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As per the curriculum of Rajasthan Technical University for III year B.Tech.
Degree, I have completed my summer training of 30 days at ST Microsystems,
Ajmer. This is my summer training report which contains a detailed
description of scada and Plc systems. An industrial SCADA & PLCs system is
used for the development of the controls of machinery. This paper describes
the basics of SCADA & PLCs systems in terms of their architecture, their
interface to the computer and each other, the functionality and the application
development facilities they provide. Some attention is also paid to the
programming in plc and some of the examples.
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CHAPTER – 1
INTRODUCTION TO AUTOMATION
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familiar appliances in homes today operate on this basis. A microwave
oven, a coffee maker, and a CD player are examples.
Larger, more complex industrial operations also use open-cycle operations.
For example, in the production of a car, a single machine may be programmed
to place a side panel in place on the car and then weld it in a dozen or more
locations. Each of the steps involved in this process—from placing the door
properly to each of the different welds—takes place according to instructions
programmed into the machine.
Other category in which automation is divided is:
a. Scientific Automation
(used by scientists)
b. Industrial Automation
(building management system)
c. Office Automation
(used by non technical staff)
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Fig 1.1
1.4 AUTOMATION- ADVANTAGES
1.5 DISADVANTAGES
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CHAPTER – 2
2.1 DEFINATION
scada stands for supervisory control and Data acquisition” It generally refers to
an industrial control system: a computer system monitoring and controlling a
process by which an operator can monitor and control the process parameters.
The operator can give commands on scada to control hardware in the field.
SCADA systems have become tools that now help field operators perform
their jobs more efficiently, provide an active interface for monitoring and
controlling plants.
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2.3 NEED OF SCADA
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Communication infrastructure connecting the supervisory system to the
Remote Terminal Units
There are various features of scada that’s why it is mostly used in industries
present time.
The main features are described below
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2.5.2 ALARMS have a very important role in automation. Generally you
have alarm states for each inputs/outputs like your temperature should not
cross 80 deg or lever should be less than 60. So if the parameters go in alarm
state the operator should be intimated with alarm. Most of the SCADA
software support four types of alarms like LOLO,LO,HI and HIHI. Deadband
the value of deadband defines the range after which a high low alarm condition
returns to normal.
2.5.3.1 Real Time Trend - This trend is used for real time monitoring of
varying parameters in the field (like Temperature) in graph form on the screen
of pc. So the user can notice the value changes and status of the parameter in
real time. So it is useful for monitoring varying quantities by graph
representation .These are dynamic and updated continuously during run time.
It allows user to chart up to 4 data values.
Fig 2.1
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2.5.3.2 Historical Trend - By historical trend feature it is
possible to record the data values up to 10 years so operator can check the data
of last ten years when needed .These are not dynamic and provide a snapshot
only of particular time. It allows user to chart up to 8 data values at a time.
Fig 2.2
2.5.4 SECURITY is on facility people generally look for. You can allocate
certain facilities or features to the operator, process people, engineering dept
and maintenance dept. for example operators should only operate the system,
he should not be able change the application. The engineers should have
access to changing the application. The engineers should have access to
changing the application developed.
When a new app is created the default user name is “Administrator”
with an access level of 9999(which allows access to all security commands).
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2.5.5 Data connectivity- It means that the data values in scada can be shared
or monitored on an other application like excel etc. and the data can be stored
as a log file for future use and can access later when needed.
There are 2 options by which data can communicate with other software.
2.5.5.2 Suite link – This option is selected when the communication of data is
between two devices via Modem or a cable. Also by this option the scada on
different computers can be exchanged. So we can say it is used when hardware
communication is required.
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2.5.7 RECIPE MANAGEMENT is an additional feature. Some SCADA
software support it, some do not. Most of the plants are manufacturing multi
products. When you have different products to manufacture, you just have to
load the recipe of the particular product.
2.5.8 Script – script is a way of writing logic in scada software. Each scada
has its own instruction set and according to then program is written and system
follows this program and works accordingly it.
So whenever a script is written the system follows the instructions
written in script and works.
There are various types of scripts.
2.8.1 Application – It is linked to entire application means it is common for
complete application.
2.8.2 Window – It is linked to a specific Window.
Fig 2.3
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2.5.9 Networking – Networking feature enables operator to link scada with
different devices like plc or with other computers and also various scada
systems on different computers can be linked together via network by which
they can communicate with each other.
