An Industrial training

report on
Study of SCADA System and PLC
Submitted by
Sonu Kumar Yadav
B te!" I# Year $#II Semester%
&le!tri!al &ngineering
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Acknowledgement
I 9ould li:e to t"an: S+,C+* I*DIA P#( LI)I(&D; *+IDA for providing me e<posure
to t"e 9"ole S!ada = PLCs Systeam I>d also li:e to t"an: &r. Rajendra Prasad (E.E.),
and &r Rajendra Patel (A.E.), for t"eir enduring support and guidan!e t"roug"out t"e
training I am very grateful to t"e 9"ole Control and Instrumentation Department for
t"eir support and guidan!e
I am also very t"an:ful to t"e 9or:ers and employees near t"e ma!"ineries and t"e
library in !"arge for t"eir support to my training
728
CERTIFICATE
("is training report is a genuine 9or:s by Mr. Sonu umar !ada", #$Tec% &
rd
'r,
Electr(cal Engg ("e report 9as made under my supervision; and I e<press my delig"t
on it su!!essful !ompletion I am also very "appy to "ave offered "er guidan!e
9"enever it 9as re?uired
I 9is" "er su!!ess in all "er future endeavors
$&r 'a@endra Prasad%
&<e!utive &ngineer
C=I )D A I
BB> (PS; Anpara
7C8
Pre)ace
An industrial SCADA = PLCs system is used for t"e development of t"e !ontrols of
ma!"inery ("is paper des!ribes t"e SCADA = PLCs systems in terms of t"eir ar!"ite!ture;
t"eir interfa!e to t"e pro!ess "ard9are; t"e fun!tionality and t"e appli!ation development
fa!ilities t"ey provide Some attention is also paid to t"e industrial standards to 9"i!" t"ey
abide t"eir planned evolution as 9ell as t"e potential benefits of t"eir use.
S*+, ,MAR !A-A.
#. TEC/, F(nal 'ear (EE)
R*00 +*. 1213141515&
738
C*+TE+TS
T(tleDDDDDDDDDDDDDDDDDDDDDDDD
Page no.
C"apter 5 Introdu!tion of
PLCDDDDDDDDDDDDDDDDDDDE4
C"apter 2 Programming 9it" PLC
DDDDDDDDDDDDDDDDDDD54
C"apter C Programming for StartFStop of
)otorDDDDDDDDDDDDDD2G
C"apter 3
SCADADDDDDDDDDDDDDDDDDDDDDDDDDDC2
C"apter H Appli!ation = Development In
SCADADDDDDDDDDDDDC6
C"apter 4
'eferen!eDDDDDDDDDDDDDDDDDDDDDDDDD3G
C"apter G
Con!lusionDDDDDDDDDDDDDDDDDDDDDDDDD3I
7H8
C/APTER 4
4.Introduct(on
4.4 P0C An *"er"(ew
A Programmable Logi! Controller; PLC; or Programmable Controller is a digital
!omputer used for automation of industrial pro!esses; su!" as !ontrol of ma!"inery on
fa!tory assembly lines /nli:e general1purpose !omputers; t"e PLC is designed for
multiple inputs and output arrangements; e<tended temperature ranges; immunity to
ele!tri!al noise; and resistan!e to vibration and impa!t Programs to !ontrol ma!"ine
operation are typi!ally stored in battery1ba!:ed or non1volatile memory A PLC is an
e<ample of a real time system sin!e output results must be produ!ed in response to
input !onditions 9it"in a bounded time; ot"er9ise unintended operation 9ill result
PLC and Programmable Logi! Controller are registered trademar:s of t"e Allen1Bradley
Company
SCADA is 0idely used in industry for Supervisory Control and Data A!?uisition of industrial
pro!esses; SCADA systems are no9 also penetrating t"e e<perimental p"ysi!s laboratories for
t"e !ontrols of an!illary systems su!" as !ooling; ventilation; po9er distribution; et! )ore
748
re!ently t"ey 9ere also applied for t"e !ontrols of smaller siJe parti!le dete!tors su!" as
t"e LC moon dete!tor and t"e *A3I e<periment; to name @ust t9o e<amples at C&'*
SCADA systems "ave made substantial progress over t"e re!ent years in terms of fun!tionality;
s!alability; performan!e and openness su!" t"at t"ey are an alternative to in "ouse development
even for very demanding and !omple< !ontrol systems as t"ose of p"ysi!s e<periments

7G8
4.6.Features o) P0Cs
Photograph showing several input and output modules of a single Allen-
Bradley PLC.
7I8
0it" ea!" module "aving si<teen KpointsK of eit"er input or output; t"is PLC "as t"e
ability to monitor and !ontrol doJens of devi!es ,it into a !ontrol !abinet; a PLC ta:es
up little room; espe!ially !onsidering t"e e?uivalent spa!e t"at 9ould be needed by
ele!trome!"ani!al relays to perform t"e same fun!tionsL
("e main differen!e from ot"er !omputers is t"at PLC are armored for severe !ondition $dust;
moisture; "eat; !old; et!% and "as t"e fa!ility for e<tensive inputFoutput $IF+% arrangements
("ese !onne!t t"e PLC to sensors and a!tuators PLCs read limit s9it!"es; analog pro!ess
variables $su!" as temperature and pressure%; and t"e positions of !omple< positioning
systems Some even use ma!"ine vision +n t"e a!tuator side; PLCs operate ele!tri! motors;
pneumati! or "ydrauli! !ylinders; magneti! relays or solenoids; or analog outputs ("e
inputFoutput arrangements may be built into a simple PLC; or t"e PLC may "ave e<ternal IF+
modules atta!"ed to a !omputer net9or: t"at plugs into t"e PLC
)any of t"e earliest PLCs e<pressed all de!ision ma:ing logi! in simple ladder logi! 9"i!"
