Project Report on Industrial Automation

Submitted in partial fulfillment of the Requirement for the degree of

Bachelor of Technology
in
Mechanical Engineering

Under Guidance of:

Submitted By:

Mr. Praveen Chugh

(Associate Professor)

Md.Shamsher Ansari
93059
ME-A (8th SEM)

Session 2009-2013
Department of Mechanical Engineering

Shri Ram College of Engineering & Management, Palwal

Affiliated to Maharishi Dayanand University, Rohtak (Haryana).

Declaration of Originality and Compliance of Academics Ethics

I/We hereby declare that this project will contain literature survey and original work
by undersigned candidate/candidates, as part of their B.Tech (Mechanical) studies.
All Information for the project will be obtained and presented in accordance with
academic rules and ethical conduct.
I/We also declare that, as required by these rules and conduct, I/We will be fully cited
and referenced all material and results that are not original to this work.

(Signature of on the job guide with date)

Mr. Praveen Chugh
(Training Guide)

(Signature of Students with date)

Md.Shamsher Ansari
93059

Certificate
This training report is a genuine works by Mr. Md Shamsher Ansari, B.tech final yr,
from Shri Ram college of engg & mangt. The report was made under my
supervision, and I express my delight on it Successful completion. I also very
happy to have offered her guidance whenever it was required.
I wish her successful in all her future endeavors.

Mr. Surinder Kumar

(HOD Mechanical)

Md Shamsher Ansari
930559
ME-A (8th SEM)

Acknowledgment
I am thankful to the Institute Prolific for providing necessary
facility to carry out my training successfully. Id also like to thank Er.
Arun sing(M.E) and Er. Miss lofa (E.E), for enduring support and
guidance throughout the training I am very grateful to the whole
control and instrumentation Department for their support and
guidance. Also, I am highly obliged to the head of our training and
placement cell Who provided me such a great opportunity to do my
summer training in a reputed institute like.
Prolific Systems & technologies pvt.ltd
ISO 9001-2008 Certified Company

Mr. Praveen Chugh

(Internal Guide)

Md. Shamsher Ansari

93059
ME-A (8th SEM)

PREFACE

It gives me an immense pleasure to submit this report as a part of practical training of

4 Months .Practical training is the most important part of the engineering studies.
During the course of the training a trainee learns to correlate both the practical
problem to the possible theoretical knowledge or solution .This training record is
prepared on the basis of my own experience gained during my practical training. On
the basis of information collected and guidance provide I had prepared a
comprehensive training report. This report contain the history,
Introduction, quality policy and description op PLC, SCADA, HMI, instrumentations

Md
Shamsher Ansari
93059
ME-A (8th SEM)

Table of Content
S.No Particulars
1. Abbreviation
2.

3.

4.

5.

Automation
Introduction
Example of automation
Types of automation, industrial automation
Programmable logic controller PLC
Introduction, Relay
History of PLC, Advantages
Inside PLC, CPU, RAM, ROM, EEPROM, I/P Module
Output Module. Sensor, Actuator
Number system, decimal, binary
Converting binary to decimal, Bits, byte words.logic1, logic0
BCD, Hexadecimal, communication
PLC operation, Programming PLC, Ladder logic, Example
SCADA
Introduction
System concept
Tags, types of Tags, classification of tags
Alarm, System components, Salient features
Benefits SCADA/HMI, Recommend
HMI
Introduction, types, difference between

Page No.
7

8
8 to 9
10 to 13

13
14 to 15
16 to 17
18 to 19
19 to 20
21 to 22
23 to 24
24 to 30

31
32
32 to 33
34 to 35
35

35 to 36

6.
7.
8.

Instrumentation, Application of automation, plc SCADA

Conclusion
References

37 to 39

9.

Bibliography

42

40
41

General Abbreviation
PLC: Programmable logic controllers.
SCADA: Supervisory control and data acquisition.
I/P: Input
O/P: Output.
T-On: On timer.
T-Off: Off timer.
M: Memory Bits.
Q: Output in program.
MW: Memory words.
NO: Normally open.
NC: Normally closed.
DCS: Distributed Control System.
HMI: Human machine interference.
VFD: Variable Frequency Drive.
MD: Memory Double Word.
MB: Memory Byte
XIC: Examine If Closed
XIO: Examine If Open

AUTOMATION

Introduction
Automation is the use of control system such as computers to control industrial
machinery & process, reducing for need for human intervention. In the scope of
industrialization,
Automation is a step beyond mechanization. whereas mechanization provided
human operators with machinery assist them with physical requirement of work,
automation greatly reduces the need for human sensory and mental requirements
as well. Process and system can also be automated.

