76 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 52, NO.
1, JANUARY/FEBRUARY 2016
Enhancing Traditional Process SCADA and
Historians for Industrial and Commercial Power
Systems With Energy (Via IEC 61850)
David C. Mazur, Member, IEEE, Rob A. Entzminger, Member, IEEE, and John A. Kay, Fellow, IEEE
Abstract—The coordination of large-scale distributed measure-
ment and control systems, such as supervisory control and data
acquisition (SCADA) and other process control system implemen-
tations, require reliable and robust networks that can connect
thousands of remote devices from multiple remote locations. Ad-
ditionally, many heavy industries have ever-increasing demands
for their infrastructure to handle more network services and
deliver a full spectrum of the control and monitoring of thousands
and even tens of thousands of points within their global business
operations. This paper will outline a novel method of providing a
convergent use of the International Electrotechnical Commission
61850 protocol within process control networks to provide a more
deterministic type of process control, monitoring, and energy
management. The benefits of the real-time archiving of process
values, process messages, the intelligent electronic device status,
and alarm data, along with process batch data, can be achieved in
an advancement of traditional historian-based systems. This new
approach provides traditional downtime reports and alarm sum-
maries for maintenance purposes and the added benefits of pro-
viding the opportunity for highly accurate and time-synchronized
energy consumption and energy balance data, along with effi-
ciency reports of various production or process operations.
Index Terms—Historical data trending, intelligent electronic
device (IED), International Electrotechnical Commission (IEC)
61850, Object Linking and Embedding Database (OLE DB),
process historian, supervisory control and data acquisition
(SCADA).
I. I NTRODUCTION
C OLLECTING large amounts of data is now less of a
challenge with current information technology and au-
tomation systems. However, it still remains a struggle to turn
all the data into actionable information. Many companies still
experience high levels of frustration sorting through all of these
Manuscript received January 27, 2014; revised September 24, 2014; accepted
November 28, 2014. Date of publication August 3, 2015; date of current version
January 18, 2016. Paper 2014-PSPC-0040.R1, presented at the 2014 IEEE
Industrial and Commercial Power Systems Technical Conference, Fort Worth,
TX, USA, May 20–23, and approved for publication in the IEEE T RANS -
ACTIONS ON I NDUSTRY A PPLICATIONS by the Power Systems Protection
Committee of the IEEE Industry Applications Society.
D. C. Mazur is with Rockwell Automation, Inc., Milwaukee, WI 53204 USA
(e-mail: dcmazur@ra.rockwell.com).
R. A. Entzminger is with Rockwell Automation, Inc., Lenexa, KS 66214
USA (e-mail: raentzminger@ra.rockwell.com).
J. A. Kay is with Medium Voltage Technologies, Rockwell Automation
Canada, Inc., Cambridge, ON N1R 5X1, Canada (e-mail: jakay@ra.rockwell.
com).
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TIA.2015.2463792
0093-9994 © 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
historical data, and sometimes, they still revert to writing down
when machines malfunction or to transferring data to spread-
sheets for review. For these data to make sense, strategically,
for any business, users must have access to both historical and
real-time data through a highly accurate and time-synchronized
referenced intelligent automation system. The benefits of the
real-time archiving of process values, process messages, the
intelligent electronic device (IED) status, and alarm data, along
with process batch data, can be now achieved using an advance-
ment of traditional historian-based systems.
Intelligent automation systems collect the information that
has the potential to refine and improve business results. For
example, production rates and/or production quality can be
monitored in a real-time environment to reveal the sections
of production that may be underperforming and deserve the
most attention. Machine or production flow characteristics may
be continuously refined and monitored to enhance production
flows, maximize specific machine outputs, establish overall
operational efficiency, and even determine appropriate main-
tenance schedules to prolong equipment life. With the ever-
present need to reduce costs, there are the added benefits
of providing the opportunity for highly accurate and time-
synchronized energy consumption and energy balance data,
along with efficiency reports for various production or process
operations.
II. I NDUSTRIAL AND C OMMERCIAL
P OWER S YSTEMS J USTIFICATION
Today, many industrial processes are controlled by a combi-
nation of systems working together (hopefully in sync) in order
to produce a target yield or product. Examples of these sys-
tems include continuous and discrete process control systems,
electrical protection, supervisory control and data acquisition
(SCADA), and a historian for archiving and reporting tools for
the trending of data.
Previous research and advancements in technology have cre-
ated a society where companies want to collect a large amount
of real-time data, sort these data, and, with the advent of the
discrete-event data, turn these into actionable information [1],
[2]. Now, there is a push to archive these discrete data so that
they can be trended at a later time and used for the modeling of
the overall process.
From an industrial manufacturing standpoint, electrical pro-
tection and SCADA data are very crucial in order to identify
MAZUR et al.: ENHANCING PROCESS SCADA AND HISTORIANS FOR POWER SYSTEMS WITH ENERGY
operating points, create predictive maintenance models, identify
load-shedding opportunities, and manage energy consumption
