ABSTRACT

In this modern world of

industrialization and automation, energy
plays a major role in the growth of any
organization. The utilization of energy plays
an impacting and direct role in the growth of
organizations like Visakhapatnam steel plant.
In vizag steel plant , there is
Supervisory Control And Data Acquisition
(SCADA) systems present for monitoring of
energy networks which are present
throughout the plant. The objective of this
proposed SCADA systems is to monitor the
energy usage and demands of various
consumers of the plant and exercise effective
control over their energy consumption
optimum utilization of in-house energy
resources.
In this modern world of competition
the technology is changing very rapidly. To
compete with the changes and to sustain the
development, Visakhapatnam Steel Plant is
going for up gradation of its existing SCADA
systems with the latest state of arttechnology with the features like using high
speed processors having cache memory and
using the powerful unix based OS.
This project makes a brief study of

existing SCADA systems present in

Visakhapatnam Steel Plant and the changes
that are going to come to in the proposed
SCADA systems that is to be installed in the
near future.

GROWTH AND IMPORTANCE OF STEEL

INDUSTRY IN INDIA.
Steel comprises one of the most important inputs in all sectors of
economy. Steel industry is a basic core industry. The economy if any
depends on strong base f iron and steel ingn that nation. History has
shown base of iron and steel industry in that nation.
History has shown that countries having a string potentially for iron and
steel production have played the prominent role in the advancement of
civilization in the world. Steel is such a versatile commodity that every
object we see in our day to day life has used steel either directly or
indirectly
However its use is innumerable to mention a few, it is used for such
small items as nails, pins, needles etc., through surgical instruments,
agricultural implements, ships, boilers, frigates, railway materials,
automobile parts etc.. The great investment that has gone into the
fundamental research in Iron and Steel technology has helped both
directly an indirectly many modern fields of todays civilization without
steel. Steel is versatile and indispensable item. The versatility of steel can
be traced through mainly these reasons :

It is the only material item which can be conveniently produced in

tonnage quantity.
It has got very good strength coupled with ductility and malleability.
Its property can be changed over a wide range.
It alloys easily with many of the common elements.
The properties can be manipulated to any extent by proper heat
treatment techniques.
Taking these factors into consideration, it can be said without
committing a serious error, that the type of steel available are
innumerable.
Visakhapatnam Steel Plant is an integrated steel plant.

Characteristics of Integrated Steel Plant.

Visakhapatnam Steel Plant is an integrated steel plant

This integrated steel plant has large capacities, highly capital
intensive, labor intensive and they would have all facilities including
raw material resources, water supply, power supply, testing and
inspection facilities, township facilities, medical, educational,
recreational etc., all under one administrative control. This would
reduce the extent of dependency on outside agencies, which would
help the smooth running of the plant.

Technology in Steel Plant

Visakhapatnam steel plant is the most sophisticated and modern
integrated steel plant in the country modern technology has been
adopted in many areas of production, some of them for the first time in
the country. Among these are

Selective crushing of coal

Evenching of coke
Conveyor charging and bell les top for blast furnace
Hundred percent continuous casting of liquid steel
Gas expansion turbine for power generation utilizing blast
furnace top gas pressure.
Hot metal desulphurization.
Extensive treatment facilities for effluence for ensuring proper
environment protection.
Computerization for process control
Sophisticated, high speech and high production rolling mills.

MAJOR DEPARTMENTS IN VSP

RAW MATERIAL HANDLING PLANT (RMHP) :
The RMHP receives the basic materials iron ore, fluxes (lime stone,
dolomite),coking and non coking coals etc. required for the steel making process
from various sources through wagons which are stacked and reclaimed by
stackers-cum

reclaimers

and

distributed

to

various

Visakhapatnam steel plant through conveyor systems.

COKE OVENS (CO):

departments

of

Blast furnaces, the mother units of any steel plant require huge quantities
of strong, hard and porous solid fuel in the form of hard metallurgical coke for
supplying necessary heat for carrying of the reduction and refining reactions
besides acting as a reducing agent.
Coke is manufactured by heating of crushed coking coal (below 3mm) is
in the absence of air at a temperature of 1000deg centigrade and above for
period of 16 hrs to 18 hrs. A coke oven comprises of two hollow chambers
namely coal chamber and heating chamber in the heating chamber a gaseous
fuel such as blast furnace gas, coke oven gas etc. is burnt. The heat so
generated is conducted through the common wall to heat and carbonize the
coking coal placed into adjacent coal chamber. Number of ovens built in series
one after the other form a coke oven battery.
At VSP there are three coke oven batteries, 7 meter tall and having 67
ovens each. Each oven is having volume of 41.6 cu meters and can hold up to
31.6 tons of dry coal charge. The carbonization takes place at 1000 to 1050
degrees centigrade in the absence of air for 16 to 18 hours.
Red hot coke is pushed out of the oven and sent to coke dry cooling
plants for cooling to avoid its combustion. There are three coke dry cooling
plants (CDCP) each having four cooling chambers. The capacity of each cooling
chamber is 50 to 52 TPH. Nitrogen gas is used as the cooling medium. The heat
recovery from nitrogen is done by generating steam and expanding in two back
pressure turbines to produce 7.5 power each.
The coal chemicals such as benzol, tar, ammonium sulphate etc. are extracted in
coal chemical plant from co gas. After recovering the coal chemicals the gas is
used as a byprioduct fuel by mixing it with gases such as BF gas, LD gas etc. A
mechanical, biological and chemical treatment plant takes care of the effluents.