Example of automation

Automatic machine tools to process parts- CNC m/c

Industrial robots

Automatic material handling

Feedback control system

EXAMPLE OF AUTOMATION

Automatic Material Handling

Conveyors.

Industrial Robots

feedback control systems

9

TYPES OF AUTOMATION

Fixed

automaton

Programmable

automation

Flexible

automation

Fixed automation
Fixed automation refers to the use of custom-engineered (special purpose) equipment to
automated a fixed sequence of processing or assembly operations. This is also called hard
automation.

The primary drawbacks are the large initial investment in requirement and the relative flexibility.

Programmable automation
In programmable automation, the equipment is designed to accommodated a specific class of product
changes and the processing or assembly operation can be changed by modifying the control program.

Flexible automation
In flexible automation, the equipment is designed to manufacture a variety of products or parts and
very little time is spend on changing from one product to another . A flexible manufacture various
combination of products according to any specified schedule.

INDUSTRIAL AUTOMATION
PLANT

Field
instrument

Intelligent
controller

Monitoring &
controller

10
Field instrument

This type of instrument mainly used to get the feedback any type of process
carried our so they mainly plant used
Sensors, Transducer, Transmitter

Proximity Sensor.

Intelligent controller

This device are basically micro control based or micro controller device mainly intelligent
controller are:

Programmable logic controller (PLC)

PID Controller
Distributed controller system (DCS)

Computer Numerical controller (CNC

PLC
11

PID

CNC MACHINE

Monitoring and controller

This type of device to control whole plant just in a setting in control room, so mainly control
device are

Supervisory Control & Data Acquisition (SCADA)

Human Machine interface (HMI)

12

600 Series touch screen HMI.

PROGRAMMABLE LOGIC CONROLLER

Introduction

A PLC is a solid device designed to perform the function previously accomplished by

components such as electromechanical relay, drums switch, mechanical timers
/counter etc. for the control and operation of manufacturing process equipment and
machinery. Even thought the electromechanical relay (control relay, pneumatic timer
relay, etc ) have served well for many generations, often under adverse conditions, the
ever increasing sophistication and complexity of modern processing equipment
requires faster acting, more reliable functions that electromechanical relays or timing
devices cant offer.

What is relay?
A relay is an electromechanical switch, operated by passing current through a coil
wire wound around a steel core, which act as an electromagnet pulling the switch
contact down or break a circuit

13

HISTORY OF PLC

The first programmable logic controller were designed and developed by

Modicon as a relay replacer for GM and landis.

This controller eliminated the need for rewiring and adding additional for each
new configuration of logics.

The new system drastically increased the functionality of the control while
reducing the cabinet space that housed the logic.

The first PLC, model 084, was invented by Dick Morley in 1969.

The first commercial successful PLC, the 184, was introduced in 1973 and was
designed Michael Greenberg

ADVANTAGES
PLC not only capable of performing the same tasks as hard-wired control, but are also
capable of many more flexible application. In addition, the PLC program and electronic
communication lines replace much of the interconnecting wires require hardwire control.
Therefore, hard wiring, thought still required to connect field device, is less intensive. This
also makes correcting errors and modified the application easier.

Some of the additional advantages of PLCs are as follow

Smaller physical size than hard-wire solutions

Easier and faster and to make changes.

PLCs have integrated diagnostics and override functions

Diagnostics are centrally available

Application can be immediately documented

14

Application can be duplicated faster and less expansively

Speed in operation

Security

Online/ offline modifications

Photograph showing several input and output modules of a single

A l l e n - Bradley PLC.

15

INSIDE PLC
The Central processing Unit (CPU), contains and internal program that tells the PLCs how to
perform the following functions:

Execute the control instructions contained in the users

Programs. This program is store in nonvolatile memory,
Meaning that the program will not be lost if power is removed.
Communicate with other device, which can include I/O
Device, programming device, networks and even other PLCs
Performs housekeeping activities such as communication, internal diagnostic, etc.

