ABSTRACT

Automation generally refers to the science and technology of process control and includes the
control of chemical and petrochemical plants, Oil refineries, iron and steel plant, Power plants,
cement mills, Paper pulp and paper mills water and waste water treatment plants and many like
all this. The basic objective of automation is identifying the information flow and manipulates
the material and energy flow as given process in a desired way. PLC & SCADA plays an
important role in automating industrial system. This work shows how automation is carried &
implemented with software interface, PLC & Micro-SCADA in C.G. Ltd. Nashik, Maharashtra,
India for CVT autoclave. The whole process is of 121 hours consisting of number of cycles,
which is automated using PLC & SCADA for all process parameters.
An industrial PLC and SCADA system is to for the development of automatic control of
machinery.

PLC and SCADA system are methods to achieve Automation. Automation industry has fast
growth potential in a country like India, which has a large industry base.

This report focuses on brief concepts of PLC and SCADA system, their development, and also
mentions possible applications of these systems. Almost every industry that has some electrical
machinery may need Automation Services. Attention is also paid to the security issues which
have arisen with time.

[1]
 CHAPTER - 1

AUTOMATION

1.1 INTRODUCTION TO AUTOMATION

Automation is the use of control systems and information technologies to reduce the need for
human work in the production of goods and services. In the scope of industrialization,
automation is a step beyond mechanization. Whereas mechanization provided human operators
with machinery to assist them with the muscular requirements of work, automation greatly
decreases the need for human sensory and mental requirements as well. Automation plays an
increasingly important role in the world economy and in daily experience.

1.2 AUTOMATION IMPACTS

 It increases productivity and reduces cost.

 Replacing human operators in tasks that involve hard physical or monotonous work.
 Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes,
nuclear facilities, underwater, etc.)
 Performing tasks that are beyond human capabilities of size, weight, speed, endurance,
etc.
 Automation is often applied primarily to increase quality in the manufacturing process,
where automation can increase quality substantially.
 Automation reduces power consumption and reduces man power requirement.
 Automation improves production quality.
 Automation provides safer working conditions.

[2]
 CHAPTER - 2

PROGRAMMABLE LOGIC CONTROLLER (PLC)

2.1 INTRODUCTION TO PLC

A programmable logic controller (PLC) or programmable controller is a digital computer

used for automation of electromechanical processes, such as control of machinery on factory
assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and
machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact. Programs to control machine operation are typically stored in battery-
backed or non-volatile memory. A PLC is an example of a hard real time system since output
results must be produced in response to input conditions within a bounded time, otherwise
unintended operation will result.

Figure 2.1 PLC

[3]
2.2 INSIDE A PLC

The Central Processing Unit (CPU) contains an internal program that tells the PLC how to
perform the following functions:

 Execute the Control Instructions contained in the User's Programs. This program is
stored in "nonvolatile" memory, meaning that the program will not be lost if power is
removed
 Communicate with other devices, which can include I/O Devices, Programming
Devices, Networks, and even other PLCs.
 Perform Housekeeping activities such as Communications, Internal Diagnostics, etc.

Figure 2.2 Major component of common plc

[4]
 Figure 2.3 Typical PLC control panel

THE CPU

The microprocessor or processor module is the brain of a PLC system. It consists of the
microprocessor, memory integrated circuits, and circuits necessary to store and retrieve
information from memory. It also includes communications ports to other peripherals, other
PLC's or programming terminals. Today's processors vary widely in their capabilities to control
real world devices. Some control as few as 6 inputs and outputs (I/O) and others 40,000 or more.
One processor can control more than one process or manufacturing line. Processors are often
linked together in order to provide continuity throughout the process. The number of inputs and
outputs PLCs can control are limited by the overall capacity of the PLC system hardware and
memory capabilities. The job of the processor is to monitor status or state of input devices, scan
and solve the logic of a user program, and control on or off state of output devices.

RAM

RAM or Random Access Memory is a volatile memory that would lose its information if power
were removed. This is why some processor units incorporate a battery back-up. The type of
RAM normally used is CMOS or Complementary Metal Oxide Semiconductor.

[5]
ROM

ROM or Read Only Memory is a non-volatile type of memory. This means you don't need an
external power source to keep information. In this type of memory, information can be read, but
not changed. For this reason the manufacture sometimes calls this firmware. there for the.

EEPROM

EEPROM or Electrically Erasable Programmable Read Only Memory is usually an add-on

memory module that is used to back up the main program in CMOS RAM of the processor. In
many cases, the processor can be programmed to load the EEPOM's program to RAM if RAM is
lost or corrupted.

INPUT MODULE

There are many types of input modules to choose from. The type of input module used is
dependent upon what real world input to the PLC is desired. Some examples of inputs are limit
switches, electric eyes, and pushbuttons. DC inputs, such as thumbwheel switches, can be used
to enter integer values to be manipulated by the PLC. DC input cards are used for this
application. Since most industrial power systems are inherently noisy, electrical isolation is
provided between the input and the processor. Electromagnetic interference (EMI) and Radio
Frequency Interference (RFI) can cause severe problems in most solid state control systems. The
component used most often to provide electrical isolation within I/O cards is called an optical
isolator or optocoupler. The wiring of an input is not complex. The object is to get a voltage at a
particular point on the card. Typically there are 8 to 32 input points on any one input module.
Each point will be assigned a unique address by the processor. Analog input modules are special
input cards that use analog to digital conversion (A to D) to sense variables such as temperature,
speed, pressure, and position. The external device normally is connected to a controller
(transducer) producing an electrical signal the analog input card can interpret. This signal is
usually 4 to 20 Ma or a 0 to 10 volt signal.