These are the various features of scada that makes it very useful in
industries at Present time.
And today almost in all large industries scada systems are used.
2.5.10 Logging/Archiving - The terms logging and archiving are often used
to describe the same facility. However, logging can be thought of as medium-
term storage of data on disk, whereas archiving is long-term storage of data
either on disk or on another permanent storage medium. Logging is typically
performed on a cyclic basis, i.e., once a certain file size, time period or number
of points is reached the data is overwritten. Logging of data can be performed
at a set frequency, or only initiated if the value changes or when a specific
predefined event occurs
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2.6.4 System tags- store information generated while the software is running
including alarm info and system time and date.
2.6.5 String tags- are used to store ASCII strings a series of characters or
whole word. The max string length is 131 characters.
2.6.6 Visibility- used to control visibility of an object based on the value of
discrete tag name or expression.
2.6.7 Blink- used to make an object blink based on the value of the discrete
tagname or expression.
2.6.8 Orientation- used to make an object rotate based on the value of a
tagname /expression.
2.6.9 Disable- used to disable the touch functionality of objects based on the
value of a tagname of expression. Often used as a part of a security strategy.
2.6.10 Value display links- provides the ability to use text object to display
the value of a discrete, analog or string tagname.
2.6.11 Percent fill links- used to provide ability to vary the fill level of a
filled shape according to the value of an analog tagname or an expression that
computes to an analog value.
Fig 2.4
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2.2.12 Application security- to an application is optional. It provides the
application developer with the ability to control whether or not specific
operators are allowed to perform specific functions within an application
Security is based on the concept of operator logging on to the application and
entering his user name and password and access level. For each operator
access to any protected function is granted upon verification of his password
and access level.
Wonderware Intouch provides a single integrated view of all your controls and
information resources. Intouch enables engineers, supervisors, operators and
managers to view to view and interact with the working of entire operation
through graphical representations of their production processes.
2.8.1 Window type – There are 3 types of windows displayed during work
with Intouch 9.5.
2.8.1.1 Application manager – In this window user has asked to input the
location of saving the project, project name. The user enters these things to
proceed.
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It is of three types and user has to select which type of window he wants to
use.
Fig 2.5
2.8.1.3 Window viewer – It is the RUN time window where we can see our
project in running condition and we can mot modify the project in this window
and we have to go again in window maker to modify the project.
To switch between Windows maker and windows viewer a button is
provided in the upper right corner in the window.
When we are in window maker a button named RUN TIME will display
and clicking on that will take project in run mode and in run mode window
clicking on DEVELOPMENT will take it back again in window maker.
2.8.2 Tags- Tag defines a process variable. It is the name given to a process
variable.
Three types of tags are used while working with scada,
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2.8.2.1 Analog Tag – The tag names given to analog variables such as
temperature, distance etc are known as analog tags.
2.8.2.2 Discrete Tag – The tag names given to discrete variables or the items
whose value can only be discrete such as switches, lights etc. It has only two
values either one or zero.
Examples – Light, Switches etc.
2.8.2.3 String Tags – These Tags are used to display some message like reset,
high voltage zone etc.
Fig 2.6
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2.8.4 Package – The scada is available in there packages and user can select
any one according to need.
2.8.4.1 DR Type – In this package the user gets the feature of both
development and run Time means user can develop, modify and can see the
project in run time.
2.8.4.2 DRN Type – In this package the user gets three features Development,
Run Time, Networking. This package is most costly.
2.8.4.3 R Type – This type of package is known as factory focus and user
can’t develop and modify projects. It is used only to see the plant status. The
companies that provide scada also create the plant project of the company for
first time and install it. And the company members can only see the status of
the plant and they are not able to change it.
2.8.5 License of scada – The companies that make scada also provide
license for certain period as user’s need. The license is provided in two ways-
2.8.5.1 Hard disk Type – In this type they installs scada on the system and
locate the product key or license on local
Hard disk. So this scada can not be used on other computer.
2.8.5.2 Dongle Type – In this type of license the user can use the scada on
different system also because the license is provided in an usb device so the
user inserts the license via usb in the system when he wants to use scada.
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2.8.6 Companies that make scada -
There are various companies in world that makes scada software. The main
companies are listed below-
Note – KPIT is only Indian company that makes scada. KPIT stands for
Krishna Palli Institute of Technology.