SINTER PLANT :
Sintering is one of the most widely used and economic agglomeration
techniques. Sinter is a hard and porous lump obtained by agglomeration of fines
of iron ore, coke, limestone , and

metallurgical waste. Sinter increases the

productivity of blast furnace, improves the quality of pig iron and decreases the
consumption of coke rate .Two 312 square meter sinter machines with 420

square meter straight stand type coolers for annual production of 5.26 MT sinter.

BLAST FURNACE (BF) :

Pig iron or hot metal is produced in the Blast Furnace .The furnace is named as
BF as it is run with blast at high temperature and pressure of 1500 deg. C. Raw
materials required for pig iron and iron are iron making ore, sinter, coke, and lime
stone. There are two 3200 cubic meter blast furnace to meet 3.0 MT annual
metal requirement. with bell- Each furnace is provided with a set of four hot
blast furnace stoves designed for supplying air blast up to 1300 deg .C. Three
turbo blowers, one for each furnace and one stand by common to both furnaces
are provided with 12 MW top pressure recovery turbo generating power. BF gas
is produced from each furnace is being cleaned in gas cleaning plant comprising
dust catcher, high pressure scrubber and is distributed through out the plant as a
fuel.

STEEL MELT SHOP (SMS) :

Steel is an alloy iron and carbon, where carbon should be less than 2%. Hot
metal produced in B.F contains impurities like carbon, sulphur, phosphorous,
silicon etc., these impurities will be removed in steel making by oxidation
process. These are the three L.D converters to convert hot metal in to steel. The
steel melt shop complex comprising two 1300-ton hot metal mixers, three 130ton LD converters (two operating) and six 4-stand bloom casters. Each converter
is being provided with gas cleaning plant for cleaning and recovery of LD gas,
which will be used as fuel in plant.

ROLLING MILLS (RM):

Blooms cannot be used as they are in daily like. These blooms have to be
reduced in size and properly shaped to fit for various jobs. Rolling is one of the
mechanical processes to reduce large size sections in to smaller ones. The cast
blooms from CCM are heated and rolled in to long products of different
specifications like high capacity, sophisticated high-speed rolling mills.

The

rolling mill complex comprises:

Light and medium merchant mill (LMMM)
Wire rod mill (WRM)
Medium merchant and structured mill (MMSM).
Each mill is well equipped with required number of walking beam furnaces for
heating of walking beam furnaces for heating of blooms or billets and except for
wire rod mills, each furnace is provided with evaporative cooling system for
generation of steel for plant consumption.

THERMAL POWER PLANT (TPP) :

The estimated power requirement for V.S.P in 280 at 3.0 MT stages, the peak
load being 292 MW

essential loads being 49

MW. The generating capacities

286.5 MW. A captive power having 3x60 MW turbo-generator sets and 5x330
ton/hr steam generators. In this plant, 6000 Nm^3/min turbo blowers are being
provided for supplying cold air blast furnaces.

COMMUNICATION SYSTEMS IN VSP

Role in co coordinating the activities of various departments / sections and in
achieving the set targets and also in improving the performance of the
organization.

In Visakhapatnam Steel Plant, different types of communication

systems are being used to meet the internal and external communication needs.
These are broadly classified as follow:

General purpose communication systems.

Process communication systems.
Monitoring & Signaling Systems.

In this modern age of industrialization telecommunications plays a very

important
Apart from the above facilities Telecom department maintains the following cable
networks also

a) DATACOM cable network.

b) Telephone cable network in plant and township
GENERAL PURPOSE COMMUNICATION SYSTEMS:
The following facilities are provided under category of general purpose
communication systems:
4000 lines IP based Telephone in Plant.
3000 lines Electronic Exchange in Township.
100 lines Electronic Exchange in Visakha Steel General Hospital.
44 lines Electronic exchange in Hill Top Guest House

2500 Lines Electronic Exchange of Bharat Sanchar Nigam ltd (BSNL) in Project
Office is catering to the needs of Plant area and Sectors-I to VII in township.
Another 2000 Lines Electronic Exchange of Bharat Sanchar Nigam ltd (BSNL) in
Township is catering to the needs of Sectors-VIII to XI in Township.
The 3000 Lines electronic exchange in plant and 3000 lines exchange in
township are having the following facilities:
Extension (subscriber) to extension call, Auto call back, Hot lines, Music on hold,
Reminder Alarm, Automatic line testing facility, Faults man ring back, Call consult
facility, Malicious call tracing facility, 3 party conference Facility and Howler Tone
alert etc. All exchanges working in the steel plant are interconnected by means
of junction lines and have closed numbering scheme.
The 3000 lines exchange in township is interconnected to the BSNL network. Due
to this interconnection all the subscribers of this exchange can receive incoming
calls from any part of the world. A few subscribers are provided with facility to
contact subscribers connected to the BSNL network and cellular and mobile
phones in and around Visakhapatnam.