[6]
OUTPUT MODULE

Output modules can be for used for ac or dc devices such as solenoids, relays, contractors, pilot
lamps, and LED readouts. Output cards usually have from 6 to 32 output points on a single
module. The output device within the card provides the connection from the user power supply
to the load. Usually silicon controlled rectifiers (SCR), triac, or dry contact relays are use for this
purpose. Individual outputs are rated most often at 2 to 3 amperes. Output cards, like input cards
have electrical isolation between the load being connected and the PLC. Analog output cards are
a special type of output modules that use digital to analog conversion (D to A). The analog
output module can take a value stored in a 12 bit file and convert it to an analog signal. Normally
this signal is 0 -10 volts dc or 4 to 20 Ma. This analog signal is often used in equipment such as
motor operated valves and pneumatic position control devices.

[7]
 CHAPTER - 3

PLC OPERATION

3.1 INTRODUCION OF PLC OPERATION

There are four basic steps in the operation of all PLCs: which continually take place in a
repeating loop.

 Input Scan
 Program Scan
 Output Scan
 Housekeeping
Input Scan: Detects the state of all input devices that are connected to the PLC
Program Scan: Executes the user created program logic.

Figure 3.1 Block diagram of control system

[8]
 Figure 3.2 PLC operation cycle

Output Scan: Energizes or de-energize all output devices that are connected to the PLC.

Housekeeping: This step includes communications with programming terminals, internal

diagnostics etc...

CHECK INPUT STATUS: First the PLC takes a look at each input to determine if it is on or off.
In other words, is the sensor connected to the first input on? Then the second input? Then the
third and so on…. It records this data into its memory to be used during the next step.

EXECUTE PROGRAM: Next the PLC executes your program one instruction at a time. Maybe
the program says that if the first input was on then it should turn on the first output. Since it
already knows which inputs are on/off from the previous step it will be able to decide whether
the first output should be turned on based on the state of the first input. It will store the execution
results for use later during the next step.

[9]
UPDATE OUTPUT STATUS: Finally the PLC updates the status of the outputs. It updates the
outputs based on which inputs were on during the first step and the results of executing your
program during the second step. Based on the example in step 2 it would now turn on the first
output because the first input was on and your program said to turn on the first output when this
condition is true.

After the third step the PLC goes back to step one and repeats the steps continuously. One scan
time is defined as the time it takes to execute the 3 steps listed above.

3.2 COMMUNICATIONS

There are several methods to communicate between a PLC and a programmer or even between
two PLCs. Communications between a PLC and a programmer (PC or Hand held) are provided
by the makers and you only have to plug in a cable from your PC to the programming port on the
PLC. This communication can be RS232; RS485 or TTY. Communications between two PLCs
can be carried out by dedicated links supplied/programmed by the makers (RS232 etc) or via
outputs from one PLC to the inputs on another PLC. This direct link method of communication
can be as simple as, if an output on the first PLC is on then the corresponding input on the
second PLC will be on and then this input is used within the program on the second PLC.

If a word of input/outputs (16 bits) are used then numerical data can be transferred from one PLC
to the other (refer back to the section on numbering systems). There are many other methods of
communication between PLCs and also from PLC to PC. Refer to the manuals supplied with the
PLC that you are using for full details on communications.

[10]
 CHAPTER - 4

PLC PROGRAMMING

4.1 VARIOUS LANGUAGES ARE USED FOR PROGRAMMING OF PLCS:

LADDER DIAGRAM (LD): Ladder diagram is a graphic programming language derived from
the circuit diagram of directly wired relay controls. The ladder diagram contains contact rails to
the left and the right of the diagram; these contact rails are connected to switching elements
(normally open / normally closed contacts) via current paths and coil elements.

Figure 4.1 Ladder diagram of PLC

FUNCTION BLOCK DIAGRAM (FBD)

In the function block diagram, the functions and function blocks are represented graphically and
interconnected into networks. The function block diagram originates from the logic diagram for
the design of electronic circuits.

Figure 4.2 Logical operation in PLC

[11]
SEQUENTIAL FUNCTION CHART (SFC)

The sequential function chart is a language resource for the structuring of sequence-oriented
control programs. The elements of the sequential function chart are steps, transitions, alternative
and parallel branching. Each step represents a processing status of a control program, which is
active or inactive. A step consists of actions which, identical to the transitions, are formulated in
the IEC 1131-3 languages. Actions themselves can again contain sequence structures. This
feature permits the hierarchical structure of a control program. The sequential function chart is
therefore an excellent tool for the design and structuring of control programs.

INSTRUCTION LIST (IL)

Statement list is a textual assembler-type language characterized by a simple machine model

(processor with only one register). Instruction list is formulated from control instructions
consisting of an operator and an operand.
LD Part_TypeA
OR Part_TypeB
AND Part_present
AND Drill_ok
ST Sleeve_in

With regard to language philosophy, the ladder diagram, the function block diagram and
instruction list have been defined in the way they are used in today’s PLC technology. They are
however limited to basic functions as far as their elements are concerned. This separates them
essentially from the company dialects used today. The competitiveness of these languages is
maintained due to the use of functions and function blocks.

STRUCTURED TEXT (ST)

Structured text is high-level language based on Pascal, which consists of expressions and
instructions. A Instructions can be defined in the main as: Selection instructions such as
IF...THEN...ELSE etc., repetition instructions such as FOR, WHILE etc. and function block
invocations.
Sleeve_in:= (Part_TypeA OR Fig. B5.7: Part_TypeB) AND Part_present AND Drill_ok;

[12]
Structured text enables the formulation of numerous applications, beyond pure function
technology, such as algorithmic problems (high order control algorithms etc.) and data handling
(data analysis, processing of complex data structures etc.).

LADDER LOGIC
Ladder Logic or Ladder Diagrams is the most common programming language used to program
a PLC.

Figure 4.3 Block diagram of single ladder

Ladder logic was one of the first programming approaches used in PLCs because it borrowed
heavily from the Relay Diagrams that plant electricians already knew.
The symbols used in Relay Ladder Logic consist of a power rail to the left, a second power rail
to the right, and individual circuits that connect the left power rail to the right. The logic of each
circuit (or rung) is solved from left to right. The symbols of these diagrams look like a ladder -
with two side rails and circuits that resemble rungs on a ladder.
The picture above has a single circuit or "rung" of ladder.