and root cause analysis. As the information age has evolved,
the technology used to transmit data from a protection sys-
tem to SCADA systems has also evolved. Power-system-based
and industrial-based electrical protection devices have evolved
over the past three decades from electromechanical-based
to microprocessor-based relays. With the advent of sophisti-
cated microprocessor-based relays, more advanced protection
schemes that correctly identify and clear faults in acceptable
time frames have been developed [3].
As microprocessor-based relay technology has evolved, com-
munication networks for electrical protection have also evolved
[4]. Electrical protection architectures have developed from
hardwired contacts to communication networks using serial
protocols such as Modbus. Serial communication has evolved
to communication protocols over the Transmission Control
Protocol (TCP)/IP stack such as Modbus TCP and DNP3
LAN/WAN, which then allowed substation devices to commu-
nicate in a peer-to-peer manner to share data.
In the past four years, research and application examples with
the International Electrotechnical Commission (IEC) 61850
standard have become more prevalent [2], [3], [5]–[7]. These
examples and applications show that an Ethernet-based stan-
dard such as IEC 61850 can be used for the protection, com-
mand and control, and SCADA gathering of data over the same
redundant wire pair [8]–[11]. As these “real time” data are
provided to the central controller or the SCADA master in
the system, graphics can be populated to alert engineers and
operations of the system status [3], [6]. Additionally, these data
can be used to make command and control decisions in an
industrial application [5].
Moreover, the data that come from IEDs via IEC 61850
come with an associated time stamp that is accurate to the
microsecond level [3], [8]. The time synchronization of automa-
tion controllers has also evolved in the past decade. Protocols
and standards such as the Global Positioning System, inter-
range instrumentation group time codes (IRIGs), the Network
Time Protocol, and the Precision Time Protocol have become
established in the industrial space [12]–[15]. Previous work
has shown that automation controllers can be synchronized to
the same timescale and accuracy of the electrical protection
network [16].
With all system components now time synchronized, the data
can become more meaningful as all time-stamped data, whether
the electrical or mechanical process is referencing to the same
reference in time or not. By creating a system that would allow
the aggregation of these time-synchronized data from different
sources, more process improvement gains can be realized.
The remainder of this paper describes how to provide time-
synchronized event data to a traditional industrial process
historian.
III. T RADITIONAL P ROCESS H ISTORIANS : P ROBLEMS
A traditional process historian system consists of three major
components, i.e., a data server, an interface node, and a histo-
rian repository, respectively. In most systems, there is a control
77
Fig. 1. Traditional process historian flow.
layer that consists of an industrial controller. A historian’s
contribution is mainly the storage of the event data in a format
that is highly recoverable and indexed on time. The historian
data are not relational and are highly scalable [17], [18].
Typically, the event time stamp is applied at the interface
node. Interface nodes collect, interrogate, and qualify the in-
formation provided by the data server [19]. If the data values
collected at the interface node exceed predefined deadband
thresholds, a time stamp is applied, and the data are trans-
ferred to the historian repository. If the data do not exceed the
threshold, the data point is disregarded and not archived. This
process is better known as exception testing and can be seen in
Fig. 1 [17], [18].
This procedure for collecting and time stamping data does
not work well for events that are time stamped at the source
device. In the aforementioned example, the event that is passed
to the interface node is value based, not time driven. After it
has been determined that an exception has occurred, a time
stamp is generated and applied to the event. For example,
if a process engineer is trying to log and store events from
IEDs, i.e., trips, alarms, etc., the time stamp of these events is
generated by the IED. Using value-based exception reporting
will not suffice in transferring meaningful time stamps from
the IED to the historian repository. Referring back to Fig. 1,
the controller does not provide a time stamp to the data server
but only provides a process value. For most manufacturing
environments, this schema is acceptable as a time-delay error
is within the poll rate of the data server.
IV. P LACING IED S IN P ROCESS SCADA S YSTEM
In an IED system with IEC 61850 communications, the event
drives both value and time-stamp changes in the data collection
system. Both the event data and the time stamp are created at
the IED and must travel together from the source of the event
to the repository to be meaningful. The previous two statements
are the root cause of the problem in attempting to store electrical
distribution values in a process control data historian. The block
diagram that describes the solution to this problem can be seen
in Fig. 2.
Fig. 2 shows the progression of data through the block
diagram system. Block 1 defines the physical IED. The IED(s)
is (are) connected to the gateway module via an Ethernet con-
nection. Additionally, the gateway module is connected to the
controller represented by the controller block. The time stamp
that is generated on the event by the IED is passed through the
gateway to the controller, as shown by the progression from
boxes 1–3.
78 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 52, NO. 1, JANUARY/FEBRUARY 2016