PROCESS COMMUNICATION SYSTEMS:

To facilitate coordination, operation & management activities of production,

maintenance & service departments,

the following process communication

systems are provided:

a) Dispatcher communication system
b) Loudspeaker intercom systems
c) Loudspeaker broadcasting systems
d) Loudspeaker conference communication system
e) Industrial public address system
f) Hotline communication systems
g) VHF communication systems

A) DISPATCHER COMMUNICATION SYSTEMS :

Initially dispatcher communication is provided with a cordless switch board type
manual exchanges of electromechanical. Since manufacture of such systems and
their spares is discontinued in the country, these dispatcher systems are being
replaced by Electronic exchanges progressively. Except the ones in CCCP other
systems have been replaced. These would also be replaced very soon.
Production coordination at plant level being conducted by ED (Works) with all
HOD s in the morning every day is facilitated with the help of the digital EXCOM
system provided in the plant control room.

B) LOUD SPEAKER INTERCOM SYSTEMS :

Loudspeaker intercom systems are working LMMM & WRM. These systems are
used for communication between various sections of the same production shop.
Communication is made possible using microphones and loudspeakers provided
in the subscriber stations. This system is very useful in noisy environment where
conventional

telephones are

ineffective.

This system helps to

establish

communication between any two stations having interconnectivity on selection

basis.

By using group call facility it is possible to communicate to all the

subscribers in the group at a time.

C) LOUDSPEAKER BROADCASTING SYSTEMS:

This system consists of centralized amplifier rack with amplifiers, desktop micro
phone with press to talk switch and a network of loud speakers connected to the
amplifiers .this is useful to make general announcements to the entire working
area as to pass on important instruction from the control room.
Loudspeaker broad casting systems are provided in C&CCD, BF, SP and SMS
departments.

D) LOUDSPEAKER CONFERENCE COMMUNICATION SYSTEMS:

Loudspeaker conference communication systems are working in CCCP. These
systems are provided with both paging and private channel communication
facilities. In case of paging a general announcement can be made which is heard
on all the stations. In the private mode communication is possible between two
selected stations only.

Here also communication is carried out by means of

microphones and loudspeakers provided in the subscriber stations.

E) INDUSTRIAL PUBLIC ADDRESS SYSTEM:

Industrial Public Address System is working in TPP. It is a combination of
loudspeaker broadcasting system and conference communication system. From
the main control room it is possible to make announcements which are heard on
the shop floor. From certain locations the communication can also be established
through handsets in private mode with the main control room.

F) HOTLINE COMMUNICATION SYSTEMS:

To ensure direct telephone communication between closely related critical locations
hot lines are provided. By using the hot lines specified locations are connected
permanently. Communication is possible only between these two locations. When

one subscriber lifts his telephone the other will immediately get a ring and
communication can be had without any loss of time.
This is useful to pass-on urgent messages. These hot lines are initially provided with
direct line communication systems which are electro mechanical systems. Due to
obsolescence electronic systems are now being used for most of the locations. Hot
lines are working in CCCP, BF, SMS, LMMM, WRM, MMSM, TPP, PPM, DNW and WMD
departments.

G) VHF COMMUNICATION SYSTEMS:

VHF

communication

systems

are

used

in

VSP

to

establish

two

way

communications between two or more when either or one of them is moving.

There are three models working in our plant. They are hand-held units (Walkietalkie), vehicle mounted mobile units and base station units.
Walkie-talkies are used by operation and service personnel in almost all of the
production shops. Vehicle mounted units are being used by DNW, CISF (Fire) and
CISF (security). Base station units are used by CISF (fire), CISF (Security),
Administration, DNW and largely by CCCP departments. In CCCP these can be
seen in pusher cars, charging cars, door extractors, electric locos, lifters and
CDCP areas. These sets are very essential and useful in answering proper
communication and coordination during alignment of oven machines while
charging and pushing the ovens and carrying out these operations safely.
Handheld VHF sets are

extensively used for establishing instantaneous

communication and ordination of operation or maintenance activities on different

departments throughout the steel plant.

MONITORING AND SIGNALING SYSTEMS:

To facilitate monitoring production, maintenance & service activities, the
following monitoring and signaling systems are provided:
a) Closed Circuit Television Systems (CCTV)
b) Central fire alarm signaling system
c) SCADA system

d) Shift change Announcement Siren System

A) CLOSED CIRCUIT TELEVISION SYSTEMS (CCTV):

For monitoring critical operations in different production units continuously from
the concerned control rooms / pulpits CCTV systems are used in SP, BF, SMS,
LMMM, WRM and MMSM departments. CCTV system comprises of CCTV camera
with a lens and a CCTV monitor.
In some cases a video switcher, a central control console, pan and tilt head and
zoom lens are also used. These are interconnected by means of control cables
and / or coaxial cables. Necessary protection is provided for the CCTV equipment
depending on the locations where they are used.

B) CENTRAL FIRE ALARM SIGNALING SYSTEM :

The central fire alarm system is provided for communicating the exact location of
outbreak of fire in any part of the steel plant complex to the central fire station
and simultaneous actuation of sirens to alert personnel of the affected plant
zone. The system employs manual call points located all over the plant.