 If Input1 is ON (or true) - power (logic) completes the circuit from the left rail to the right
rail – and Output1 turns ON (or true).
 If Output1 is OFF (or false) - then the circuit is not completed and logic does not flow to
the right – and Output 1 is OFF.
There are many logic symbols available in Ladder Logic - including Timers, Counters, Math,
and Data Moves-such that any logical condition or control loop can be represented in Ladder
Logic. With just a handful of basic symbols - a Normally Open Contact, Normally Closed
Contact, Normally Open Coil, Normally Closed
Coil, Timer, Counter - most logical conditions can be represented.

[13]
CONTACTS AND COILS

With just the Normally Open Contact and Normally Open Coil - a surprising array of basic
logical conditions can be represented.

Normally Open Contact. This can be used to represent any input to the control logic - a
switch or sensor, a contact from an output, or an internal output.
When "solved" the referenced input is examined for an ON (logical 1) condition. If it is ON, the
contact will close and allow power (logic) to flow from left to right. If the status is OFF (logical
0), the contact is Open, power (logic) will NOT flow from left to right.

Normally Open Coil. This can be used to represent any discrete output from the control
logic. When "solved" if the logic to the left of the coil is TRUE, the referenced output is ON
(logical 1).

SOLVING A SINGLE RUNG

Figure 4.4 Single Rung

Suppose a switch is wired to Input1, and a light bulb is wired through Output1 in such a way that
the light is OFF when Output1 is OFF, and ON when Output1 is ON.
When Input1 is OFF (logical 0) the contact remains open and power cannot flow from left to
right. Therefore, Output1 remains OFF (logical 0).
When Input1 is ON (logical 1) then the contact closes, power flows from left to right, and
Output1 becomes ON (the light turns ON).

[14]
THE AND RUNG
The AND is a basic fundamental logic condition that is easy to directly represent in Ladder
Logic.

Figure 4.5 Block diagram of AND operation

Suppose a switch is wired to Switch1, a second switch is wired to Switch2, and a light bulb is
wired through Light1 in such a way that the light is OFF when Light1 is OFF, and ON when
Light1 is ON.
In order for Light1 to turn ON, Switch1 must be ON, AND Switch2 must be ON.
If Switch1 is OFF, power (logic) flow from the left rail, but stops at Switch1. Light1 will be OFF
regardless of the state of Switch2.
If Switch1 is ON, power makes it to Switch2. If Switch2 is OFF, power cannot flow any further
to the right, and Light1 is OFF.
If Switch1 is ON, AND Switch2 is ON - power flows to Light1 solving its state to ON.

THE OR RUNG
The OR is a logical condition that is easy to represent in Ladder Logic.

Figure 4.6 Block diagram of OR operation

[15]
Suppose a switch is wired to Switch1, a second switch is wired to Switch2, and a light bulb is
wired through Light1 in such a way that the light is OFF when Light1 is OFF, and ON when
Light1 is ON. In this instance, we want to the light to turn ON if either Switch1 OR Switch2 is
ON.
If Switch1 is ON - power flows to Light1 turning it ON.
If Switch2 is ON - power flows through the Switch2 contact, and up the rail to Light1 - turning it
ON.
If Switch1 AND Switch 2 are ON - Light1 is ON.
The only way Light1 is OFF is if Switch1 AND Switch2 are OFF.
* Another set of basic contacts and coils that can be used in Ladder Logic are the Normally
Closed Contact and the Normally Closed Coil. These work just like their normally open
counterparts - only in the opposite.

When "solved" the referenced input is examined for an OFF condition. If the status is OFF
(logical 0) power (logic) will flow from left to right. If the status is ON, power will not flow.

When "solved" if the coil is a logical 0, power will be turned on to the device. If logical 1,
power will be OFF.

TIMERS AND COUNTERS

Many times we will want to take action in a control program based on more than the states of
discrete inputs and outputs. Sometimes, we will want to turn something on after a delay, or count
the number of times a switch is hit. To do these simple tasks, we will need Timers & Counters.
Simple Timers (TIM)
A timer is simply a control block that takes an input and changes an output based on time. There
are two basic timer types we will deal with initially (there are other advanced timers, but we will
start with the basics first) - On-Delay Timer and the Off-Delay Timer.
On-Delay Timer
This timer takes an input, waits a specific amount of time, then turns ON an output (or allows
logic to flow after the delay).

[16]
Off-Delay Timer
this timer takes turns ON an output (or allows logic to flow) and keeps that output ON until the
set amount of time has passed, then turns it OFF (hence off-delay)
Simple Counter (CNT)
A counter simply counts the number of events that occur on an input. There are two basic types
of counters - Up counter and a Down counter.
Up Counter
As its name implies, whenever a triggering event occurs, an up counter increments
the counter.
Down Counter
whenever a triggering event occurs, a down counter decrements the counter.

Figure 4.7 Block diagram of time counter operation

[17]
4.2 EXAMPLES OF PLC PROGRAMMING SOFTWARE:

 Allen-Bradley – Rockwell Software RSLogix500

 Modicon - Modsoft

 Omron - Syswin

 GE-Fanuc Series 6 – LogicMaster6

 Square D- PowerLogic

 Texas Instruments – Simatic

[18]
 CHAPTER - 5

ADVANTAGES, DISADVANTAGES, APPLICATIONS AND

APPLICATIONS EXAMPLES OF PLC

5.1 ADVANTAGES OF PLC

PLCs not only are capable of performing the same tasks as hard-wired control, but are also
capable of many more complex applications. In addition, the PLC program and electronic
communication lines replace much of the interconnecting wires required by hard-wired control.
Therefore, hard-wiring, though still required to connect field devices, is less intensive. This also
makes correcting errors and modifying the application easier.

Some of the additional advantages of PLCs are as follows:

 Smaller physical size than hard-wire solutions

 Easier and faster to make changes.
 PLCs have integrated diagnostics and override functions.
 Diagnostics are centrally available.
 Applications can be immediately documented.
 Applications can be duplicated faster and less expensively.