Fig. 2. Progression of data.

Fig. 3. Ladder logic.

Although the controller data table contains both the event

value and the IED time stamp, it is not inherently passed to the
historian repository. In order for an event with a historian tag to
persist, the configuration of a digital alarm (ALMD) instruction
associates the event to the point ID of the historian tag. A
historian point ID is a unique identifier for a tag in the historian
repository. When an alarm occurs, the following parameters are
known: the time stamp of the IED, the unique point ID, the time
stamp of the entering alarm, the value of the alarm, and the event
association ID. An example of this logic is shown in Fig. 3.
Fig. 4 shows the configuration of the ALMD instruction with
the associated IED time stamp (1) and point ID (2). It is impor-
tant to note that the severity is set to 200 (the default is 500) in
order to provide the control system a way to differentiate tags
as electrical distribution tags. The data type of the time stamp is
the long integer (LINT), which is a 64-bit representation of the
number of microseconds from January 1, 1970, which is also
known as the Unix Epoch.
When the alarm is triggered, a message is sent to the alarm and
events (A&E) data server, as depicted in Fig. 2. The data server Fig. 4. Alarm configuration.
then populates the condition event table in the A&E database
(dashed arrow). Fig. 5 shows an example of this table. The
condition event table shows InputValue, EventAssociationID,
Tag1Value (the IED time stamp), and Tag2Value (the point ID). Fig. 5. A&E table example.
Fig. 5 also shows the off/on and on/off transition of an alarm
event, which is represented by the EventAssociationIDs being In Fig. 2, the top path in block 4 represents the traditional
equal. data flow within the process historian system. The solution
MAZUR et al.: ENHANCING PROCESS SCADA AND HISTORIANS FOR POWER SYSTEMS WITH ENERGY
Fig. 6. GUI tool.
Fig. 7. Database query.
developed for this paper takes an alternative approach to pro-
viding data to the historian repository, as represented by the
lower path through the RACE SOE/Historian tool. This GUI
tool is shown in Fig. 6. The GUI program was written using
the .NET framework. The results workgroup represents the two
collections, i.e., the A&E records and the historian tags. Con-
nections to both the A&E database and the process historian are
defined in the Object Linking and Embedding Database (OLE
DB) connection strings.
Now that an event with point ID 297 has been captured in the
A&E database, the information, including the associated IED
time stamp, needs to persist to the historian tag. This is accom-
plished by the user with an insert query to the process historian.
After the insert is successful, an artifact record is written to an
additional table in the FT A&E database called SOEtoFTH.
Fig. 7 defines the query to display the information in the
SOEtoFTH table. The result of this query can be seen in Fig. 8.
79
Fig. 8. Result of the query.
Fig. 9. Historian time stamp.
Note that Active is the input state of the alarm instruction
(ALMD). Tag1Value is the time stamp from the IED, and
Tag2Value is the point ID of the historian tag; FTHTS is the
historian time stamp. FTHInsertTime is the time used in the
insert to the historian. FTHTS and FTHInsertTime can be up
to +/−15 μs as this is the highest resolution that this time-
stamp object can represent. Fig. 9 shows the complete run of
the GUI tool with the FTHTS column populated. The difference
between the IED time and the historian time for the first two
events are 2 and 7 μs, respectively, which are well within the
error bars of the defined system.
This tool, much similar to the hardware, is multithreaded so
that it does not burden the machine upon which it is installed.
The application has two modes auto and manual, i.e., the A&E
that have occurred that have a severity of 200 is collected. Then,
if in the auto mode, the items are processed and passed off to a
separate thread that handles the insertion into the historian and
the logging of each inserted event. If in the manual mode, the
operator has the choice to process the events. If the operator
wants to process the events, the same thread is used to process
the events into the historian. After the events are processed and
are in the auto mode, the application will sleep for a default of
10 min, and then, it will reprocess the events that have happened
in the last 10 min. The logic flowchart is shown in Fig. 10.
80 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 52, NO. 1, JANUARY/FEBRUARY 2016
Fig. 10. Software flowchart.
Fig. 11. Device data flow.
Fig. 11 shows the flow of information created by the de-
velopment of the software discussed in this paper. As shown,
the information moves from the IEDs in the field through the
gateway module to the controller. From the controller, these
values can be then inserted into the historian and are trended
in reports on view screens for visualization and reporting.
Fig. 12. Calculation values.
V. T ESTING AND VALIDATION OF T OOL
The enterprise management tool (the historian), which was
used to collect real-time data and events, does not accept for-
eign time stamps due to the way traditional process historians
function. In order to test the functionality of this software tool,
2000 alarms were created and tested on IEDs in a system.
As long as a time stamp inserted into the historian was within
15 μs of the IED published time, the tool was within tolerance,
and no further error propagated throughout the system. The
±15-μs specification results from the time-stamp tolerance
within the historian [17]. The time stamps that were compared
are shown in Fig. 12.
The FTHTS time stamp corresponds to the time stamp
published to the process historian, and the FTHInsert time
stamp corresponds to the time stamp published by the IED
network. As long as the time difference between the FTHTS
and FTHInsert time stamps is less than or equal to 15 μs, the
MAZUR et al.: ENHANCING PROCESS SCADA AND HISTORIANS FOR POWER SYSTEMS WITH ENERGY 81