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INTRODUCTION TO PLC AND ITS PROGRAMMING
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or host computers through a sort of communication network, in order
to integrate the control of a complex process.
Programmable controllers have many definitions. However, PLCs
can be thought of in simple terms as industrial computers with
specially designed architecture in both their central units (the PLC
itself) and their interfacing circuitry to field devices (input/output
connections to the real world).
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Fig 3.4 PLC BLOCK diagram
Some PLCs are integrated into a single unit, whereas others are
modular. Integrated PLCs are sometimes called shoebox or brick
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PLCs because of their small size. If an integrated PLC is available
with the capabilities that a user needs, it is usually the most
economical option. Modular PLCs consist of optional components
required for a more complex control application, as selected and
assembled by the user.
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because each module plugs directly into its neighboring module.
A PLC system with these components is all that is needed to
control an automated system. Since a PLC must be programmed
before it can be used, another component is required:
A programming unit is necessary to create the user-program
and send it to a PLC CPU module's memory.
This basic scan cycle inherent in all PLCs is shown in Figure 2-1. Every time
the PLC finishes one scan cycle and starts another, the operating system also
restarts a watchdog timer. The watchdog timer runs while the scan cycle
executes. If the watchdog timer reaches its pre-set value before being restarted
(if a scan cycle takes unusually long to complete), the PLC will immediately
fault, and stop running.
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Fig 3.7 Standard PLC Scan Cycle
As mentioned previously, some PLCs are integrated into a single unit and
some are modular. A modular PLC consists of several components that can be
connected by being plugged into a common bus or rack. Every PLC needs:
• A CPU module
• A power supply module
• At least one I/O module
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(programmable read-only memory) containing the PLC’s operating system,
driver programs, and application programs, and RAM where the user-written
programs and working data are stored. PLC manufacturers offer various types
of retentive memory to save user programs and data while power is removed,
so that the PLC can resume execution of the user-written control program as
soon as power is restored. If the PLC has one of the following retentive
memory options, it doesn’t have to be reprogrammed each time it is 15 turned
on, so a keyboard and monitor don’t need to be included as a part of every Plc
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3.5.3 THE POWER SUPPLY
power supply module converts available power to dc power at the level(s)
required by the CPU and I/O module internal circuitry. Usually, the available
power is typically 60 Hz/120 Vac or 50 Hz/220 V ac, although power supply
modules are available for other input power characteristics. Output power must
drive the computer circuitry at 5 V dc. Power supply modules may be
connected to the bus or may have to be wired to the CPU module in modular
PLC systems.
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Fig 3.3 Output devices
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not try to write data to an input module. (The CPU module's memory will still
contain an input image and an output image data word for each slot, but the
data won't reflect sensor or actuator states).
There are various types of languages available when working with plc.
1). Ladder Logic Language
2). Function Block Diagram(FBD)
3). Statement Text List(STL)
4). Sequentially Function Chart(SFC)
5). Continuous function Chart(CFC)
Mostly ladder language is used today.
3.7 PROTOCOL
Nodes – 1
Length – 15 meter
2) DH PLUS –
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Nodes – 32
3) PROFIBUS –
Nodes – 126
Length – 1.2 km
4) ETHERNET –
Nodes – Unlimited
Length – Unlimited
Allen Bradley is a us company that manufactures Plc’s and their scada on very
large scale . Their scada name is Rs view(Rockwell solution).
The family of allen bradley consists of following Plc’s which are tabulated as
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FLEX LOGIX RS-LOGIX 5000 RS-LINX 1,28,000
STANDARD RS-LOGIX 5000 RS-LINX 1,28,000
LOGIX
1) CPU Module
2) Inputs
3) Outputs
4) Power supply
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Push Buttons, Relays, NO switches, NC switches, sensors, Temperature
sensor, Level sensor, Pressure sensor, Proximity sensor, switches etc
3.8.1.3 Outputs(4)- The output modules converts signals from the processor to
levels capable of driving the connected analog or discrete output devices.The
output Devices can be connected to plc via this Module .These output device
turn on or turn off according to the signal received from processor after
processing on input signals.
There are various types of output devices that can be connected in output
Module are motors, Heaters, Sirens, Lightings, Fans, Hooters etc.