5.2 DISADVANTAGES OF PLC

 When a problem occurs, hold-up time is indefinite, usually long.

 There are limitations of working of PLCs under high temperature, vibration conditions.
 Some PLCs turns on when power is restored and may cause any accident.

[19]
5.3 AREAS OF APPLICATION

 Manufacturing / Machining
 Food / Beverage
 Metals
 Power
 Mining
 Petrochemical / Chemical

5.4 PLC APPLICATION EXAMPLE:

Automation using a plc

PLCs are electronic devices that work on the basic principle of logic gates. It was a major
leap from sequencing automation with rotating cams or with series of electrical relay
switches, to using microprocessor based PLC sequencers. With microprocessors, the
sequencers could be programmed to follow different sequences under different conditions.
The physical structure of a PLC is as important as a feature as its computerized inwards. The
central component, the CPU, contains the digital computer and plugs into a bus or a rack.

Figure 5.1 Automated car parking system

[20]
Other PLC modules can be plugged into the same bus. Optional interface modules are available
for just about any type of sensor or actuator.
The PLC user buys only the modules needed, and thus avoids having to worry about
compatibility between sensors, actuators and the PLC. Most PLCs offer communication modules
now, so that the PLC can exchange data with at least other PLCs of the same make.

Automated parking is a method of automatically parking and retrieving cars typically using a
computerized system of lifts and carriers. As the system removes the need for driveways and
ramps, the floor area and the volume of the parking station itself can be more efficiency used.

For the driver, the process is very simple. They park their car at an entrance point then leave the
vehicle. From there, the car is automatically moved through the parking system. It's returned to
the driver in the same fashion using a signaling device (similar to a credit card) or for a public
car park a ticket and payment system in a designated waiting zone.
Automated parking systems can be designed to fit above or below ground, allowing for flexible
usage of land space; this means the footprint can be reduced to one-third of the land required by
conventional car parking solutions. Cost-effective on a number of fronts, automated parking also
offers significantly improved service to the customer.

Figure 5.2 Automated car parking system

[21]
These automated car parking systems are suitable for installation in basements, open floors or
open spaces outside commercial buildings, residential buildings, shopping malls, and other
public places. Such multi-level automated car parking systems have been installed all around the
world, especially in Europe, Korea, Japan and some other parts of South-East Asia.
There is an overwhelming need for these systems because of increasing traffic and non-
availability of adequate parking spaces, especially in urban cities. The most unique feature of
such systems is that they increase the parking space available on the ground by more than 30%,
depending upon the kind of system installed and the contours of the space available.
Multi-level parking systems require careful planning and assessment of the space available,
traffic flows, and the capacity utilization within that space. These systems can be integrated
within concrete (RCC) structures.

[22]
 CHAPTER - 6

SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA)

6.1 INTRODUCTION TO SCADA

 SCADA stands for “Supervisory Control and Data Acquisition”. SCADA is a type of
process control system architecture that uses computers, networked data communications
and graphical Human Machine Interfaces (HMIs) to enable a high-level process
supervisory management and control.
 SCADA systems communicate with other devices such as programmable logic
controllers (PLCs) and PID controllers to interact with industrial process plant and
equipment.
 SCADA systems form a large part of control systems engineering.
 SCADA systems gather pieces of information and data from a process which are
analyzed in real-time (the “DA” in SCADA).
 It records and logs the data, as well as representing the collected data on various HMIs.
This enables process control operators to supervise (the “S” in SCADA) what is going on
in the field, even from a distant location. It also enables operators to control (the “C” in
SCADA) these process by interacting with the HMI.

Figure 6.1 Generic SCADA system

[23]
 SCADA systems are essential to a wide range of industries, and are broadly used for the
controlling and monitoring of a process. SCADA systems are prominently used as they
have the power to control, monitor, and transmit data in a smart and seamless way. In
today’s data-driven world, we are always looking for ways to increase automation and
make smarter decisions through the proper use of data – and SCADA systems are a great
way of achieving this.
 SCADA systems can be run virtually, that allows the operator to keep a track of the entire
process from his place or control room. Time can be saved by using SCADA efficiently.
One such excellent example is, SCADA systems are used extensively in the Oil and Gas
sector. Large pipelines will be used to transfer oil and chemicals inside the manufacturing
unit.
 Hence, safety plays a crucial role, such that there should not be any leakage along the
pipeline. In case, if some leakage occurs, a SCADA system is used to identify the
leakage. It infers the information, transmits it to the system, displays the information on
the computer screen and also gives an alert to the operator.

Figure 6.2 SCADA Architecture

[24]
  Generic SCADA systems contain both hardware and software components. The computer
used for analysis should be loaded with SCADA software. The hardware component
receives the input data and feds it into the system for further analysis. SCADA system
contains a hard disk, which records and stores the data into a file, after which it is printed
as when needed by the human operator. SCADA systems are used in various industries
and manufacturing units like Energy, Food and Beverage, Oil and Gas, Power, Water,
and Waste Management units and many more.

A SCADA System usually consists of the following Subsystems:

 A Human-Machine Interface (HMI) is the apparatus which presents process data to a

human operator, and through this, the human operator monitors and controls the process.
 A supervisory (computer) system, gathering (acquiring) data on the process and sending
commands (control) to the process.
 Remote Terminal Units (RTU) connecting to sensors in the process, converting sensor
signals to digital data and sending digital data to the supervisory system.
 Programmable Logic Controller (PLC) used as field devices because they are more
economical, versatile, flexible, and configurable than special-purpose RTUs.
 Communication infrastructure connecting the supervisory system to the Remote Terminal
Units.

[25]
 CHAPTER - 7

SCADA OPREATION

7.1 OPREATIONS OF SCADA SYSTEM

These functions are performed by sensors, RTUs, controller, communication network. The
sensors are used to collect the important information and RTUs are used to send this information
to controller and display the status of the system. According to the status of the system, the user
can give command to other system components. This operation is done by the communication
network.