appeared similar to ele!tri!al s!"emati! diagrams ("e ele!tri!ians 9ere ?uite able to tra!e
out !ir!uit problems 9it" s!"emati! diagrams using ladder logi! ("is program notation 9as
!"osen to redu!e training demands for t"e e<isting te!"ni!ians +t"er early PLCs used a
form of instru!tion list programming; based on a sta!:1based logi! solver
("e fun!tionality of t"e PLC "as evolved over t"e years to in!lude se?uential relay
!ontrol; motion !ontrol; pro!ess !ontrol; distributed !ontrol systems and net9or:ing
("e data "andling; storage; pro!essing po9er and !ommuni!ation !apabilities of some
modern PLCs are appro<imately e?uivalent to des:top !omputers
768
1.3 Wiring In a PLC
1 Block diagram of a PLC
75E
8
1.4 Generation of Input Signal
Inside the PLC housing, connected between each input terminal and the
Common terminal, is an opto-isolator device Light-!mitting "iode# that
provides an electrically isolated $high$ Logic signal to the computer%s circuitry a
photo-transistor interprets the L!"%s light# when there is &'( )AC power
applied between the respective input terminal and the Common terminal. An
indicating L!" on the front panel of the PLC gives visual indication of an
$energi*ed$ input
+
"iagram ,howing !nergi*ed input terminal -&
7558
1.5 Generation of Output Signal
.utput signals are generated by the PLC%s computer circuitry activating a
switching device transistor, /0IAC, or even an electromechanical relay#,
connecting the $,ource$ terminal to any of the $1-$ labeled output terminals.
/he $,ource$ terminal, correspondingly, is usually connected to the L& side of
the &'( )AC power source. As with each input, an indicating L!" on the front
panel of the PLC gives visual indication of an $energi*ed$ output
In this way, the PLC is able to interface with real-world devices such as switches
and solenoids.
/he actual logic of the control system is established inside the PLC by means of
a computer program. /his program dictates which output gets energi*ed under
which input conditions. Although the program itself appears to be a ladder logic
diagram, with switch and relay symbols, there are no actual switch contacts or
relay coils operating inside the PLC to create the logical relationships between
input and output. /hese are imaginary contacts and coils, if you will. /he
program is entered and viewed via a personal computer connected to the PLC%s
programming port.
7528
"iagram ,howing !nergi*ed .utput 1&
1.6 P0C com7ared w(t% ot%er control s'stems
PLCs are 9ell1adapted to a !ertain range of automation tas:s ("ese are typi!ally industrial
pro!esses in manufa!turing 9"ere t"e !ost of developing and maintaining t"e automation
system is "ig" relative to t"e total !ost of t"e automation; and 9"ere !"anges to t"e system
9ould be e<pe!ted during its operational life PLCs !ontain input and output devi!es !ompatible
9it" industrial pilot devi!es and !ontrolsM little ele!tri!al design is re?uired; and t"e design
problem !enters on e<pressing t"e desired se?uen!e of operations in ladder logi! $or fun!tion
!"art% notation PLC appli!ations are typi!ally "ig"ly !ustomiJed systems so t"e !ost of a
pa!:aged PLC is lo9 !ompared to t"e !ost of a spe!ifi! !ustom1built !ontroller design ,or "ig"
volume or very simple fi<ed automation tas:s; different te!"ni?ues are used
A mi!ro!ontroller1based design 9ould be appropriate 9"ere "undreds or t"ousands of units 9ill be
produ!ed and so t"e development !ost $design of po9er supplies and inputFoutput "ard9are% !an
be spread over many sales; and 9"ere t"e end1user 9ould not need to alter t"e !ontrol Automotive
appli!ations are an e<ampleM millions of units are built ea!" year; and very fe9 end1users alter t"e
programming of t"ese !ontrollers .o9ever; some spe!ialty ve"i!les su!" as transit busses
75C8
e!onomi!ally use PLCs instead of !ustom1designed !ontrols; be!ause t"e volumes are lo9
and t"e development !ost 9ould be une!onomi!
PLCs may in!lude logi! for single1variable feedba!: analog !ontrol loop; a Kproportional;
integral; derivativeK or KPID !ontrollerK A PID loop !ould be used to !ontrol t"e temperature of
a manufa!turing pro!ess; for e<ample .istori!ally PLCs 9ere usually !onfigured 9it" only a
fe9 analog !ontrol loopsM 9"ere pro!esses re?uired "undreds or t"ousands of loops; a
distributed !ontrol system $DCS% 9ould instead be used .o9ever; as PLCs "ave be!ome
more po9erful; t"e boundary bet9een DCS and PLC appli!ations "as be!ome less !lear
7538
4.8 -(g(tal and analog s(gnals
Digital or dis!rete signals be"ave as binary s9it!"es; yielding simply an +n or +ff signal $5 or E;
(rue or ,alse; respe!tively% Pus"buttons; limit s9it!"es; and p"otoele!tri! sensors are
e<amples of devi!es providing a dis!rete signal Dis!rete signals are sent using eit"er voltage
or !urrent; 9"ere a spe!ifi! range is designated as On and anot"er as Off ,or e<ample; a PLC
mig"t use 23 # DC IF+; 9it" values above 22 # DC representing On; values belo9 2#DC
representing Off; and intermediate values undefined Initially; PLCs "ad only dis!rete IF+
Analog signals are li:e volume !ontrols; 9it" a range of values bet9een Jero and full1
s!ale ("ese are typi!ally interpreted as integer values $!ounts% by t"e PLC; 9it"
various ranges of a!!ura!y depending on t"e devi!e and t"e number of bits available to