C) SCADA SYSTEM :
To monitor the generation and

consumption of various energies

by various

users in the plant the SCADA system is provided. Scada system is located at
Energy and Telecom centre.
The system comprises of a master servers ,23 Remote Terminal Units (RTUs)
installed in different plant units and display units.

The RTUs will collect the

signals from the tranducers & electrical systems and transmitting to the master
servers by means of communication channel. The RTUs are connected to the
master servers by under ground laid telephone cables.

D) SHIFT CHANGE ANNOUNCEMENT SIREN SYSTEM:

The shift change announcement siren system is provided for ensuring uniform
and accurate shift timings throughout the plant.

This system consists of two

quartz crystal controlled master clocks in the Energy & Telecom Centre. The shift
timings are programmed in the Master Clock. At the specified time, the signal
will be transmitted for energizing the sirens located at strategic points in plant
area simultaneously at the preset timings.

SCADA SYSTEM:
SCADA is an acronym for Supervisory Control and Data Acquisition system, a
computer system for gathering and analyzing real time data. SCADA systems are
used to monitor and control a plant or equipment in industries such as water and
waste control, energy, oil and gas refining and transportation. A SCADA system
gathers information, such as where a leak on a pipeline has occurred, transfers
the information back to a central site, alerting the home station that the leak has
occurred, carrying out necessary analysis and control, such as determining if the
leak is critical, and displaying the information in a logical and organized fashion.
SCADA systems can be relatively simple, such as one that monitors
environmental conditions of a small office building, or incredibly complex, such
as a system that monitors all the activity in a nuclear power plant or the activity
of a municipal water system.
SCADA systems were first invented in the 1960s.

The signals for a plant unit will normally be concentrated in the control room of
the unit from where the unit is being operated. PLCs/RTUs of the SCADA will
be installed in these main control rooms and the tele- transmission signals
identified for the units will be wired to the PLCs/RTUS .

The PLCs/RTUs are micro processor based intelligent units , responsible for
acquisition of inputs from the plant units and convert them in to digital code
for Tele -- transmission to the Master station computer of SCADA through the
5 pair telephone cable . Some plant unit where few signals are available
for tele-transmission , A junction box will be installed in the control room (
instead of an PLCs) for the termination of inputs and these inputs are further
connected to the nearest PLCs through the multi core control cables.

The 23 PLC s are located in different parts of the plant are connected to the
center master station through modems. The Master station located in the
E&T centre of the Visakhapatnam steel plant will acquire all Information
through PLC and LAN and Process the information for displays and report
generation .

The SCADA system acquires various electrical & utility parameters for effective
monitoring & control operation. The various parameters acquired are electric
power , voltages , currents , etc.,
under
electrical monitoring and
parameters such as flows , temperatures, pressures , etc..

CATEGORY OF ENERGY FORMS IN VSP

Utility systems

Electrical systems
WATER

UTILITY SYSTEMS:
The utility system covers the services like fuel , gases , stream ,
compressed air, water etc.. The services covered by the utility systems of
CSCS are broadly classified in to following groups.

Fuel gases system: CO, BF, Mixed & converter gases.

Process gas system : Nitrogen, Oxygen ,Argon, Acetylene.

Steam Distribution system: Steam at 40 KSCG, 13 KSCG.

Compressed air system: Compressed air and instrumentation grade air

Chilled water system: Chilled water.

Fuel oil system: LSHS, LDO and LTF.

Water
Water systems: make up water, fire and drinking water

ELECTRICALSYSTEM:

The electrical system covers the complete electrical distribution network inside
the Visakhapatnam Steel Plant like 220 KV ,11 KV, 6.6 KV systems in
MRS, LBSS , 1, 2 , 3 , 4 and 5 , LBDSS.
For centralized supervisory of above services in utility and electrical systems and
also to exercise control over their optimum utilization, following types of signals
are considered for the users.

Analog input (AI)

Digital input (DI)

EM SIGNALS

The input signals acquired by the PLCs are tele-transmitted to the Master station
and are sorted out according to the above subsystem division i.e utility and
electrical.

SCADA systems monitor a total of 4000 different signals originating at

different depts. in VSP. Among these 4000 signals, 1500 signals are
catered to monitor utility system and 2 500 signals are electrical
system.

ARCHITECTURE OF THE SCADA

ARCHIECTURE OF THE FIELD PLC/RTUS

PLC Architecture:

The selected PLC has got powerful processor to take care of the data acquisition
requirements of the VSP. The PLC interfaces with field to acquire the data from
various field instruments. The offered PLC system supports maintenance from
the Engineering station

in master station.

The PLC will be supplied with

ladder programming language for building local automation sequences. The

offered PLC is fully modular and supports distributed I/O for future expansion.
The PLC supports a total of 20,000 I/O ports.

The functional architecture of the PLC system will be as follows.

The offered

architecture is latest state-of-the-art in which the PLC processor communicates

with individual I/O stations over a highly reliable Ethernet ring. The extension
racks will be available for any more expansion in I/Os. The system will support a
total of 20,000I/Os.