There are various types of inputs and outputs that can be connected to This
PLC.
Digital Output- A discrete output is either in an ON or OFF condition.
Solenoids, contactors coils, lamps are example of devices connected to the
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Discrete or digital outputs. Below, the lamp can be turned ON or OFF
by the PLC output it is connected to.
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3.8.2 Programming In Allen Bradley PLC -
3.8.2.1 NO and NC concept- these are normally open and normally closed
switches that will be used in programming that allows to pass the input
signal under close condition.
Power flows through these contacts when they are closed. The Normally open
(NO) is true when the input or output status bit Controlling the contact is 1.
The normally closed (NC) is true When the input or output status bit
controlling the contact is 0.
1). No Button
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Fig 3.17 NO Button
2). NC Button
3). Latch-Unlatch
2).Timer/ counter
1). TON Timer – This is low to high pulse on timer . There are two bits in it
. EN bits goes high when timer is enable and DN bit is for done bits it goes
high when timer completes its timing or reaches preset value.
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Fig 3.21 TON Timer
2). TOF Timer – This is also low to high pulse timer and working is similar
to TON timer.
3). RTO
4). CTU – It is for up counting and loaded with preset value and it goes on
increasing and when accumulator reaches to preset the DN bit goes high.
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5). CTD - – It is for down counting and loaded with preset value and it goes
on decreasing and when accumulator reaches to Zero the DN bit goes high.
3). COMPARE
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Fig 3.28 Greater than Instruction
The general syntax for addressing digital inputs and outputs is given as
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File name: Location. Word number/Bit number
The file name for Digital input is I and for output is O for analog inputs and
outputs are Ai and Ao respectively.
The word number represents a memory area and each word consists of 16
bits. and location specify the in which slot the module is connected.
Normally it is 1 for input and 2 for output and 3 for analog input/output
module. For example The 16 inputs can be addressed as I:1.0/0, I:1.0/1,
I:1.0/2,……………. I:1.0/15.
In addressing of analog inputs and outputs the bit number is not used. So
the syntax is as
The basic rules while programming that place inputs at the left side and
outputs in the right side. and assign address to each input and output used.
All these inputs and outputs are connected on a Rung which is vertical line
on the left size.
Program File-
The following Table shows program file that contains various file names
and their numbers that are commonly used in programming.
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File Name Name used in Number
programming
Output File O 0
Input File I 1
System File S 2
Binary file B 3
Timer File T 4
Counter File C 5
Control File R 6
Integer File N 7
Float File F 8
For example In 8th Number file Float file is save That means all instructions
related to float numbers are saved in that file.
Mathematical Instructions are saved in the control file , Integer file , Float
file.
From the system file we can check the availability of inputs and outputs . It
also tells that how many inputs and outputs are left that can be used.
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| |
+----[ ]--+
run
Fig 3.37 Program for Start/Stop of a Motor
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The pushbutton switch connected to input X1 serves as the "Start" switch, while the switch
connected to input X2 serves as the "Stop." Another contact in the program, named Y1, uses
the output coil status as a seal-in contact, directly, so that the motor contactor will continue to
be energized after the "Start" pushbutton switch is released. You can see the normally-closed
contact X2 appear in a colored block, showing that it is in a closed ("electrically conducting")
state.
If we were to press the "Start" button, input X1 would energize, thus "closing" the X1 contact
in the program, sending "power" to the Y1 "coil," energizing the Y1 output and applying 120
volt AC power to the real motor contactor coil. The parallel Y1 contact will also "close," thus
latching the "circuit" in an energized state:
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3.8.4.2 Logic for Continous Running of motor When Start Button is
Released
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3.8.4.3 TO STOP THE MOTOR
To stop the motor, we must momentarily press the "Stop" pushbutton, which
will energize the X2 input and "open" the normally-closed "contact," breaking
continuity to the Y1 "coil:"
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CONCLUSION
SCADA is used for the constructive working not for the destructive work
using a SCADA system for their controls ensures a common framework not
only for the development of the specific applications but also for operating the
detectors. Operators experience the same "look and feel" whatever part of the
experiment they control. Where PlC controls the plant automatically if a
programming logic is downloaded in it . so SCADA and PLC systems are the
need of industries in order to accuracy , fastness , less chances of faults.
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BIBLIOGRAPHY
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