store t"e data As PLCs typi!ally use 541bit signed binary pro!essors; t"e integer values
are limited bet9een 1C2;G4I and NC2;G4G Pressure; temperature; flo9; and 9eig"t are
often represented by analog signals Analog signals !an use voltage or !urrent 9it" a
magnitude proportional to t"e value of t"e pro!ess signal ,or e<ample; an analog 312E
mA or E 1 5E # input 9ould be !onverted into an integer value of E 1 C2G4G
Current inputs are less sensitive to ele!tri!al noise $ie from 9elders or ele!tri! motor
starts% t"an voltage inputs
75H8
E9am7le
As an e<ample; say t"e fa!ility needs to store 9ater in a tan: ("e 9ater is dra9n from t"e tan: by
anot"er system; as needed; and our e<ample system must manage t"e 9ater level in t"e tan:
/sing only digital signals; t"e PLC "as t9o digital inputs from float s9it!"es $tan: empty and
tan: full% ("e PLC uses a digital output to open and !lose t"e inlet valve into t"e tan:
If bot" float s9it!"es are off $do9n% or only t"e Otan: emptyO s9it!" is on; t"e PLC 9ill open t"e
valve to let more 9ater in +n!e t"e Otan: fullO s9it!" is on; t"e PLC 9ill automati!ally s"ut t"e
inlet to stop t"e 9ater from overflo9ing If only t"e Otan: fullO s9it!" is on; somet"ing is 9rong
be!ause on!e t"e 9ater rea!"es a float s9it!"; t"e s9it!" 9ill stay on be!ause it is floating;
t"us; 9"en bot" float s9it!"es are on; t"e tan: is full (9o float s9it!"es are used to prevent a
OflutterO $a ripple or a 9ave% !ondition 9"ere any 9ater usage a!tivates t"e pump for a very s"ort
time and t"en dea!tivates for a s"ort time; and so on; !ausing t"e system to 9ear out faster
An analog system mig"t use a load !ell $s!ale% t"at 9eig"s t"e tan:; and an ad@ustable
$t"rottling% valve ("e PLC !ould use a PID feedba!: loop to !ontrol t"e valve opening
("e load !ell is !onne!ted to an analog input and t"e valve is !onne!ted to an analog
output ("is system fills t"e tan: faster 9"en t"ere is less 9ater in t"e tan: If t"e 9ater
level drops rapidly; t"e valve !an be opened 9ide If 9ater is only dripping out of t"e
tan:; t"e valve ad@usts to slo9ly drip 9ater ba!: into t"e tan:
A real system mig"t !ombine bot" approa!"es; using float s9it!"es and simple valves
to prevent spills; and a rate sensor and rate valve to optimiJe refill rates Ba!:up and
maintenan!e met"ods !an ma:e a real system very !ompli!ated
7548
C/APTER 6
Programm(ng w(t% P0C
&arly PLCs; up to t"e mid156IEs; 9ere programmed using proprietary programming panels or
spe!ial1purpose programming terminals; 9"i!" often "ad dedi!ated fun!tion :eys representing
t"e various logi!al elements of PLC programs Programs 9ere stored on !assette tape
!artridges ,a!ilities for printing and do!umentation 9ere very minimal due to la!: of memory
!apa!ity )ore re!ently; PLC programs are typi!ally 9ritten in a spe!ial appli!ation on a
personal !omputer; t"en do9nloaded by a dire!t1!onne!tion !able or over a net9or: to t"e PLC
("e very oldest PLCs used non1volatile magneti! !ore memory but no9 t"e program is stored
in t"e PLC eit"er in battery1ba!:ed1up 'A) or some ot"er non1volatile flas" memory
&arly PLCs 9ere designed to be used by ele!tri!ians 9"o 9ould learn PLC programming on
t"e @ob ("ese PLCs 9ere programmed in Kladder logi!K; 9"i!" strongly resembles a
s!"emati! diagram of relay logi! )odern PLCs !an be programmed in a variety of 9ays;
from ladder logi! to more traditional programming languages su!" as BASIC and C Anot"er
met"od is State Logi!; a #ery .ig" Level Programming Language designed to program
PLCs based on State (ransition Diagrams
6.4 0adder log(c
Ladder logi! is a met"od of dra9ing ele!tri!al logi! s!"emati!s It is no9 a grap"i!al
language very popular for programming Programmable Logi! Controllers $PLCs% It 9as
originally invented to des!ribe logi! made from relays ("e name is based on t"e
observation t"at programs in t"is language resemble ladders; 9it" t9o verti!al KrailsK
and a series of "oriJontal KrungsK bet9een t"em
A program in ladder logi!; also !alled a ladder diagram; is similar to a s!"emati! for a set of
relay !ir!uits An argument t"at aided t"e initial adoption of ladder logi! 9as t"at a 9ide variety
of engineers and te!"ni!ians 9ould be able to understand and use it 9it"out mu!" additional
75G8
training; be!ause of t"e resemblan!e to familiar "ard9are systems $("is argument "as
be!ome less relevant given t"at most ladder logi! programmers "ave a soft9are
ba!:ground in more !onventional programming languages; and in pra!ti!e implementations
of ladder logi! "ave !"ara!teristi!s P su!" as se?uential e<e!ution and support for !ontrol
flo9 features P t"at ma:e t"e analogy to "ard9are some9"at impre!ise%
Ladder logi! is 9idely used to program PLCs; 9"ere se?uential !ontrol of a pro!ess or
manufa!turing operation is re?uired Ladder logi! is useful for simple but !riti!al !ontrol
systems; or for re9or:ing old "ard9ired relay !ir!uits As programmable logi! !ontrollers
be!ame more sop"isti!ated it "as also been used in very !omple< automation systems
Ladder logi! !an be t"oug"t of as a rule1based language; rat"er t"an a pro!edural language A
KrungK in t"e ladder represents a rule 0"en implemented 9it" relays and ot"er
ele!trome!"ani!al devi!es; t"e various rules Ke<e!uteK simultaneously and immediately 0"en
implemented in a programmable logi! !ontroller; t"e rules are typi!ally e<e!uted se?uentially by