 Monitoring/Control: SCADA systems continuously monitor the physical parameters.

The SCADA system uses different switches to operate each device and displays the status
at the control area. Any part of the process can be turned ON/OFF from the control
station using these switches. SCADA system is implemented to work automatically
without human intervention but at critical situations it is handled by man power.
 Measure: It measures the parameter for processing.
 Data Acquisition: It acquires data from RTU, data loggers, Real time system consists of
thousand of components and sensors. It is very important to know the status of particular
components and sensors. For example, some sensors measure the water flow from the
reservoir to water tank and some sensors measure the value pressure as the water is
release from the reservoir.
 Data Communication: It helps to communicate and transmit a large amount of data
between MTU and RTU units. The SCADA system uses wired network to communicate
between user and devices. The real time applications use lot of sensors and components
which should be control remotely. The SCADA system uses internet communications.
All information is transmitted through internet using specific protocols. Sensor and relays
are not able to communicate with the network protocols so RTUs used to communicate
sensors and network interface.

 Automation: It helps for automatic transmission and functionality.

[26]
 Information/Data presentation: The normal circuit networks have some indicators
which can be visible to control but in the real time SCADA system, there are thousand of
sensors and alarm which are impossible to be handled simultaneously. The SCADA
system uses human machine interface (HMI) to provide all of the information gathered
from the various sensors.

 Human machine interface: The SCADA system uses human machine interface. The
information is displayed and monitored to be processed by the human. HMI provides the
access of multiple control units which can be PLCs and RTUs. The HMI provides the
graphical presentation of the system. For example, it provides the graphical picture of the
pump connected to the tank. The user can see the flow of the water and pressure of the
water. The important part of the HMI is an alarm system which is activated according to
the predefined values.

Figure 7.1 Water tank level Alarm

For example: The tank water level alarm is set 60% and 70% values. If the water level
reaches above 60% the alarm gives normal warning and if the water level reach above
70% the alarm gives critical warning.

[27]
7.2 HARDWARE AND SOFTWARE OF SCADA AND COMPONENTS

The SCADA systems consist of hardware units and software units. SCADA applications are run
using a server. Desktop computers and screens act as an HMI which are connected to the server.
The major components of a SCADA system include:

 Master Terminal Unit (MTU)

 Remote Terminal Unit (RTU)
 Communication Network

Figure 7.2 Functional Units of SCADA

Master Terminal Unit (MTU)

MTU is the core of the SCADA system. It comprises a computer, PLC and a network server that
helps MTU to communicate with the RTUs. MTU begins communication, collects and saves
data, helps to interface with operators and to communicate data to other systems.

[28]
Remote Terminal Unit (RTU)
Being employed in the field sites, each Remote Terminal Unit (RTU) are connected with sensors
and actuators. RTU is used to collect information from these sensors and further sends the data to
MTU. RTUs have the storage capacity facility. So, it stores the data and transmits the data when
MTU sends the corresponding command. Recently developed units are employed with
sophisticated systems, that utilizes PLCs as RTUs. This helps for direct transfer and control of
data without any signal from MTU.

Figure 7.3 Remote terminal unit

Communication Network
In general, network means connection. When you tell a communication network, it is defined as
a link between RTU in the field to MTU in the central location. The bidirectional wired or
wireless communication channel is used for the networking purpose. Various other
communication mediums like fiber optic cables, twisted pair cables, etc. are also used.

[29]
SCADA SOFTWARE
As discussed earlier, SCADA software plays a significant role in the whole process analysis.
There are several big manufacturing companies who work exclusively on SCADA software.
There are many factors to be looked upon before the SCADA software is selected and
implemented. To mention a few,

 The lifespan of the Software: Since you are going to invest a lot for procuring the
software, it is always better to check if the software would last between 5 to 10 years
down the lane.

 Request for Information: It is a business term used to specify details about vendors and
suppliers. If you buy software from a particular vendor, he/she should be able to give you
technical support whenever required.

 Historian Software: The term historian means, the software should save data with
timestamps, that can be used for future reference. So, your software should be proficient
of handling the data from the field and logging the same.

 SCADA technology: As we all know, technology is growing rapidly so as to meet with

our needs. When you mean technology, it does not imply that always you need to use the
latest technology that pops up in the market. Rather, you should choose a technology that
can stay stable and secure for a longer time.

 Alarm Supervision and Management: Almost all SCADA systems have an alarming
feature that comes along with software developed. Configuration of alarm is important.
There are two types of alarm system namely system defined alarm managed by the
system by itself and user-defined alarm which is managed by the user.

[30]
Let us have a look into software developed by big players in the market.
 Citect SCADA – Schneider Electric:
A compact, flexible and reliable SCADA software developed by Schneider

Electric. The latest product released by them is Vijeo Citect (version7.10) Citect

SCADA is still one of the commonly used SCADA technologies and you certainly

need to learn about this platform as a SCADA developer. It has actually become

part of the SCADA alternatives for Wonderware.

 InTouch – Wonderware:
InTouch, which has become one of the largest SCADA suppliers on the market, comes
from Wonderware, now owned by Schneider Electric. Although Wonderware is relatively
new to the market, it is quickly gaining popularity. The Wonderware system platform is a
SCADA system with many “plug-and-play” parts that is modular and very versatile.
Because of the modularity of this scheme, you can readily customize it to your
requirements if you choose this SCADA software. The benefit of In Touch is that they
use open standards of communication and can operate with most PLC systems.
 Experion SCADA – Honeywell:
Honeywell is commonly used PLC systems (particularly in the US). They are also a big
player in the SCADA market, providing a software platform for programming SCADA
and HMI systems. You can either use their software for a stand-alone SCADA scheme or
use it with Honeywell’s PLC platform (e.g. C200 and C300 platform) as well as RTU’s
like Control Edge RTU. Although Honeywell’s SCADA software works are optimized to
communicate with other Honeywell products (e.g. PLCs and RTUs), it will still work
when paired with non-Honeywell products.
 iFIX – General Electric:
General Electric (GE) is one of the world’s largest manufacturing businesses, is also a
significant player on the SCADA market. IFIX is one of their software solutions and it is
a very flexible SCADA system. The advantage of using iFIX is its ability to develop
screens quickly with HTML5. Another reason is the many drivers that allow you to set up
networked and distributed systems, allowing you to connect and exchange information