The PLC presented above shall have the following characteristics:

High capacity controller for I/O signals

High memory capacity and expandable

Input digital signals cards

Input analog signal cards

Galvanic isolation for the signal.

Empty slots for future expansions

Ports to connect to field buses (RS232C/RS485)

Configurable to standard protocols (MODBUS RTU / Profibus DP)

Comprehensive self-testing and diagnostic facilities

SCADA Master Station over dedicated telephone cables.

HARDWARE COMPONENTS OF THE PLC :

1.

Power Supply Unit.

2.

Programming Unit.

3.

Central Processing Unit.

4.

Bus Controller Unit.

5.

Communication unit to Interface with External Programming unit.

6.

Input and Output modules.

1. POWER SUPPLY UNIT :

The power supply modules provide the power supply for each rack.
The required power supply standard format or double format model. The
mains electrical supply ~200..240V

Description of the Power Supply Unit:

1.

Display blocks comprising.

OK lamp (GREEN), if voltages are present and correct.

BAT lamp (RED), if the battery is faulty or missing.

24V lamp (GREEN) when sensor voltage is present

2.

RESET pencil-point push button causing a warm restart of the application.

3.

Slot for a battery which protects the internal RAM memory of the processor.

4.

Cover to protect the front panel of the module.

5.

Screw terminal for connecting:

To mains supply.

The alarms relay contact.

The sensors power supply for a.c supplies.

6.

Opening for cable clamp.

7.

Fuse located beneath the module and protecting.

8.

24VR voltage on the non-isolated d.c supply.

Primary voltage on the other power supplies.

110/220 voltage selector

CHARACTERISTICS OF THE POWER SUPPLY

The characteristics of the power supply module are

Primary Power supply Module:

Voltage (in V)
Nominal

~100240

Limit

~85..264

Frequency (in Hz)

Nominal /limit

5060/47..63

Current (in A)
Nominal input 1ms

0.5 at ~100v
0.3 at ~240V

Secondary power supply Module:

Output
Nominal voltage

5V

Nominal current

5A

Power

25W

Output
Nominal voltage

24V

Nominal current

0.6A

Power (typical)

15 W

Description of the 12 slot Rack Power Supply Unit:

It is possible to constitute a PLC station with premium processors with just a

single rack. These racks are connected to each other.

The Racks comprise :

1. Metal frame.
2. Slots for anchoring the Module pins.
3. 48-way female DIN connectors for module-rack connections
4. Locating slot for the power supply module.
5. Trapped holes for mounting the module.
6. Four holes for mounting the rack.
7. Position for rack address label.
8. Position for station network address label.
9. Two earth terminals for earthing the rack.
10.Micro switches for coding the rack address
11.Two 9-way female SUB-D connectors for the remote connection of bus X to
another rack.

Rack address:

Address 0: This address is always assigned to the rack which holds the
processor.
This rack can be located in any position on the line.
Addresses 1 to 7: These can be assigned in any order to all other extendable
racks of the station.
As the two racks with 4, 6 or 8 slots which make up each pair can have the same
address on the bus X , position numbers are defined as follows:
Rack n less- significant : position 00 to xx;
Rack n most-significant ; position 08 to yy;
Each rack with 12 slots holds an address

Specifications of power supply :

Type

Modular

No.of Slots

12 slots inclusive of power supply slot

Dimensions in mm

482.6(W) x 151.5 (H)

Reserved slots

Slot-1 for power supply

Slot -2,3 for processor

Functions of the power supply module:

Alarm Relay:

The alarm relay located in each power supply module has a volt-free
contact which can be accessed on the connection screw terminal of the module.
Principle:

Module alarm relay on the processor rack (rack 0): In normal operation, PLC in
RUN, the alarm relay is activated and its contact is closed. Whenever the
application stops, even partially, occurrence of a blocking fault, incorrect
output voltages or loss of mains power, the relay de-energizes and the
associated contact opens(state 0).

Alarm relay of power supply modules located on the other racks(racks 1to
7).when the module is powered up and if the output voltages are correct, the
relay is activated and its contact is closed (state 1).when the mains power is
lost or if the output voltages are incorrect, the relay de-energizes (state 0).

Back-up battery:

Each power supply module has a slot reserved for a battery which provides the
power supply to the internal RAM memory located in the processors, in order to
ensure that data is saved when the PLC is switched off. The duration of data
back-up is one year. The battery must be changed as soon as the BAT lamp(RED)
on the front panel lights up.

RESET Push button:

Pressing this push button, which located on the front panel of the power supply
module, triggers a sequence of service signals which is the same as that for:

A power breaks when the push button is pressed.

A power up when the push button is released.

Sensor power supply:

The sensor power supply (a.c) modules have an integrated power supply which
provides a voltage of 24V to supply the input sensors. Connection to this sensor
power supply can be accessed via module screw terminal.

2. PLC PROGRAMMING

PLC acronym for Programmable Logic Controller is an industrial computer control

system that continuously monitors the input devices and performs a sequence of
operations depending of inputs. The output is user defined through a set of
instructions, integrating the process sequences and interlocks.

Programmable Logic Controller is a solid state device, basically designed to

perform logic decision making for industrial control applications. Sincere their
development in early 1970s PLC have evolved to challenge not only relays but
also other discrete control devices such as stepping switches, drum sequencers
etc.