soft9are; in a loop By e<e!uting t"e loop fast enoug"; typi!ally many times per se!ond; t"e
effe!t of simultaneous and immediate e<e!ution is obtained In t"is 9ay it is similar to ot"er rule1
based languages; li:e spreads"eets or SQL .o9ever; proper use of programmable !ontrollers
re?uires understanding t"e limitations of t"e e<e!ution order of rungs
E9am7le o) a s(m7le ladder log(c 7rogram
("e language itself !an be seen as a set of !onne!tions bet9een logi!al !"e!:ers $relay
!onta!ts% and a!tuators $!oils% If a pat" !an be tra!ed bet9een t"e left side of t"e rung and
t"e output; t"roug" asserted $true or K!losedK% !onta!ts; t"e rung is true and t"e output !oil
storage bit is asserted $5% or true If no pat" !an be tra!ed; t"en t"e output is false $E% and
t"e K!oilK by analogy to ele!trome!"ani!al relays is !onsidered Kde1energiJedK ("e analogy
bet9een logi!al propositions and relay !onta!t status is due to Claude S"annon
Ladder logi! "as K!onta!tsK t"at Kma:eK or Kbrea:K K!ir!uitsK to !ontrol K!oilsK &a!" !oil or
!onta!t !orresponds to t"e status of a single bit in t"e programmable !ontrollerOs memory
/nli:e ele!trome!"ani!al relays; a ladder program !an refer any number of times to t"e
status of a single bit; e?uivalent to a relay 9it" an indefinitely large number of !onta!ts
75I8
So1!alled K!onta!tsK may refer to inputs to t"e programmable !ontroller from p"ysi!al
devi!es su!" as pus"buttons and limit s9it!"es; or may represent t"e status of internal
storage bits 9"i!" may be generated else9"ere in t"e program
&a!" rung of ladder language typi!ally "as one !oil at t"e far rig"t Some manufa!turers
may allo9 more t"an one output !oil on a rung
--( )-- a regular !oil; true 9"en its rung is true
--(\)-- a KnotK !oil; false 9"en its rung is true
--[ ]-- A regular !onta!t; true 9"en its !oil is true $normally false%
--[\]-- A KnotK !onta!t; false 9"en its !oil is true $normally true%
("e K!oilK $output of a rung% may represent a p"ysi!al output 9"i!" operates some
devi!e !onne!ted to t"e programmable !ontroller; or may represent an internal storage
bit for use else9"ere in t"e program
6.& :enerall' ,sed Instruct(ons ; s'm<ol For P0C Programm(ng
In7ut Instruct(on
$$= >$$ T%(s Instruct(on (s Called I?C or E9am(ne I) Closed.
(e@ I) a +* sw(tc% (s actuated t%en onl' t%(s (nstruct(on w(ll <e true. I) a +C
sw(tc% (s actuated t%en t%(s (nstruct(on w(ll not <e true and %ence out7ut w(ll
not <e generated.
--[\]-- T%(s Instruct(on (s Called I?* or E9am(ne I) *7en
7568
(e@ I) a +C sw(tc% (s actuated t%en onl' t%(s (nstruct(on w(ll <e true. I) a +C sw(tc% (s
actuated t%en t%(s (nstruct(on w(ll not <e true and %ence out7ut w(ll not <e generated.
*ut7ut Instruct(on
--( )-- T%(s Instruct(on S%ows t%e States o) *ut7ut.
(e@ I) an' (nstruct(on e(t%er ?I* or ?IC (s true t%en out7ut w(ll <e %(g%.
-ue to %(g% out7ut a 6A "olt s(gnal (s generated )rom P0C 7rocessor.
Rung
'ung is a simple line on 9"i!" instru!tion are pla!ed and logi!s are !reated
&gM 111111111111111111111111111111111111111111111
.ere is an e<ample of 9"at one rung in a ladder logi! program mig"t loo: li:e In real
life; t"ere may be "undreds or t"ousands of rungs
,or e<ample
1. ----[ ]---------|-- [ ]--|------ ( )--
X | Y | S
| |
|-- [ ]--|
Z
("e above realises t"e fun!tionL S R S A*D $Y +' T%
(ypi!ally; !omple< ladder logi! is OreadO left to rig"t and top to bottom As ea!" of t"e
lines $or rungs% are evaluated t"e output !oil of a rung may feed into t"e ne<t stage of
t"e ladder as an input In a !omple< system t"ere 9ill be many KrungsK on a ladder;
9"i!" are numbered in order of evaluation
1. ----[ ]-----------|---[ ]---|----( )--
72E8
X | Y | S
| |
|--- [ ]--- |
Z
2. ---- [ ]----
[ ] -------------------
( )--
S X T
2 ( R S A*D S 9"ere S is e?uivalent to U5 above
("is represents a slig"tly more !omple< system for rung 2 After t"e first line "as been
evaluated; t"e output !oil $S% is fed into rung 2; 9"i!" is t"en evaluated and t"e output
!oil ( !ould be fed into an output devi!e $buJJer; lig"t et!% or into rung C on t"e ladder
$*ote t"at t"e !onta!t S on t"e 2nd rung serves no useful purpose; as S is already a
OA*DO fun!tion of S from t"e 5st rung%
("is system allo9s very !omple< logi! designs to be bro:en do9n and evaluated
11 more 7ract(cal e9am7les
&<ample15
------[ ]--------------[ ]----------------O---
Key Switch 1 Key Switch 2 Door Motor
("is !ir!uit s"o9s t9o :ey s9it!"es t"at se!urity guards mig"t use to a!tivate an ele!tri!
motor on a ban: vault door 0"en t"e normally open !onta!ts of bot" s9it!"es !lose;
ele!tri!ity is able to flo9 to t"e motor 9"i!" opens t"e door ("is is a logi!al A*D
7258
E9am7le$6
+ften 9e "ave a little green KstartK button to turn on a motor; and 9e 9ant to turn it off
9it" a big red KStopK button
--+
----[
]--+----[\]----( )---
| strt | sto! r"#
| |
+----[ ]--+
r"#
-------[ ] --------------( )---
r"# $otor
2 Example With PLC
Consider the following circuit and PLC program+
-------[ ]-------------- ( )---
r"# $otor
7228
2hen the pushbutton switch is unactuated unpressed#, no power is sent to
the -& input of the PLC. 3ollowing the program, which shows a normally-
open -& contact in series with a 1& coil, no $power$ will be sent to the 1&
coil. /hus, the PLC%s 1& output remains de-energi*ed, and the indicator lamp
connected to it remains dar4.