TABLE I
R AW D ATA F ROM THE T RIAL

Total
Time Error [us] 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Number of results 172 176 137 116 97 164 170 152 151 161 115 112 92 85 63 37 2000

Fig. 13. Time variance results.

Fig. 15. Ground current example.

Fig. 14. Relay configuration simulator software.

tool has no added delay outside the tolerance of current process
historian systems. The results of the testing can be seen in
Table I and Fig. 13.
Table I and Fig. 13 also show that, after 2000 test trials, all
resulting data points are within the error bars of 15 μs. The
data suggest that 74.7% of the results are within 9 μs of each
other, which is well within the 15-μs tolerance provided by the
historian used to store real-time data and events.
In addition to the testing of the time discrepancy, this test
also checked whether fundamental parameters could be trended
against electrical faults in the system. To check this, a second
vendor’s IED was tested as it had a built-in simulator to test
the relay functionality and trip settings. This software can be
seen in Fig. 14. By adjusting the slider bars in the simulator, the
currents, voltages, and harmonics of the corresponding wave-
forms were adjusted. The relay tripped when the set thresholds
of these parameters were exceeded, thus triggering an alarm to
be logged by the controller and the historian system.
The information for analog parameters can be also logged
and trended in the historian, as shown in Fig. 15. In this figure,
the lowest trace represents the trip status of the relay, which,
in this example, was set to trip on a ground current greater
than 60 A (the third trace down), regardless of the currents on
phases A and B (first and second traces). As shown in this figure,
the lowest trace is asserted any time the process parameter, i.e.,
Fig. 16. Analog waveform trending.
the ground current (the third trace), exceeds 60 A and resets
when the relay resets. In this example, this occurs when the
ground current is less than 60 A.
Analog waveforms can be depicted if the IED manufacturer
allows this information to be sent over the IEC 61850 standard.
These waveforms can be seen in Fig. 16. Fig. 16 shows the
waveforms zoomed to approximately eight electrical cycles.
VI. C ONCLUSION
In conclusion, the time stamping of event data can be placed
in a process historian, although the act of event detection is a
distributed system component. This enables reporting and key
performance indicator calculations based on energy data and
manufacturing processes variables.
The impact of manufacturing intelligence with power system
data will yield relationships that, to date, have not been avail-
able in typical reporting environments.
IEDs are critical to the management and control of industrial
and commercial power systems, and they can provide value in
an environment with process historians.
Highly accurate and time-synchronized energy consumption
and energy balance data can be utilized to determine the
overall process efficiency for various production or process
82 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 52, NO. 1, JANUARY/FEBRUARY 2016
operations. The data from trip and alarm events can be de-
terministically used to establish maintenance schedules to
prolong equipment life. Additionally, machine or production
flow characteristics can be continuously refined and monitored
to enhance production rates and maximize specific machine
capabilities.
Understanding the resolution of time accuracy is critical when
doing comparisons and aggregating data from various pieces
of a process system. For example, if the data are being logged
with an accuracy of 15 μs, then the system must have time syn-
chronization to that degree. A time stamp taken as close to the
electrical event as possible will yield better correlation of the