[31]
 with most contemporary PLCs. GE also have their own branded PLCs – but a GE
SCADA system does not require these GE PLCs to function correctly.
 Ignition – Inductive Automation:
Ignition is a SCADA scheme that uses the latest IoT architecture to its full potential.
Ignition from Induction Automation is a very nice option if you want a system that is up-
to-date with all Industry 4.0 norms and techniques. Ignition is relatively new to the
SCADA industry compared to some of the veteran systems. That said between Ignition’s
IoT integrations and the fact that they work with most PLC systems, Ignition has been
chosen by many businesses as their SCADA solution.
 SIMATIC WinCC V7 – Siemens:
The Siemens SCADA system has been around for many years, and is known as
“WinCC”. Siemens is one of the largest players on the PLC and SCADA industry, and
many businesses use the Siemens platform. Siemens is a huge company that has been
evolving their PLC and SCADA platforms over the years to adopt modern technologies.
The fact that they are a large and veteran player in the SCADA industry gives many
businesses confidence in entrusting them with their SCADA applications.

[32]
 CHAPTER - 8

ADVANTAGES, DISADVANTAGES AND APPLICATIONS OF SCADA

8.1 ADVANTAGES OF SCADA

Following are the advantages of SCADA:

 The system provide facility to store large amount of data.

 The data can be displayed in various formats as per user requirements.
 It provides interface to connect thousands of sensors across wide region for various
monitoring and controlling operations.
 It is possible to obtain real data simulations with the help of operators.
 Many types of data can be gathered from RTUs (Remote Terminal Units) connected with
the master unit.
 With the advanced protocols and application software, the data can be monitored from
anywhere and not just from local site.
 The redundancy of units are incorporated in the SCADA system in order to have backup
in the event of faults or failures. This makes system more robust.
 It is fast in obtaining response.
 It is scalable and flexible in adding additional resources.
 It is used in wide industries and departments including telecommunications, energy etc.

8.2 DISADVANTAGES OF SCADA

Following are the disadvantages of SCADA:

 PLC based SCADA system is complex in terms of hardware units and dependent
modules.
 As the system is complex, it requires skilled operators, analysts and programmers to
maintain SCADA system.
 Installation costs are higher.
 The system increases unemployment rates.
 The system supports use of restricted software and hardware equipment.

[33]
8.3 APPLICATIONS OF SCADA

SCADA has made comprehensive use of features such as flexibility, reliability, and scalability in
automating complex systems. There are countless applications in the real world where SCADA
has already been effective in providing surveillance and control alternatives across a broad
spectrum of sectors, from energy production to agricultural systems. SCADA is widely used in
different areas from chemical, gas, water, communications and power systems.

Electric Power Generation, Transmission, and Distribution:

Using SCADA systems, electrical utilities detect current flow and line voltage, monitor circuit
breaker operation, and take sections of the power grid online or offline.

Manufacturing Units:
SCADA systems are used to regulate industrial automation and robots, and monitor process and
quality control

Mass transit and Railway Traction:

Transit officials use SCADA to regulate electricity for subways, trams and trolley busses; to
automate railway traffic signals; to monitor and identify trains and busses, and to control railway
crossing doors

Buildings, Facilities, and Environments:

Facility managers use SCADA to regulate HVAC, cooling, lighting and input systems.

Water, Waste Water Utilities and Sewage:

State and municipal water utilities use SCADA to monitor and control water flow, tank
concentrations, pipe pressure, and other variables.

Water Security: The Role of the SCADA System:

A lot of research continues to be performed on how to implement modern SCADA concepts into
water treatment plants whilst minimizing the risk of unauthorized network access (cyber risk is

[34]
an ongoing issue in large enterprises). The communication network of SCADA is distributed
across the water distribution system as shown in the figure below. Workstations, typically PC-
based are situated at a treatment facility in a control room, enable operators to view the entire
process and take control measures.
Within the plant, PLCs are used in chemical treatment and filters. Local Area Network (LAN) is
utilized to link the controllers to workstations. Remote terminal units (RTUs) are used in remote
locations and are generally found in sensitive fields such as pump stations, storage tanks, valve
vaults, and treatment centers. The RTU communicates on a wide area network typified by the
radio scheme shown in the following figure. A significant benefit of SCADA schemes is the
coordination of safety measures with activities. A SCADA system connected to perimeter
surveillance systems can either decrease the need for manned patrols considerably or eliminate
them.

Figure 8.1 In Water Treatment Plant

The SCADA scheme can provide ongoing surveillance of all places, unlike patrols. You can
easily interface security systems or appliances, including video cameras, motion detectors,
contact switches, keypad entry devices, and card readers, either directly to the SCADA network
or via a neighboring remote terminal unit (RTU). Today’s SCADA systems also give alarm
management in instances where many alarms happen in a brief moment.
[35]
Thermal Power Plants:
Most operational inspections of thermal power plants are automatic. However, manual action
may be necessary at times. The plant is therefore equipped with monitoring and alarm systems
that alert plant operators when certain working para counter deviate significantly from their
normal range. The demand for greater reliability and effectiveness is growing in thermal power
plants. After periodic intervals, the power plant needs continuous inspection and tracking. There
may be chances of mistakes when human employees measure at different phases. To improve
reliability, automation is required to improve the general power plant efficiency. Automation is
established through the use of PLC & SCADA, which decreases human workers’ mistakes.
SCADA system is used to supervise a complete process.

Figure 8.2 In Thermal Power Plants

Forestry, Pulp and Paper Industry:

The forestry, pulp and paper industry also relies on SCADA systems. From automation &
process control, energy management, drive control, power protection, enclosure systems, and
safety – the industry has ample uses for SCADA.