If the pushbutton switch is pressed, however, power will be sent to the PLC%s
-& input. Any and all -& contacts appearing in the program will assume the
actuated non-normal# state, as though they were relay contacts actuated
by the energi*ing of a relay coil named $-&$. In this case, energi*ing the -&
input will cause the normally-open -& contact will $close,$ sending $power$
to the 1& coil. 2hen the 1&coilof the program $energi*es,$ the real 1& output
will become energi*ed, lighting up the lamp connected to it+
72C8
Lamp -lo9s 9"en at Input S9it!" is A!tuated
It must be understood that the -& contact, 1& coil, connecting wires, and
$power$ appearing in the personal computer%s display are all virtual. /hey do
not e5ist as real electrical components. /hey e5ist as commands in a
computer program -- a piece of software only -- that 6ust happens to
resemble a real relay schematic diagram.
7238
!7ually important to understand is that the personal computer used to
display and edit the PLC%s program is not necessary for the PLC%s continued
operation. .nce a program has been loaded to the PLC from the personal
computer, the personal computer may be unplugged from the PLC, and the
PLC will continue to follow the programmed commands. I include the
personal computer display in these illustrations for your sa4e only, in aiding
to understand the relationship between real-life conditions switch closure
and lamp status# and the program%s status $power$ through virtual contacts
and virtual coils#.
/he true power and versatility of a PLC is revealed when we want to alter the
behavior of a control system. ,ince the PLC is a programmable device, we can
alter its behavior by changing the commands we give it, without having to
reconfigure the electrical components connected to it. 3or e5ample, suppose we
wanted to ma4e this switch-and-lamp circuit function in an inverted fashion+
push the button to ma4e the lamp turn off, and release it to ma4e it turn on.
/he $hardware$ solution would re7uire that a normally-closed pushbutton switch
be substituted for the normally-open switch currently in place. /he $software$
solution is much easier+ 6ust alter the program so that contact -& is normally-
closed rather than normally-open.
72H8
CHAP!" #
Programming $or Start%Stop of &otor '( PLC
+ften 9e "ave a little green KstartK button to turn on a motor; and 9e 9ant to turn it off
9it" a big red KStopK button
--+
----[
]--+----[\]----( )---
| strt | sto! r"#
| |
+----[ ]--+
r"#
7248
/he pushbutton switch connected to input -& serves as the $,tart$ switch,
while the switch connected to input -' serves as the $,top.$ Another contact
in the program, named 1&, uses the output coil status as a seal-in contact,
directly, so that the motor contactor will continue to be energi*ed after the
$,tart$ pushbutton switch is released. 1ou can see the normally-closed
contact -' appear in a colored bloc4, showing that it is in a closed
$electrically conducting$# state.
3.1 Starting of &otor
If we were to press the $,tart$ button, input -& would energi*e, thus
$closing$ the -& contact in the program, sending $power$ to the 1& $coil,$
energi*ing the 1& output and applying &'( volt AC power to the real motor
contactor coil. /he parallel 1& contact will also $close,$ thus latching the
$circuit$ in an energi*ed state+
72G8
3.2 Logic for Continou) "unning of motor W*en Start Button i)
"elea)ed
8ow, if we release the $,tart$ pushbutton, the normally-open -& $contact$
will return to its $open$ state, but the motor will continue to run because the
1& seal-in $contact$ continues to provide $continuity$ to $power$ coil 1&,
thus 4eeping the 1& output energi*ed+
72I8
7268
3.3 o Stop t*e &otor
/o stop the motor, we must momentarily press the $,top$ pushbutton, which
will energi*e the -' input and $open$ the normally-closed $contact,$
brea4ing continuity to the 1& $coil+$
2hen the $,top$ pushbutton is released, input -' will de-energi*e, returning
$contact$ -' to its normal, $closed$ state. /he motor, however, will not start
again until the $,tart$ pushbutton is actuated, because the $seal-in$ of 1&
has been lost+
7CE8
C/APTER A
Mean(ng o) SCA-A
SCADA stands for Supervisory Control and Data A!?uisition As t"e name indi!ates; it is not
a full !ontrol system; but rat"er fo!uses on t"e supervisory level As su!"; it is a purely
soft9are pa!:age t"at is positioned on top of "ard9are to 9"i!" it is interfa!ed; in general
via Programmable Logi! Controllers $PLCs%; or ot"er !ommer!ial "ard9are modules
SCADA systems are used not only in industrial pro!essesL eg steel ma:ing; po9er generation
$!onventional and nu!lear% and distribution; !"emistry; but also in some e<perimental fa!ilities
su!" as nu!lear fusion ("e siJe of su!" plants range from a fe9 5EEE to several 5E t"ousands
inputFoutput $IF+% !"annels .o9ever; SCADA systems evolve rapidly and are no9 penetrating
t"e mar:et of plants 9it" a number of IF+ !"annels of several 5EE KL 9e :no9 of t9o !ases of
near to 5 ) IF+ !"annels !urrently under development
SCADA systems used to run on D+S; #)S and /*ISM in re!ent years all SCADA
