       a. Client access to communication diagnostics for each telemetry channel and for each RTU/PLC.   b. One AES installation to support multiple protocols.   c. Multiple protocols can be supported over one communication channel.   d. Client-Server interface to give a Client full control of all aspects of the server including:
           (1) Polling Interval   (2) Demand Polling   (3) Telephone number for dial-up   
           e. AES redundant devices: RTU/PLCs.   f. Automatic fail-over to back-up device   g. AES supports redundant telemetry channels/methods to a single device:   h. Data Logging:
           (1) Uploaded data can be logged to any leading database via OLE DB.   (2) EFM data uploads can be written to Flow Cal files or to Flow Cal Enterprise (Oracle) format.   (3) User defined periodic file closing: file size control   (4) User defined path to file location   (5) User defined directory and file labels identify file content, date and time.   (6) User defined automatic file purging: directory size control   
           i. Diagnostic Logging:
           (1) AES logs diagnostic and forensic data to an ASI Viewer and/or Log file.   (2) Data that can be activated for Diagnostic Logging includes the following.   
           j. Message Errors   k. Send Messages   l. Receive Messages   m. Device and Item Activity   n. Status Changes   o. Client Data Received   p. Field Device Data Received   q. Event Notification from Ports   r. Receive Buffer Contents and Data   s. Item Name, Value and Quality   t. Changes in Client Status   u. Changes in AES Configuration   v. Data Flow Between AES Components   w. Performance Data regarding Threads   x. AES Footprint or Tracing Information   
       

   The invention has as features:
     1. Control, alarm monitoring, data logging, data acquisition, and communication functions of the embedded SoftRTU are implemented using ARME.   2. Data acquisition immediately on power-up without configuring or programming.   3. A fill-in-the-blank configuration interface that is used to setup RTU functions without programming.   4. Ability to reconfigure RTU&#39;s while they are on-line.   5. Loading of new configurations over the telemetry system.   6. Loading of RTU configurations to be uploaded and modified for downloading to other RTU&#39;s.   7. Configuration to archive data for periods greater than one year to nonvolatile memory.   8. Synchronization utilities between the RTU and the host computer.   

   This SCADA system can be used for: 
   1. Electrical Power Quality Monitoring 
   2. Electronic Flow Measurement (EFM) 
   3. Compressor Control 
   4. Wastewater Collection and Water Distribution Systems 
   5. Pump Control 
   6. Pipeline Valve Control 
   7. Surveillance 
   8. Environmental Monitoring 
   9. Traffic Control 
   10. Safety and Early Warning Systems 
   Connection features are as follows:
     1. Connection (OPC MESSENGER) is a data logger that has a DDE/OPC Client Interface.   2. OPC MESSENGER can acquire data from any DDE, OPC or ODBC source, and store the data via ODBC to any compliant database.   3. OPC MESSENGER can also retrieve data from the database and write the data to an RTU or PLC via the DDE/OPC Server.   4. Data is acquired on an Interval, External Trigger, Change in Value or Change of State, and synchronous with the clock.   5. Multiple logging or retrieval plans, called Schemes, can be configured to transfer data periodically or on event for various business, engineering, or research purposes. Each logging Scheme subsequently writes the data to its specific database file format or to a file.   6. OPC MESSENGER also has a Watch-Dog-Timer to insure data is not lost during a network failure or due to the loss of a network storage device. Data is logged to the secondary path on failure of the Watch-Dog-Timer.   7. The intervals at which OPC MESSENGER log files are closed are configurable for each Scheme.   8. The interval at which the directory for OPC MESSENGER log files is purged is configurable for each Scheme.   9. DDE formats supported include Microsoft formats and Advanced DDE.   10. OPC MESSENGER is especially suited for uploading time-stamped data from intelligent data acquisition and control systems.   11. OPC MESSENGER runs on Windows 2000™ and Windows NT™.   

   While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.