The PLC is composed of electric circuit with a microcomputer centered.

However , it can be equivalently regarded as an integrated body of ordinary
relay, timer, counter etc.

There are different methods of programming PLCs .They are

1.

Ladder diagram programming.

2.

Function blocks programming.

3.

Instruction list programming.

4.

Structure text programming.

Ladder diagram:
It is graphic and very easy to understand. It closely
resembles the old relay logic diagram. Generally shop floor maintenance people
easily understand and prefer it. The drawback of this language is, occupies more
memory space and slow.

Function diagram:
It is also easy to understand and pictorial representation. It
closely resembles the controller programming. This is also very slow. Most of the
PLCs use a combination of ladder and function block programming.

Instruction List:
It uses he mnemonic codes of a microprocessor. It is very fast
but it requires familiarity with assembly language programming of
microprocessor.

Structured text:
It is nothing but C language programming. It is a fastest of all
languages. But it requires through knowledge of C language programming.

Function of the PLC:

House Keeping:
It consists of internal checksums and diagnostics that the
processor executes every scan cycle. These can be done at the beginning or the
end of the scan cycle or both depending upon the PLC.

Input Scan:
It consists of reading the current state for each input
connected to the PLC system and updating the input memory tables.

Logic Scan:
It consists of reading the use program that ahs been stored in
the PLC memory. These programs can be written in ladder logic, instruction list,
sequential flow charts, function block, structure test, c code or state logic
depending upon their manufacturer of the system. Some system supports
programming using combination of languages within the same program.

Output scan:
It consists of adjusting the values of outputs connected to the
system based upon the status of inputs and execution of the logic.
Service communications:
It consists of opening the window of time for the
processor to communicate to other devices. These can be programming devices,

operator interface devices, remote IO controllers, other PLCs or any devices

having communication capability that is compatible with the PLC system.

3. CENTRAL PROCESSING UNIT:

This CPU is a double format high performance processor.

F IGURE 1

The CPU displays 6 additional display lamps

1.
RUN lamp

(GREEN)

: Ethernet TCP/IP port ready.

ERR lamp

(RED)

: Ethernet port fault

COL lamp

(RED)

: Collision detection.

STS lamp

(YELLOW) : Ethernet link diagnostics.

2TX and Rx lamp (YELLOW) : Tx/Rx activity.

2. A Memory Extract button for extracting the PCMMCIA memory extension

card.
The associated Memory extract ready display lamp indicates that this card
can be extracted safely.

3. RESET button causing a cold restart of the PLC when it is activated.

4.An 8-way female mini-DIN connector marked AUX for connecting a

programming adjustment.
5. A USB type connector marked TER for connecting a programming terminal.

6. A PCM CIA slot (no.0) for a memory extension card.

7. A PCM CIA slot (no.1) for a communication card or memory Extension card for
storing additional data.
8. NOT APPLICABLE FOR THIS MODEL.

9. An RJ 45 type connector for connection to the Ethernet TCP/IP 10BASE-T/100

BASE-Tx network.

MEMORY STRUCTURE

The application memory is divided into memory areas physically distributed in

the internal RAM memory and on 0, 1 or 2 PCMCIA memory extension cards.

1. The application data area, which may be one of 2 possible types, is always
in the internal RAM.

Located Data: It is defined by an address (e.g. %MW237) which a symbol may

be associated.
Unlocated Data: It is defined by the symbol. This type of symbol addressing
removes the memory memory management constraints because address is
assigned automatically.

2. Area in internal RAM or PCMCIA memory card for the program and
symbols. In the event of this area being in internal RAM.
It also supports the area for modifying the program in online mode.
This area contains the programs executable binary code and IEC source
code.
The user selects the type of information to be stored in the PLC memory.

3. Constants area in the internal RAM or the PCMCIA memory card (slot no .0)

4. Storage area for additional data (slot no. 0 or no.1)

Ex: For production data and manufacturing recipes.

Application of the internal RAM:

In this case, the application is entirely loaded in the processors internal batterybacked RAM(2). It varies at 96 to 640 Kb.

Application in PCMCIA card:

IN this case, the internal RAM is reserved for the application data. The PCMCIA
memory card (slotno.1) contains the program space (programs, symbols and
constants areas). It varies at 224 to 7168 Kb.

The internal RAM memory is backed up by an optional battery (3 years life)

located in the power supply module.

Extension of data storage area:

Memory cards reserved for data storage (4096 or 8192 Kb) are used to:

Access the data storage area when the application is entirely

supported by the internal RAM. In this case, the data storage memory
card is inserted into PCMCIA slot no.0

Free up memory space to provide additional program space when the

application is in the PCMCIA card (slot no.0).In this case, the data storage
memory card is inserted into PCMCIA slot no.1.

Protecting the application:

Regardless of the PLC memory structure (whether it is located in the

internal RAM or in the PCMCIA memory card), it is possible to protect this
order to prevent it being accessed (read or modify program) by only
loading the executable code on the PLC.

A memory protection bit, set in configuration mode, is also available

to prevent any program modification (via the programming terminal or
downloads).