[36]
8.4 FEATURES OF SCADA

 Dynamic Process Graphic

 Alarm summary

 Alarm history
 Real time trend

 Historical time trend

 Security (Application Security)

 Data base connectivity

 Device connectivity

 Scripts

 Recipe management

Dynamic Process Graphics

 Using this feature, one can develop graphics which can resemble the plant.

 The graphic can include Reactor, Valves, Pumps, agitators, conveyors as well as other
equipment and machinery used in the plant.

 The status of the equipment running / stopped can be shown using different color /
animations.

 Typically the SCADA Software will have many ready to use symbols for proper
representation which can be used in any type of industry.

Figure 8.3 Schematic of DPG

[37]
Real-time and Historical Trends

 This facility is used for representing the data in graphical form.

 Typically the trends plot the value with reference to the time.

 Real-time data will plot the real-time value fixed period of time while historical data
stored value which can be viewed on demand.

 Depending upon the storing capacity of the hard-disk on can specify the no of days the
data can be stored.
 Some SCADA software show real-time and historical trends in single graphics while few
others use separate tools.

Figure 8.4 Schematic of Trends

Alarms

 Every plant need proper monitoring and control of the process parameters.

 Alarms represent warnings of process conditions that could cause problems, and require an
operator response.
 Generally alarms are implemented by using the lamps or hooters in field but in SCADA it
can be represented using animation.

 In many SCADA software, four type of alarm limits are used i.e. HI, HIHI, LOW, and
LOW LOW.

[38]
 Figure 8.5 Schematic of Alarm

Recipe Management

 In many case we use the same plant for manufacturing different product range. For example
an oil blending plant can manufacture power oil, transformer oil, and automobile oil.

 The recipe management is facility is used to maintain various recipes of different products
and implement it on the process.

 The recipe can be stored in a single server and it can be fetched by any client server from any
area to run the process.

Figure 8.6 Schematic of Recipe management

[39]
 Figure 8.7 Recipe manager window

Security

 Every SCADA Software has various levels of security for securing the application by
avoiding unauthorized access.

 Depending upon the access level given the operator / engineers is allowed to do the task. In
the most of the case, operators are allowed only to operate the plant while maintenance
engineers can do the application modifications.

 The security can be given for individuals as well as for groups.

Figure 8.8 Schematic of Security

[40]
 Device Connectivity

 Every Control hardware has its own communication protocol for communicating with
different hardware / software. Some of the leading communication protocol includes Modbus,
Profibus, Ethernet, Dh+, DH 485, Devicenet, and Control net.

 The Scada Software needs device driver software for communication with PLC or other
control hardware.

 More the driver software available better is the device connectivity. Most of the SCADA
software used in the industry has connectivity with most of the leading control system.

Database Connectivity

 In many plants, it is important to download the real-time information to the Management

information system. In this case the database connectivity is must.

 Many SCADA software don’t have their own database. Hence for storage and reporting they
use third party database like MS Excel or SQL.

Scripts

 Script is a way of writing logic in SCADA software; every SCADA software has its own
instruction and way of writing program.

 Use scripts, one can develop complex applications. You can create your own functions to suit
the requirement execution.

 Various types of scripts make project execution simpler for programmer.

[41]
 CHAPTER - 9

DIFFERENCE BETWEEN PLC AND SCADA

9.1 DIFFERENCE BETWEEN PLC AND SCADA

 SCADA and PLCs can easily be confused when you’re first learning about control
engineering. You will often hear the terms “PLC” and “SCADA” used within the same
breath. Although they are related, they are distinctly different from one another.

 A PLC is a “Programmable Logic Controller”. This is essentially a ruggedized mini-

computer that sits out in the field within a panel, with a bunch of inputs and outputs
leading from devices in the field into the PLC. The PLC will monitor the state of these
inputs (e.g. the speed of a motor) and depending on the program inside, programmatically
output various signals to control these field devices (e.g. stop the motor).

 SCADA systems sit “on top” of PLCs. PLCs are almost always part of a SCADA
network and form an interface between the field and SCADA. The data that is logged and
stored in a SCADA system is typically acquired through communication with the PLC.
The PLC will continue to execute its program, reading inputs and writing outputs. The
SCADA system is used to keep a log of the historical state of these inputs and outputs,
which can be used for data analysis or auditing. PLCs have limited capacity for long-term
data storage.

 Although SCADA systems can be programmed to control certain aspects of the field –
this is usually an unwanted situation. Ideally, your PLC would run autonomously, able to
programmatically handle any situation it encounters. Due to the complexity of the real
world, this is often not the case. In these cases, operator input is required for the correct
functioning of these semi-autonomous systems.

[42]
 Hence the level of “control” to the SCADA screen (i.e. HMI) that the operator interacts
with is generally much less than the control executed by a PLC. Anything that can be
easily programmed into logic (e.g. IF the flow rate exceeds 100 meters/second, STOP the
pump) will be programmed into the PLC.

 So SCADA systems are primarily used for monitoring and data acquisition, with control
capabilities used under irregular or complex circumstances. SCADA allows operators
(and control systems engineers) to see an overview of the plant from a distance, giving
them the ability to respond to any abnormal states. It should be noted that a SCADA
system technically includes PLCs, which SCADA will communicate with.
 A PLC sits in the field and will read field inputs (e.g. conveyor belt has stopped) and
write outputs (e.g. start conveyor belt) depending on how it is programmed. A PLC forms
part of a SCADA network, asynchronously receiving and executing certain commands
from SCADA (e.g. operator commands to stop the pump), as well as being read by a
SCADA network as a source of data.

[43]
 CHAPTER – 10

PROJECT

AUTOMATIC CAR WASH USING PLC

10.1 INTRODUCTION
Automatic car washing system is very common in developed countries. Automatic car wash
systems can normally be seen at fuel filling stations. Such systems generally have heavy
machinery like motor pumps, brush drives etc. which are governed by programmable logical
controllers. The automatic car wash consists of five stages namely clean water spray, soapy
water spray, brushing, clean water spray and drying. This system uses large quantity of water;
thus water recycling plant should also be there to manage water wastage properly but at this level
we are only presenting the car washing.