vendors "ave moved to *( and some also to Linu<
7C58
Arc%(tecture
("is se!tion des!ribes t"e !ommon features of t"e SCADA produ!ts t"at "ave been evaluated
at C&'* in vie9 of t"eir possible appli!ation to t"e !ontrol systems of t"e L.C dete!tors 758; 728
35 /ardware Arc%(tecture
+ne distinguis"es t9o basi! layers in a SCADA systemL t"e K!lient layerK 9"i!" !aters
for t"e man ma!"ine intera!tion and t"e Kdata server layerK 9"i!" "andles most of t"e
pro!ess data !ontrol a!tivities ("e data servers !ommuni!ate 9it" devi!es in t"e field
t"roug" pro!ess !ontrollers Pro!ess !ontrollers; eg PLCs; are !onne!ted to t"e data
servers eit"er dire!tly or via net9or:s or field buses t"at are proprietary $eg Siemens
.5%; or non1proprietary $eg Profibus% Data servers are !onne!ted to ea!" ot"er and to
!lient stations via an &t"ernet LA* ("e data servers and !lient stations are *(
platforms but for many produ!ts t"e !lient stations may also be 06H ma!"ines
7C28
32 Commun(cat(ons
A.&.4 Internal Commun(cat(on
Server1!lient and server1server !ommuni!ation is in general on a publis"1subs!ribe and
event1driven basis and uses a (CPFIP proto!ol; ie; a !lient appli!ation subs!ribes to a
parameter 9"i!" is o9ned by a parti!ular server appli!ation and only !"anges to t"at
parameter are t"en !ommuni!ated to t"e !lient appli!ation
A.&.6 Access to -e"(ces
("e data servers poll t"e !ontrollers at a user defined polling rate ("e polling rate may be
different for different parameters ("e !ontrollers pass t"e re?uested parameters to t"e data
servers (ime stamping of t"e pro!ess parameters is typi!ally performed in t"e !ontrollers
and t"is time1stamp is ta:en over by t"e data server If t"e !ontroller and !ommuni!ation
proto!ol used support unsoli!ited data transfer t"en t"e produ!ts 9ill support t"is too
("e produ!ts provide !ommuni!ation drivers for most of t"e !ommon PLCs and 9idely
used field1buses; eg; )odbus +f t"e t"ree fieldbuses t"at are re!ommended at
C&'*; bot" Profibus and 0orld flip are supported but CA*bus often not 7C8 Some of
t"e drivers are based on t"ird party produ!ts $eg; Appli!om !ards% and t"erefore "ave
additional !ost asso!iated 9it" t"em #)& on t"e ot"er "and is generally not supported
A single data server !an support multiple !ommuni!ations proto!olsL it !an generally
support as many su!" proto!ols as it "as slots for interfa!e !ards
("e effort re?uired to develop ne9 drivers is typi!ally in t"e range of 214 9ee:s
depending on t"e !omple<ity and similarity 9it" e<isting drivers; and a driver
development tool:it is provided for t"is
7CC8
A.&.& Inter)ac(ng
("e provision of +PC !lient fun!tionality for SCADA to a!!ess devi!es in an open and
standard manner is developing ("ere still seems to be a la!: of devi!esF!ontrollers;
9"i!" provide +PC server soft9are; but t"is improves rapidly as most of t"e produ!ers
of !ontrollers are a!tively involved in t"e development of t"is standard +PC "as been
evaluated by t"e C&'*1I(1C+ group
("e produ!ts also provide
1 An +pen Data Base Conne!tivity $+DBC% interfa!e to t"e data in t"e
ar!"iveFlogs; but not to t"e !onfiguration database;
2 An ASCII importFe<port fa!ility for !onfiguration data;
3 A library of APIs supporting C; CNN; and #isual Basi! $#B% to a!!ess data in t"e
'(DB; logs and ar!"ive ("e API often does not provide a!!ess to t"e produ!tOs
internal features su!" as alarm "andling; reporting; trending; et!
("e PC produ!ts provide support for t"e )i!rosoft standards su!" as Dynami! Data
&<!"ange $DD&% 9"i!" allo9s eg to visualiJe data dynami!ally in an &SC&L
spreads"eet; Dynami! Lin: Library $DLL% and +b@e!t Lin:ing and &mbedding $+L&%
("e !onfiguration data are stored in a database t"at is logi!ally !entraliJed but
p"ysi!ally distributed and t"at is generally of a proprietary format
,or performan!e reasons; t"e '(DB resides in t"e memory of t"e servers and is also of
proprietary format
("e ar!"ive and logging format is usually also proprietary for performan!e reasons; but
some produ!ts do support logging to a 'elational Data Base )anagement System
$'DB)S% at a slo9er rate eit"er dire!tly or via an +DBC interfa!e
7C38
A.&.A Scala<(l(t'
S!alability is understood as t"e possibility to e<tend t"e SCADA based !ontrol system by adding
more pro!ess variables; more spe!ialiJed servers $eg for alarm "andling% or more !lients ("e
produ!ts a!"ieve s!alability by "aving multiple data servers !onne!ted to multiple !ontrollers
&a!" data server "as its o9n !onfiguration database and '(DB and is responsible for t"e
"andling of a sub1set of t"e pro!ess variables $a!?uisition; alarm "andling; ar!"iving%
A.&.5 Redundanc'
("e produ!ts often "ave built in soft9are redundan!y at a server level; 9"i!" is
normally transparent to t"e user )any of t"e produ!ts also provide more !omplete
redundan!y solutions if re?uired
Funct(onal(t'
A.A.4 Access Control
/sers are allo!ated to groups; 9"i!" "ave defined readF9rite a!!ess privileges to t"e
pro!ess parameters in t"e system and often also to spe!ifi! produ!t fun!tionality
A.A.6 MMI
("e produ!ts support multiple s!reens; 9"i!" !an !ontain !ombinations of synopti!