THE CPU
The microprocessor or processor module is the brain of PLC system. It consists of the
microprocessors, memory integrate circuits, and circuits necessary to store and retrieve
information from memory. It also includes communication ports to the other peripherals,
other PLCs or programming terminals. Todays processors vary widely in their capabilities
to control the real world devices. Some control as few as 6 inputs and

outputs (I/O) and other 40,000 or more. One processor can be control more than one
process or manufacturing line. Processors are often linked together in order to provide
continuity throughout the process.

RAM

RAM or Random Access Memory is a volatile memory that would lose its information if
power were removed. This is why some processors units incorporate a battery back-up.
This type of RAM normally used CMOS or Complementary Metal Oxide Semiconductor.
CMOS RAM is used for storage of the users program (ladder logic diagrams) and storage
memory

16

ROM

ROM or Read only memory is a non volatile memory. This means you dont need external
power source to keep information. In this type of memory, information can be read, but
not changed. For these reason the manufacture sometimes calls this firmware. It is placed
their for the internal use and operation of processors units.

EEPROM

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

memory module that is used to back of the main program in COSMOS RAM of the
processors. Can be programmed to load the EEPROMs program to RAM is lost or corrected.

INPUT MODULE

There are many types of input module to choose form. These type of module used is
dependent upon what real world input to the PLCs is desired. Some example input are limit
switches, electric eyes, and pushbuttons. DC input, such as thumbwheels switches, can be
used to enter integer values to the 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. Electromechanical interference
(EMI) and radio frequency interference (RF) can be 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. 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 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 connect to a controller (transducer) producing an electrical signal the
analog input card can interpret. This signal is usually 4 to 20 Ma or 0 to 10 volts.

17

OUTPUT MODULE

Output modules can be used for ac or dc devices such as solenoids, relay, contractor, pilot
lamps, and LED readouts. Output card usually have from 6 to 32 outputs on a signal
module. The output device within the cards provides the connection from the user power
supply to the load. Usually silicon controlled rectifier (SCR), triac, or dry contact relay are
use for this purpose. Individual output 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 be take a value store 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 device.

SENSORS
A sensor is a device that converts a physical condition into an electrical signal for use by the
PLC. Sensors are connected are input of a PLC. A pushbutton is one example of sensors that
is connected to the PLC input. An electrical signal is sent from the pushbutton to the PLC
indicating the condition (open/closed) of the pushbutton contacts

Pushbutton (Sensors)
PLC INPUT

18

ACTUATOR

Actuators convert an electrical signal from the PLCs into a physical condition. Actuators are
connected to the PLC output. A motor starter is one example of actuator that is connected to
the PLC output. Depending on the PLC signal the motor starter will either start or stop motor.

PLC
INPUT

Motor
Actuator (Starter)

NUMBER SYSTEM
Since PLCs is computer it stores information in the form of on or off conditions (1 to 0),
refers to as binary digits (bits). Sometimes binary digits are used individually and
sometimes they are used to represent numerical valves.

DECIMAL SYSTEM

Various number system are used by PLCs. All number systems have the same three
characteristic:

Digits
Base
Weight.
The decimal system, which is commonly used in everyday life, has the following characteristic:
Ten digits

0,1,2,3,4,5,6,7,8,9

Base

10

Weights

1, 10, 100, 1000

19

BINARY SYSTEM
The binary system is used by programmable controllers. The binary system has the
following characteristic:

Two digits 0,1

Base

Weights power of base 2 (1, 2, 4, 8, 1, 6)

In the binary system 1s 0s are arranged into columns. Each column is weights. The first
column has a binary weight of 2.
This is equivalent to decimal 1. This is referred to as the least significant bit. The binary
weight is double with each succeeding column. The next column, for example, has a weight
of 2^1which is equivalent to decimal 2. The decimal value is double in each successive
column. The number in the far left hand column is referred to as the most significant bit. In
this example, the most significant bit has a binary weight of 2^7. This is equivalent to
decimal to 128.

20

CONVERTING BINARY TO DECIMAL

The following steps can be used to interpret a decimal number from a binary value.

1. Search from least to most significant bit for 1s .

2. Write done the decimal representation of each column containing a 1.
3. Add the columns values.
In the following example, the fourth and fifth columns from the right containing a 1.The decimal
values of the fourth column from the right is 8, and the decimal value of the fifth column from the
right is 16. The decimal equivalent of this binary number is 24. The sum of all the weighted
columns that contains a 1is the decimal number that the PLC has stored

BITS, BYTES, AND WORDS

Each binary piece of data is a bit. Eight bits make of one byte.
Two bytes, or 16 bits, make of one word.