root cause when used in a wider view of analysis. These high-
resolution data can be passed to a process historian, which, in
turn, can be reported via web clients, as described in this paper.
This paper has been conducted due to the push of
communications-based protection and SCADA protocols and
standards. The evolution of hardwired contacts to serial com-
munications to Ethernet-based communications has led to
the ability to pass large amounts of time-synchronized data
throughout industrial and commercial power systems. Recently,
standards such as DNP3 LAN/WAN and IEC 61850 have
been able provide a time resolution to the millisecond and
microsecond, respectively.
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David C. Mazur (S’07–M’12) received the
B.S.E.E. (summa cum laude) and M.S.E.E. degrees
and the Ph.D. degree in mining engineering from
Virginia Polytechnic Institute and State University,
Blacksburg, VA, USA, in 2011, 2012, and September
2013, respectively. His M.S.E.E. studies were on the
rotor angle measurement of synchronous machines,
and his Ph.D. studies were on the automation
and control of the International Electrotechnical
Commission 61850 standard.
He is a Global Technical Consultant with Rock-
well Automation, Inc., Milwaukee, WI, USA, currently focusing on supervi-
sory control and data acquisition (SCADA) communications and substation
automation. His experience includes the development of regenerative variable-
frequency drive technology. He has also helped develop the technology for
time-synchronized continuous casters for the steel industry. He also ran a
project that aimed to assess the power quality of Asia-Pacific and European
countries.
Dr. Mazur is an active member of the IEEE Industry Applications Society
(IAS) and serves as the Working Group Chair for the Communication-Based
Protection of Industrial Applications Working Group. He also serves as a
member of the Mining Industry Committee and the Industrial and Commercial
Power Systems Committee (I&CPS) of the IAS. He is also an active voting
member of the IEEE Standards Association.
Rob A. Entzminger (M’14) received the B.S.E.E.
degree from the University of Wisconsin–Milwaukee,
Milwaukee, WI, USA, in 1981.
He is a Commercial Engineer with the Infor-
mation Software Team, Rockwell Automation, Inc.,
Lenexa, KS, USA.
Mr. Entzminger is a member of the IEEE Industry
Applications Society. He is a Registered Professional
Engineer in the State of Wisconsin.
John A. Kay (M’94–SM’98–F’12) received the
B.S. degree in electrical/electronic engineering tech-
nology from Conestoga College, Kitchener, ON,
Canada, in 1977.
He is currently with Medium Voltage Technolo-
gies, Rockwell Automation Canada, Inc., Cambridge,
ON, Canada, as a Senior Product Specialist. He is
the author or coauthor of a wide variety of award-
winning technical papers and other technical articles
and manuals related to medium-voltage electrical
control and protection systems, arc-resistant equip-
ment, and infrared technologies. Several of his papers have been published in
the IEEE T RANSACTIONS ON I NDUSTRY A PPLICATIONS and IEEE Industry
Applications Magazine.
Mr. Kay is a member of the IEEE Industry Applications Society (IAS) and
is actively involved with its Pulp and Paper Industry Committee, serving on its
main executive board, on the conference committee, and on several subcommit-
tees. He is a member of several other technical groups and participated on the
local planning committees for the 2011 IEEE Petroleum and Chemical Industry
Conference and the 2002 IEEE Pulp and Paper Industry Conference. He was
the recipient of several IEEE Paper Awards and the Meritorious Service Award
from the IAS Pulp and Paper Industry Committee. He is a Certified Engineering
Technologist in the Province of Ontario, Canada.