diagrams and te<t
("ey also support t"e !on!ept of a Kgeneri!K grap"i!al ob@e!t 9it" lin:s to pro!ess variables ("ese
ob@e!ts !an be Kdragged and droppedK from a library and in!luded into a synopti! diagram
)ost of t"e SCADA produ!ts t"at 9ere evaluated de!ompose t"e pro!ess in Katomi!K parameters
$eg a po9er supply !urrent; its ma<imum value; its onFoff status; et!% to 9"i!" a (ag1name is
asso!iated ("e (ag1names used to lin: grap"i!al ob@e!ts to devi!es !an be edited as re?uired ("e
produ!ts in!lude a library of standard grap"i!al symbols; many of 9"i!" 9ould "o9ever not
7CH8
be appli!able to t"e type of appli!ations en!ountered in t"e e<perimental p"ysi!s !ommunity
Standard 9indo9s editing fa!ilities are providedL Jooming; re1siJing; s!rolling +n1line
!onfiguration and !ustomiJation of t"e ))I is possible for users 9it" t"e appropriate privileges
Lin:s !an be !reated bet9een display pages to navigate from one vie9 to anot"er
A.A.& Trend(ng
("e produ!ts all provide trending fa!ilities and one !an summariJe t"e !ommon
!apabilities as follo9sL
1 t"e parameters to be trended in a spe!ifi! !"art !an be predefined or defined on1line
2 a !"art may !ontain more t"an I trended parameters or pens and an unlimited
number of !"arts !an be displayed $restri!ted only by t"e readability%
3 real1time and "istori!al trending are possible; alt"oug" generally not in t"e same !"art
4.5 Alarm /andl(ng
Alarm "andling is based on limit and status !"e!:ing and performed in t"e data servers
)ore !ompli!ated e<pressions $using arit"meti! or logi!al e<pressions% !an be
developed by !reating derived parameters on 9"i!" status or limit !"e!:ing is t"en
performed ("e alarms are logi!ally "andled !entrally; ie; t"e information only e<ists in
one pla!e and all users see t"e same status $eg; t"e a!:no9ledgement%; and multiple
alarm priority levels $in general many more t"an C su!" levels% are supported
It is generally possible to group alarms and to "andle t"ese as an entity $typi!ally filtering on
group or a!:no9ledgement of all alarms in a group% ,urt"ermore; it is possible to suppress
alarms eit"er individually or as a !omplete group ("e filtering of alarms seen on t"e alarm page
or 9"en vie9ing t"e alarm log is also possible at least on priority; time and group .o9ever;
relations"ips bet9een alarms !annot generally be defined in a straig"tfor9ard manner &1mails
!an be generated or predefined a!tions automati!ally e<e!uted in response to alarm !onditions
7C48
A.2 0ogg(ngBArc%("(ng
("e terms logging and ar!"iving are often used to des!ribe t"e same fa!ility .o9ever; logging
!an be t"oug"t of as medium1term storage of data on dis:; 9"ereas ar!"iving is long1term
storage of data eit"er on dis: or on anot"er permanent storage medium Logging is typi!ally
performed on a !y!li! basis; ie; on!e a !ertain file siJe; time period or number of points is
rea!"ed t"e data is over9ritten Logging of data !an be performed at a set fre?uen!y; or only
initiated if t"e value !"anges or 9"en a spe!ifi! predefined event o!!urs Logged data !an be
transferred to an ar!"ive on!e t"e log is full ("e logged data is time1stamped and !an be
filtered 9"en vie9ed by a user ("e logging of user a!tions is in general performed toget"er 9it"
eit"er a user ID or station ID ("ere is often also a #C' fa!ility to play ba!: ar!"ived data
A.8 Re7ort :enerat(on
+ne !an produ!e reports using SQL type ?ueries to t"e ar!"ive; '(DB or logs Alt"oug"
it is sometimes possible to embed &SC&L !"arts in t"e report; a K!ut and pasteK
!apability is in general not provided ,a!ilities e<ist to be able to automati!ally generate;
print and ar!"ive reports
A.C Automat(on
("e ma@ority of t"e produ!ts allo9 a!tions to be automati!ally triggered by events A
s!ripting language provided by t"e SCADA produ!ts allo9s t"ese a!tions to be defined
In general; one !an load a parti!ular display; send an &mail; run a user defined
appli!ation or s!ript and 9rite to t"e '(DB
("e !on!ept of re!ipes is supported; 9"ereby a parti!ular system !onfiguration !an be
saved to a file and t"en re1loaded at a later date
7CG8
C/APTER 5
A77l(cat(on ; -e"elo7ment In SCA-A
7CI
8
5.4 Con)(gurat(on
("e development of t"e appli!ations is typi!ally done in t9o stages ,irst t"e pro!ess
parameters and asso!iated information $eg relating to alarm !onditions% are defined t"roug"
some sort of parameter definition template and t"en t"e grap"i!s; in!luding trending and alarm
displays are developed; and lin:ed 9"ere appropriate to t"e pro!ess parameters ("e produ!ts
also provide an ASCII &<portFImport fa!ility for t"e !onfiguration data $parameter definitions%;
9"i!" enables large numbers of parameters to be !onfigured in a more effi!ient manner using
an e<ternal editor su!" as &<!el and t"en importing t"e data into t"e !onfiguration database
.o9ever; many of t"e PC tools no9 "ave a 0indo9s &<plorer type development studio
("e developer t"en 9or:s 9it" a number of folders; 9"i!" ea!" !ontains a different
aspe!t of t"e !onfiguration; in!luding t"e grap"i!s
("e fa!ilities provided by t"e produ!ts for !onfiguring very large numbers of parameters
are not very strong .o9ever; t"is "as not really been an issue so far for most of t"e