21

LOGIC 1, LOGIC 0
Programmable controllers can only understand a single that that is on or off (present or not
present).the binary system is a system in which there are only two numbers, 1 and 0.
Binary 1 indicates that a signal is present, or the switch is on.
Binary 0 indicates that a signal is present, or the switch is off.

BCD (Binary-coded decimal)

Binary-coded decimal (BCD) are the decimal number where the each digit is represented by
a four-bit binary number. BCD is commonly used with input and output devices.
Thumbwheel stitch is one example of an input device that uses BCD. The binary number
are broken into group of four bits, each group representing decimal equivalent. A four-digit
thumbwheel switch, like the one show here, would control 16 (4*4) PLC inputs.

22

HEXADECIMAL
Hexadecimal is another system used in PLCs. The hexadecimal has the following
characteristic:

16 digits 0,1,2 ,3,4,5,6,7,8,9,A,B,C,D,E,F

Base 16, weights power of base 16(16, 256, 4096..)

The ten digits of the decimal system are used for the first ten digits of the hexadecimal
system. The first six letter of the alphabet are used for the remaining six digits.

A=10, B=11, C=12, D=13, E=14, F=15

The hexadecimal system used in PLCs because it allows the statues of large number of
binary bits to the represented in a small space such as on a computer screen or
programming device display. Each hexadecimal digit represented the exact of the four
binary bits. To convert a decimal number to a hexadecimal number the decimal number is
divided by the base of 16.

To convert decimal 28, for example, to hexadecimal

Decimal 28 divided by 16 is 1 with a remainder 12. Twelve is equivalent to C in

hexadecimal. The hexadecimal equivalent of decimal 28 is 1c.
The decimal value of a hexadecimal is obtained by multiplying the individual hexadecimal
digits by the base 16 weight and the adding the results. In the following example the
hexadecimal number 2B is converted to its decimal equivalent
Of 43.

23

COOMUNICATION

There are several methods to communicate between a PLC and 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. The communication can be RS232, RS485 or TTY.
Communication 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 input on
another PLC. The direct link method of communication can be as a simple as, if an output
on the PLC is on then the corresponding input on the second PLC will be on and then this
input is used within on the program on the second PLC

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
Detect the state of all input device that are connect to the PLCs

Program Scan
Execute the user create program logic.
24

OUTPUT SCAN
Energize or de-energize all output devices that are connect to the PLCs.
HOUSEKEEPING
This step includes communication with program terminals, internal diagnostic etc.

CHECK INPUT STATES

First the PLC takes a look at each input to determine if is on or off. In other words, is
the sensors connected to the first input on? Then second input? Then the third so
onit
record this data into its memory to be used during the next step.

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

UPDATE OUTPUT STATES

Finally the PLC updates the state of the outputs. It update the outputs base on which
inputs were on during the first step and the result of executing your program during
the second step. Based on the example of 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 step continuously.
One scan time is defined as the time is takes to execute the 3 steps listed below.

25

PROGRAMMING PLC
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 control. The ladder diagram contains contact rails to the left the right of
the diagram, these contact rails are connected to switching elements (normally open/
normally closed contacts) via current path and the coil elements.

FUNCTION BLOCK DIAGRAM (FBD)

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

26

SEQUENTIAL FUNCTION CHART (SFC)

The sequential function chart is language resource for the structuring of sequenceoriented control programs. The element of the sequential function charts are steps,
transition, alternative and parallel branching. Each step represents a processing state of a
control program, which is active or inactive. A step consists of action which identical to the
transition, are formulated in the IEC 1131-3 languages. Action themselves can again
contain sequence structure. The feature permits the hierarchical structure of the control
program. The sequential Function Chart therefore an excellent tool for the design and
structuring of control programs.

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

Ladder Logic was one of the first programming approaches used in PLCs because it
borrowed heavily from the relay diagram that plant electricians already knew.
The symbols used in relay ladder Logic consists of a power rail to the left, a second power
rail to the right. The logic of each circuit (or rung) is solved to the left to right. The symbols
of these diagram look like a ladder with two side rails and circuits that resemble rungs on
ladder.