This system is very complex and expensive so it has used very less no of cities in India as
compared to foreign countries. But to help our project we have tried to minimize the device list
to minimize the cost.

10.2 WORKING

The sensors are used to sense the position of tyres and the system will deploy several rollers. The
tyre sensor lets the wash know where the wheels are and how far apart they are. On other
systems which are not that much automated the employee may guide the customer on and hit a
'Send Car' button on the tunnel controller, to manually send the rollers which push the car
through. When the customer is on the conveyor, the attendant will instruct the customer to turn
off the vehicle, release all brakes, and not to steer. Failure to do so can cause an accident on the
conveyor. The rollers come up behind the tires to push the car through a detector, which
measures vehicle length, allowing the controller to teller the wash to each individual vehicle. The
number of equipment, frames, or arches, may vary in number and type. A good car wash makes
use of many different pieces of equipment and stages of chemical application to thoroughly clean
the vehicle.

[44]
10.3 PLC LADDER PROGRAMMING

Figure 10.1 Plc Ladder Programming

10.4 PROGRAM DESCRIPTION

 RUNG000: This rung is used to create a Master Coil, in other words, Master Start and
Stop which controls the entire system. To activate this system, this Master Start has to be
pressed.
 RUNG001 is used to activate Soaping process which is operated by a switch input I:1/1,
when car is detected, Soap sprinklers are activated. And RUNG002 is used to generate a

[45]
 time delay which terminates the Soaping process by using XIO of T4:0/DN bit after a
definite time.
 As soon as Soaping is done, RUNG003 has Washing outputs which washes the car by
water sprinklers and RUNG004 is used to generate a time delay which terminates the
washing process by using XIO of T4:1/DN bit after a definite time.
 RUNG005 is activated as soon as the washing process is done. It has motor coil’s output
to run the conveyer on which car moves to the last step of car washing, drying of car. At
the end of the conveyor, a limit switch is mounted which stops the conveyor and till then
Drying is done through RUNG006 and RUNG007 similar to previous operations.

10.5 BLOCK DIAGRAM

Figure 10.2 Automatic car washing process

10.6 LIST OF HARDWARE COMPONENTS

 PLC (Allen Bradley Micro logix 1000 AC/DC).

 DC MOTOR HIGH TORQUE (10rpm).
 Conveyor belt.

[46]
  DC Motor (100 rpm).
 AC water pumps.
 Drying fans.
 Rollers.
 Water showers.
 Wooden base.
 Acrylic sheets.
 Shafts.
 Water pipes.
 Buckets.
 Connecting wires.
 Clamps.
 Brushes.
 Push buttons.
 Relay.

10.7 MERITS
 No man power required.
 If we use special car washing pressure pumps no compressor will be required.
 Can be use in domestic service stations.
 Very less maintenance.
 Comparatively cost of system is less.
 Less space is required.
 No environmental pollution
 Fast and accurate operations.

[47]
10.8 DEMERITS
The primary environmental considerations for car washing are:

 Use of water and energy sources.

 Contamination of surface waters.
 Contamination of soil and ground water.

10.9 RESULT

In Automatic Car Washing System, we performed all the operations needed to clean the car
successfully by using PLC and made a small working model of automatic car wash station. It can
be implied on more than one car wash at a time, by simply changing the coding and making
small changes in the model.

This prototype will help to perform car washing automatically and results in high quality end
product. Thus it will be User-friendly and capable to wash multiple cars at a time. It also requires
lesser man power, time and do not pollute the environment.

10.10 REFERENCES

 www.electrical-engineering-portal.com.
 www.plcs.net.
 Allen Bradley's PLC Programming Handbook.
 www.engineersgarage.com.
 Programmable logic controller - definition.

[48]
 CONCLUSION

This report has discussed the role that programmable logic controllers have in the efficient
design and control of mechanical processes. Also discussed was the understanding SCADA and
the programming involved with it. Finally, the report has discussed relay logic and the evolution
that ladder logic made from it.

 Programmable Logic History: This section discussed the history and advancement of
controls technology, with a comparison of programmable logic controllers and hard-
wired relays.
 PLC components: This section defined what programmable logic is and described all
hardware associated with it.
 PLC Programming: This section covered various technique of PLC programming.
 SCADA: This section contain basic introduction of SCADA system.

[49]
 REFERENCES

 "American Blackout". National Geographic Channel. Retrieved 14 October 2016.

 Kovaliuk, D. O., Huza, K. M., & Kovaliuk, O. O. (2018). Development of SCADA System
based on Web Technologies. International Journal of Information Engineering and
Electronic Business (IJIEEB).
 Abbas, H.A. (2014). Future SCADA challenges and the promising solution: the agent-
based SCADA.
 J. Russel. "A Brief History of SCADA/EMS (2015)". Archived from the original on 11
August 2015.
 "ICSA-11-094-01-WONDERWARE INBATCH CLIENT ACTIVEX BUFFER
OVERFLOW". 13 April 2011. Retrieved 26 March 2013.
 "Siemens: Stuxnet worm hit industrial systems". Archived from the originalon 25 May
2012. Retrieved 16 September 2010.
 "SIMATIC WinCC / SIMATIC PCS 7: Information concerning Malware / Virus /
Trojan". Siemens. 21 July 2010. Retrieved 22 July 2010. malware (trojan) which affects
the visualization system WinCC SCADA.
 R. J. Robles and T. H. Kim, “Architecture for SCADA with Mobile Remote
Components”, Proceedings of the 12th WSEAS International Conference on Automatic
Control, Modelling & Simulation.
 "Industrial Security Best Practices". Rockwell Automation. Retrieved 26 March 2013.
 Boyer, Stuart A. (2010). SCADA Supervisory Control and Data Acquisition. USA: ISA -
International Society of Automation. p. 179. ISBN 978-1-936007-09-7.

[50]