produ!ts to1date; as large appli!ations are typi!ally about HEK IF+ points and database
population from 9it"in an ASCII editor su!" as &<!el is still a 9or:able option
+n1line modifi!ations to t"e !onfiguration database and t"e grap"i!s are generally
possible 9it" t"e appropriate level of privileges
7C68
5.6 -e"elo7ment Tools
("e follo9ing development tools are provided as standardL
1 A grap"i!s editor; 9it" standard dra9ing fa!ilities in!luding free"and; lines; s?uares
!ir!les; et! It is possible to import pi!tures in many formats as 9ell as using
predefined symbols in!luding eg trending !"arts; et! A library of generi! symbols is
provided t"at !an be lin:ed dynami!ally to variables and animated as t"ey !"ange It
is also possible to !reate lin:s bet9een vie9s so as to ease navigation at run1time
2 A data base !onfiguration tool $usually t"roug" parameter templates% It is in general
possible to e<port data in ASCII files so as to be edited t"roug" an ASCII editor or &<!el
3 A s!ripting language
4 An Appli!ation Program Interfa!e $API% supporting C; CNN; #B
73E8
5.& E"olut(on
SCADA vendors release one ma@or version and one to t9o additional minor versions
on!e per year ("ese produ!ts evolve t"us very rapidly so as to ta:e advantage of ne9
mar:et opportunities; to meet ne9 re?uirements of t"eir !ustomers and to ta:e
advantage of ne9 te!"nologies
As 9as already mentioned; most of t"e SCADA produ!ts t"at 9ere evaluated de!ompose t"e
pro!ess in Katomi!K parameters to 9"i!" a (ag1name is asso!iated ("is is impra!ti!al in t"e
!ase of very large pro!esses 9"en very large sets of (ags need to be !onfigured As t"e
industrial appli!ations are in!reasing in siJe; ne9 SCADA versions are no9 being designed to
"andle devi!es and even entire systems as full entities $!lasses% t"at en!apsulate all t"eir
spe!ifi! attributes and fun!tionality In addition; t"ey 9ill also support multi1team development
As far as ne9 te!"nologies are !on!erned; t"e SCADA produ!ts are no9 adoptingL
1 0eb te!"nology; A!tiveS; Vava; et!
2 +PC as a means for !ommuni!ating internally bet9een t"e !lient and server
modules It s"ould t"us be possible to !onne!t +PC !ompliant t"ird party
modules to t"at SCADA produ!t
7358
5.A Eng(neer(ng
0"ilst one s"ould rig"tly anti!ipate signifi!ant development and maintenan!e savings by
adopting a SCADA produ!t for t"e implementation of a !ontrol system; it does not mean a
Kno effortK operation ("e need for proper engineering !an not be suffi!iently emp"asiJed to
redu!e development effort and to rea!" a system t"at !omplies 9it" t"e re?uirements; t"at
is e!onomi!al in development and maintenan!e and t"at is reliable and robust &<amples of
engineering a!tivities spe!ifi! to t"e use of a SCADA system are t"e definition ofL
1 a library of ob@e!ts $PLC; devi!e; subsystem% !omplete 9it" standard ob@e!t be"avior
$s!ript; se?uen!es; %; grap"i!al interfa!e and asso!iated s!ripts for animation;
2 templates for different types of KpanelsK; eg alarms;
3 instru!tions on "o9 to !ontrol eg a devi!e ;
7328
1 a me!"anism to prevent !onfli!ting !ontrols $if not provided 9it" t"e SCADA%; alarm
levels; be"avior to be adopted in !ase of spe!ifi! alarms
73C8
5.5 Potent(al <ene)(ts o) SCA-A
("e benefits one !an e<pe!t from adopting a SCADA system for t"e !ontrol of
e<perimental p"ysi!s fa!ilities !an be summariJed as follo9sL
1 A ri!" fun!tionality and e<tensive development fa!ilities ("e amount of effort
invested in SCADA produ!t amounts to HE to 5EE p1yearsW
2 ("e amount of spe!ifi! development t"at needs to be performed by t"e end1user
is limited; espe!ially 9it" suitable engineering
3 'eliability and robustness ("ese systems are used for mission !riti!al industrial
pro!esses 9"ere reliability and performan!e are paramount In addition; spe!ifi!
development is performed 9it"in a 9ell1establis"ed frame9or: t"at en"an!es
reliability and robustness
4 (e!"ni!al support and maintenan!e by t"e vendor
7338
73H8
REFERE+CES
758 ADaneels; 0Salter; K(e!"nology Survey Summary of Study 'eportK; I(1
C+F6I1EI1E6; C&'*; -eneva 24
t"
Aug 566I
[2] ADaneels; 0Salter; KSele!tion and &valuation of Commer!ial SCADA
Systems for t"e Controls of t"e C&'* L.C &<perimentsK; Pro!eedings of t"e
5666 International Conferen!e on A!!elerator and Large &<perimental P"ysi!s
Control Systems; (rieste; 5666; pCHC
[3] -Baribaud et al; K'e!ommendations for t"e /se of ,ieldbuses at C&'* in
t"e L.C &raK; Pro!eedings of t"e 566G International Conferen!e on A!!elerator
and Large &<perimental P"ysi!s Control Systems; Bei@ing; 566G; p2IH
[4] 'Barillere et al; K'esults of t"e +PC &valuation done 9it"in t"e VC+P for t"e
Control of t"e L.C &<perimentsK; Pro!eedings of t"e 5666 International Conferen!e on
A!!elerator and Large &<perimental P"ysi!s Control Systems; (rieste; 5666; pH55
734
8
C*+C0,SI*+
SCADA is used for t"e !onstru!tive 9or:ing not for t"e destru!tive 9or: using a
SCADA system for t"eir !ontrols ensures a !ommon frame9or: not only for t"e
development of t"e spe!ifi! appli!ations but also for operating t"e dete!tors +perators
e<perien!e t"e same Kloo: and feelK 9"atever part of t"e e<periment t"ey !ontrol
.o9ever; t"is aspe!t also depends to a signifi!ant e<tent on proper engineering
73G
8