Program modification in online mode:

The function of this PLC is, it allows program code and data in
different parts of the application to be added or modified in a single
modification session.
Any program modification made in online mode.

CHARACTERISTICS AND PERFORMANCE

The characteristics and performance are

Functions:

Max No. in Rack

Discrete I/O

2048

Analog I/O

256

Process control channels

20 (up to 60 simple loops)

Application- specific channels (counter, serial

links)

64

Integrated Connections
Ethernet TCP/IP

Serial link

1x12 Mbps USB link(TER)

1x19.2 Kbps (AUX) link

Maximum no. of connections

Network
(Ethernet,TCP/IP,Fipway,Ethway,ModbusPlus)

4;3if integrated Ethernet is used

Memories:

Maximum capacity
Without PCMCIA card (in Kb)

320prog + data

With PCMCIA card (in Kb)

2048 prog, 440 data

Data Storage

16,384 Kb

Execution time: 11.4 Instructions /Ms

Execution time for 1K instructions: 1/11.4 =0.0877ms
Total memory: 324 kb (with CPU) +256kb (with PCMICA memory Card) = 580kb
Assuming 50% Program memory loading =290kb
Scan time 290*0.0877 = 25.433ms
Communication protocol with Scada: Modbus TCP/IP.
Communication with SCADA: Built in-Ethernet module

INPUT AND OUTPUT MODULES:

1. Analog Module
2. Digital Module

Analog Module :

The front panels of analog module comprise

iv.

i.

A display and module diagnostics block.

ii.

A connector for receiving the screw terminal block.

iii.

A rotating supports containing the module locating device.

A removable screw terminal for direct connection of the I/O to the sensors and
preactutators.

v. A pivoting cover for accessing the terminal block screws and holding the
identification label.
vi.

A screw terminal blocks encoder.

vii.

A 25-way SUB-D connector for connecting the sensors.

Functions of Analog Module:

1.

Scanning of input channels, protection against over voltages, adaptation

of signals by analog filtering, scanning by solid state multiplexing.

2.

Adaptation to input signals: Gain selection, drift compensation.

3.

Digitization of signals: 12-bit analog/digital conversion.

4.

Converting input measurements to user format: recalibration coefficient,

filtering, scaling.

5.

Module monitoring: conversion circuit test, range overshoot test,

terminal block presence test, watch dog test.

6.

Fast processing of inputs

Specifications:

Channels

16channels

Isolation
Between Bus and channels

1000 v RMS

Between channels and earth

1000 v RMS

Resolution

12 bits

Input operating range

+/-10 V DC,0-10V,0-5V,1-5V,0-20mA,420mA

Maximum Over Voltage

+/- 30 V

Maximum Over current

+/- 30 mA

Digital Module :

The front panels of Digital module comprise

Functions of the Digital Module :

I/O assignment :

Each module is functionally organized into groups of 8 channels. Each group of

channels can be assigned a specific application task.

Reactivation of Outputs :

If a fault has caused an output to trip, output can be reactivated if no other

terminal fault is present. The reactivation command, defined during
configuration, can be automatic or controlled via program. Reactivation is carried
out in groups of 8 channels. This function can be accessed on modules with solid
state d.c outputs. For relay and triac output modules protected by fuse, the same
type of reactivation is necessary after replacement of one or more fuses.

RUN /STOP command :

An input can be configured to control the Run /STOP mode for the PLC.
The command is accepted on a rising edge. A STOP command via an input takes
priority over a change to RUN via the terminal or via a network command.

Output Fallback:

When an application is placed in STOP mode, Outputs must be set to a state

which is not harmful to the application. This state known as the fallback position
is defined for each module when its outputs are configured.
This configuration enables the choice between:
Fall back: channels are set to state 0 or 1 depending on the fallback value
entered.

Maintain: outputs retain the state they were in before the PLC stopped.

Diagnostic functions:

Module diagnostics:
Any exchange fault preventing normal operation of an
output module or fast input mode is signaled. Similarly, any internal module fault
is signalled.
Process diagnostics:
Sensor/procurator voltage check, terminal blocks
presence check, short circuit and overload check, preactuator voltage check.

Specification:

Nominal Input Voltage

24 VDC

Input characteristics
Input voltage

24 V DC

On state voltage

>=11 V

Off state current

>= 3mA

On state voltage

=<5 V

Off state current

=<1.5 mA

On response time

4ms

Off response time

Web servers:
The web server module is a standalone TCP/IP module gateway
module used to connect a Modbus device to a TCP/IP network. It is a standard
device. It has a built in RS 232 serial link which can be used to connect an
external modem.

Mainly this module is used to perform the following functions:

Modbus messaging over TCP/IP,

SMTP service

SNMP service.

Embedded Web server.

Option of having a user web site.

Specifications:

Functions

Embedded web server ,

Option of having a user website
Modbus messaging over TCP/IP
SMTP service
SNMP service

No. of Ports

1-RJ 45 connector
1-RJ 45 connector for RS 485 link

A 9-pin SUB D connector for a modem link

No. of simultaneous connections

16 Internet browsers

Energy Meters:

The energy meter portable working is a 3 phase portable electronic meter

test unit for use as a working standard to test both single and 3 phase electricity
meters on site. This device allows checking of all meter installation parameters
and associated circuits. The energy meters is available in accuracy classes
0.1.The unit can be used either with a direct connection in the range 1mA..12A.
Function:

Active, reactive and apparent energy measurement for single phase and 3
phase, 3 or 4 wire circuits with integrated error calculator.