The picture above represented single rung of ladder

If input is on (or true)- power (logic) completes the circuits from the left rail- and output turns ON(or true)
If output is off (or false)- then the circuit is not complete and logic does not follow to the right- and output
1 is OFF
There are many logic symbols available in ladder logic-includes
Timers , counter , Math, and Data moves such that any logical condition or control loop can be represented
in ladder Logic. With just hand full of basics symbols a normally open contact, normally closed contact,
normally open coli, normally close coils, timer, counter most logical conditions can be represented.

CONTACT AND COILS

With just the normally open contact and normal open coil a surprising array of basic logical conditions can
be represented.

27

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 reference input is examined for an ON (Logic1) condition. if it is ON, contact will
closed and allow power (logic) to flow from left to right. If the state is off (logic 0).then contact is open,
power (logic) will NOT from left to right.

Normally open coil

This can be used to represent any discrete output from the control logic

When solve if the logic to left of the coil is TRUE, the referenced OUT is ON (logic1)

SOLVING SINGLE RUNG

Suppose a switch is wired to input, and a light bulb is wired through output 1 in a such way
that the light is OFF when output1 is off and ON when output1is ON.
When input1 is OFF (logic 0) the contact remaining open and power cant flow from left to
right, therefore,Output1 remain off (logic 0)
When input is ON (logic 1) then the contact close, power flows from left to right, and
output1 becomes ON (the right turns ON)

28

THE AND RUNG

The AND is a basic fundamental logic condition that is easy to directly represent in Ladder
Logic.

Suppose a switch is wired to Switch1, a second switch is wired toSwitch2, 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 that is easy to represent in ladder diagram

Suppose a switch is wired to switch 1, second switch is wired to switch 2, and the light bulb is wired
through a light1 in such a way the light is OFF when light is OFF, and ON when light is ON. In this instance,
we want to the light to turn ON if either switch1 OR switch is ON.
If switch1 is ON - power flow to Light1 turning it ON.
If switch2 turn is ON power flows through the switch2 contact, and up the rail to light1- turning it ON.
If switch1 AND Switch2 are ON- light1 is ON.
The only way Light1 is OFF is if Switch1 AND Switch2 are OFF.
29

MOTOR STARTER EXAMPLE:

First consider a hardwired approach

The following line diagram illustrate how a normally open and a normally closed pushbutton might be
connected to control a three -phase AC motor as shown above figure.
In this example , a motor starter coil (M) is wired in series with a normally open, momentary start
pushbutton, a normally closed , momentary stop pushbutton , and normally closed overload relay (OL)
contacts.
Momentarily pressing the start push button complete the path for current flow and energies the motor
starter (M). This close the associated M and Ma (auxiliary contact located in the motor starter ) contacts.
When the start button is released, current
Continues to flow through the stop button and the Ma contacts, and the M coil remains energized. The
motor will run until the normally closed stop button is pressed, unless the overload relay (OL) contacts
open . when the stop button is pressed, the path for current is interrupt , opening the associated M and
Ma contacts and the motor stop

30

SCADA
Introduction
SCADA is not a specific technology, but a type of application
SCADA stands for Supervisory Control And Data Acquisition any application can gets data
about a system in order to control the system is a SCADA application it is a purely software
package that is positioned on top of hardware to which it is interfaced , in general via
Programmable logic controller (PLCs), or other commercial hardware modules.

In other words
SCADA: the term refers to a large scale, distributed measurement (and control) system.
SCADA are used to monitor or to control chemical, physical or transport process.
SCADA it is refers to an industrial control system a computer system monitoring and
controlling process. The process can be industrial, infrastructure or facility describe below

Industrial process: it is includes those of manufacturing, production, power generation,

fabrication, and refining and process may be in continuous, batch, repetitive or discrete or
modules.

Infrastructure process: it may be public or private and water treatment and distribution,
wastewater collection, and treatment, oil and gas pipelines , electric power transmission
and distribution, and large communication systems.

Facility Process: it is occur both in public facilities and private ones, including building,
airports, ship and space station. The monitor and control HVAC, access and energy
consumption
A SCADA system usually consists of following subsystem

A Human Machine interface (HMI) is the apparatus which present process data to
human operator, and through this, the human operator monitor and control the
process.

A supervisory (computer) system, gathering (acquiring) data on the process and sending commands.

Programmable Logic Controller (PLC) used as field devices because they are more economical, versatile,
flexible configurable than special purpose -RTUs.

Communication infrastructure connection the supervisory system to the Remote Terminal Unit.

Remote terminal unit (RTU) connection to sensors in the process and converting sensors signals to digital
data and sending digital data to the supervisory system.

31

Systems Concepts
The terms SCADA usually refer to a central system that monitors and controls a complete
site. The bulk of the site control is actually performed automatically by a Remote Terminal
Unit (RTU) or by a programmable Logic controller (PLC). Host control functions are almost
always restricted to basic site over- ride or supervisory level capability.
EX: A PLC may control the flow of cooling water through part of an industrial process, but
the SCADA system may allow operators to change the set points for the flow, and enable
alarm condition, such as loss of flow and high temperature, to be displayed and recorded.
The feedback control loop passes through the RTU or PLC while the SCADA system monitors
the overall performs of the loop.

TAGS (POINTS)
It is logical name of a variable or object that be used in our animation of a plant.
Tags are two types

System defined Tags

User defined tags
32

System defined tags

It is represent the system value in the SCADA it is represented by dollar sing $

User defined tags
This tag are defined by the user or programmer
Except (A,S) are not defined.
Trends:
it is used for graphical representation of process

Two types
Real times trends
Historical Times trends
Classification of tags

Direct tags
Indirect tags
Direct tags
These tags are directly used by the programmer to represent the value of plant or variable

Indirect tags
These tags are used by the another tags to show or represent the value of plant or variable
Direct tags

Memory tags : these tags having no connection with process the plant.

33

ALARM
An important part of most SCADA implementation is alarm handling. The system monitors
whether certain alarm conditions are satisfied, to determine when an alarm event has
occurred. Once alarm event has been detected, one or more action are taken (such as the
activation or remote SCADA operators are informed) in many case, a SCADA operate may
have to knowledge the alarm event, these may be deactivate some alarm indicators
whereas other indicators remain active until the alarm conditions are cleared. Alarm
conditions can be explicit - for example, an alarm point is a digital status point
that has either the value NORMAL or ALARM that is calculated by a formula based on
the values in other analogue and digital points- or implicit: the SCADA system might
automatically monitor whether the value in an analogue point lies outside high and low

limit values associated with that point. Examples of alarm indicators include a siren, a popup box on a screen, or a colored or flashing area on a screen (that might act in a similar
way to the "fuel tank empty" light in a car); in each case, the role of the alarm
indicator is to draw the operator's attention to the part of the system 'in alarm' so that
appropriate action can be taken. In designing SCADA systems, care is needed in coping
with a cascade of alarm events occurring in a short time, otherwise the under lying cause
(which might not be the earliest event detected) may get lost in the noise. Unfortunately,
when used as a noun, the word 'alarm' is used
rather loosely in the industry; thus, depending on context it might mean an alarm point, an
alarm indicator, or an alarm event.

SYSTEM COMPONENTS

The three components of a SCADA system are:

1. Multiple Remote Terminal Units (Also knows as RTUs or outstation)
2. Central control Room with host computer (s)
3. Communication infrastructure

Remote Terminal Unit (RTU)

The RTU connects to physical equipment and read status dada such as the open/close status from a switch or
a valve, read measurements such as pressure, flow, voltage or a valve, or setting the speed of a pump. The
RTU can read digital status data or analogue measurement dada, and send out digital commands or analogue.

34

Salient feature of modern SCADA system

1.
2.
3.
4.
5.

User- friendly (X-windows/graphic) interface.

Automatic control.
Off-line processing.
Integrated environments.
Extensive Historical data manipulation.

6. Extremely high data throughput

7. On-line complex electrical network analysis.
8. Real time supply/ demand- side economic calculations.
9. Automatic voltages and power factor correction.
10.Distributed processing power.

Benefits HMI/SCADA
1.
2.
3.
4.
5.
6.

Powerful monitoring and control over your production

Ease of use for New and experienced users.
Robust connectivity to other software, system and devices
True client /server Architecture for ease Scale ability
Powerful thin client technology.
Sophisticate Alarm and trending.

SCADA Recommended
1.
2.
3.
4.
5.
6.
7.
8.

LAN /WAN support

Import from multiple PLC system
Support for low bandwidth operation.
Secure & flexible.
Low CPU & memory requirements.
Drives work on Rs232, 422, 485, TCP/IP.
Unlimited number of tags (tags support 80 char).
Graphic (transparent color support, advanced animation without coding, import graphic window bitmap
Auto Cad, fax image.
9. Supervision
10. Controlling
11. Dada collection
12. Interface of PLCs
13. Alarm.

Human Machine Interface (HMI)

Introduction
HMI is the smallest form of SCADA which is used for monitoring and controlling and it is
combination of hardware and software.
35

Human machine Interface:

The HMI/SCADA industry was essentially out of a need for user friendly front-end to a control
system containing programmable logic controller (PLC). While a PLC does provide
automated, preprogrammed control over a process, they are usually distributed across a

plant, making a difficult to gather data from them manually. additionally, the PLC information
are usually in crude user-unfriendly format. The HMI/SCADA gather information from the
PLCs via some form of communication method, and combines and formats the information.
Since the early1990s the role of SCADA system in large civil engineering solutions has
changed, requiring them to perform more operations automatically. A sophisticated HMI may
also be linked to a database to provide instant trending diagnostic data, scheduled
maintenance procedures, logistic information, detail schematics for a particular sensors or
machine, expert system troubleshooting guides.
Since about 1998 , virtually all major PLC manufacture have offered integrated HMI/SCADA
system, many of them using open and non proprietary communication protocols

Types of HMI

1. Keypad
2. Touch screen
3. Keypad + touch screen

Difference between SCADA and HMI

SCADA

HMI

It is software

it is combination of s /w and h/w

It is work at low temperature

it is work at high temperature & low

Screen ratio of SCADA is large

Screen ratio of HMI is Low i.e 6 inch

Local and Remote control

LAN area Control

Data base connectivity is possible

Data base connectivity is not possible

Range of SCADA

Range of HMI is 100m

36

Instrumentation

Instrumentation is a branch of engineering electric (science) which is used for

measurement of process parameters and electric parameters it include, flow meter,
thermocouple, level instrument etc.

Transducer:
It is device which converted one form of engineering into another form of energy.

Sensors:
It is transducer which converted one form of energy into measurable form of energy.
Types of sensors
1. Flow meter
2. Pressure sensors
3. Ambient meter
Transmitter
It is a device which is used for the transmission of signal over long distance so generally
used for transmitter.

37

Electric power generation, transmission and Distribution.

Manufacturing industries.
Mass transit & whether management system
Traffic signals.
Cement and petrochemicals industries.
Automobiles industries

38

Application for PLC in substation automation & SCADA

There are many applications for PLC for substation automation, distribution automation &
SCADA system. As utility engineers become more familiar with capability of PLCs and PLC
manufactures develop a new substation specific products. The number and type of
potential applications continues to increase.
RTU (Remote terminal Unit) emulation & replacement

Alarm reduction & intelligent messaging

Utilize existing SCADA protocols

Ethernet, TCP/IP

Multiprotocol, DNP 3.0, Modbus plus

Analog & Discrete I/O

Protection & control

Protective relay interface/ intrection

Automatic switching

Automatic transfer schemes

Circuit breaker control &interlocking

Feeder automation & fault recovery

Automatic service restoration

Emergency load Shedding

Station HMI- Graphic user interface (GUI)

Remote control

Demand control

39

CONCULAION

This report has discussed the role that programmable logic controller have in
efficient design and control of mechanical process. Also discussed was the
understanding,

AUTOMATION, SCADA, HMI, Instrumentation and the programming

involved with it. Finally, the report has discussed as complete Automation, like
a , relay, Components, history.
Programmable Logic Controller, history, advantages. Inside PLC etc

PLC components, understanding Ladder logic, example

SCADA: this section contains basic introduction of SCADA, features,

Recommended, Tags, Trends

Difference between SCADA & HMI.

HMI: This section contains basic HMI, types of HMI, introduction.

40

REFERANCE

Pollet, Jonathan, SCADA Security Strategy, Plant data Technology, August 8, 2002
www.scadanews.com
www.princeton-indiana.com/wasetewater/Pages
www.ref.web.cern.ch/ref/CERN
www.sss-mag.com/scada.html
www.scada.com
www.scrib.com

41

BIBLIOGRAPHY

Study material by Prolific automation system pvt. Ltd.

Study material by Futronix automation pvt. ltd.
Programmable logic by John. R . Hockwarth
controllers
Programmable logic by L.N.Bryan
controllers E.A.Bryan
Programmable logic by W.Batton
Controllers
Automatic manufacturing by Hugh Jack
System with PLC
Communication technology guidelines for SCADA system, power delivery by Marihart,
D.J

42