Advantages:

Wide measuring range with auto ranging.

Display of vector diagram for analysis of mains conditions and meter
connections.
Measurements of wave from and harmonics with display.
Easy detection of circuit connection faults.
Data memory.
Small dimensions and light in weight.
Serial interface for data transfer.
Application:

Specifications:

On site test of electricity meters.

Power consumption

10VA

Current range

1mA.12A

Voltage range

10V..300V

CABLES
In both interrogation and broadcasting mode there is a
continuous transfer of information between the PLC and the MS so
there is a necessity of a physical medium to facilitate the flow of
information( Electrical Signal). Cables perform the job of interconnected the
field PLCs and MS.
The inter- connecting cables required for connecting various terminals
can

be

classified

in to 3 categories and

the

technical

specification of

various cables are also given below .

CATEGORY I :
Telephone cables required for inter connection of PLCs and the MS.
5Pair Petroleum jelly filled.
Armored.
Over all polythene packed.
Solid annealed high conductivity copper.
Diameter 0.633mm.
Resistance 57 ohm /KM.

CATEGORYII:
Twisted pair cables required for the inter connection of remote
video terminal to the master stations .
5Pair.
Diameter 7/ 0.2 mm.
Individually and over all shielded.
Armored cables.

CATEGORY III :
Control cables required for the inter connection of signals from plant units
and junction boxes to the PLCs .
# Size 1.5 mm.
# Solid annealed copper conductor.
# Multi core control cable.
# Armored and unarmored.
# Thickness 0.8 mm.
# Resistance 12.1 ohm / KM.
# PVC Insulated.

The cables will be laid partly on cable trays in cable

and balance the directly buried under ground .

tunnels

LAN EXTENDERS

The RTUs are connected to the MS by underground telephone cables

with one pair of Lan extenders.

Descriptions of Modems.

The SHDSL (Single-Paired High Speed Digital Subscriber Loop) routers/lan

extenders comply with10/100 Base-T auto-negotiation. It provides businessclass, multi-range form64Kbps to 2.304Mbps (for 2-wire mode) or 128kbps
to 4.608Mbps (for 4-wire mode) payload rates over exiting single-pair copper
wire. The SHDSL routers are designed not only to optimize the service bit rate
from central office to customer premises also it integrates high-end
Bridging/Routing. Because of rapid growth of network, virtual LAN has become

one of the major new areas in Internetworking industry. The SHDSL routers
support port-based and IEEE 802.1q VLAN over ATM network.

The firewall routers provide not only advanced functions, Multi-DMZ,

virtual server mapping and VPN pass-through but advanced firewall, SPI, NAT,
DOS protection serving as a powerful firewall to protect from outside intruders of
secure connection.
The SHDSL routers allow customers to leverage the latest in broadband
technologies to meet their growing data communication needs. Through the
power of SHDSL products, you can access superior manageability and reliability.
Features:
1. Easy configuration and management with password control for various
application
Environments
2. Efficient IP routing and transparent learning bridge to support broadband
Internet services
3. VPN pass-through for safeguarded connections
4. Virtual LANs (VLANs) offer significant benefit in terms of efficient use of
bandwidth, flexibility, performance and security.
5. Build-in advanced firewall (Firewall router)
6. Four 10/100Mbps network connectivity (4-port router)
7. Getting enhancements and new features via Internet software upgrade.
Specification
Bridging:
1. IEEE 802.1D transparent learning bridge
2. IEEE 802.1q VLAN
3. Port-based VLAN (4-port router)
4. Spanning tree protocol

Management:

1. Easy-to-use web-based GUI for quick setup, configuration and management

2. Menu-driven interface/Command-line interface (CLI) for local console and
Telnet
Access
3. Password protected management and access control list for administration
4. Software upgrade via web-browser/TFTP server

LAN Interface:
1. 4-ports switching hub (4-port router)
2. 10/100 Base-T auto-sensing and auto-negotiation

LAN LAN Connection:

Communication Types :

Citect SCADA supports four types of I/O device communication:

1. Serial communication
2. PLC interface board
3. Data acquisition board
4. Dynamic data exchange (DDE) Server

Whether the I/O device is local or remote, communicating with I/O devices is
Usually via a simple serial connection using the RS-232or RS-485
standard.

With Citect SCADA there are many I/O device communications options,
through Citect SCADA computer's COM port, through a high-speed serial board,
or through a communications board supplied by the I/O device manufacturer.
Whichever option you choose, use the Express I/O Device Setup wizard.

Advantages:
1. Flexible.
2. Scalable.
3. Reliable.
4. Reduce Implementation Time.
5. Low cost.

MASTER STATION/Master server

SERVERS:

WINDOWS based operating software shall be considered as SCADA

servers. Servers shall work on hot redundant server configuration. All the PLCs
shall be communicating directly to both the servers. The data updates taking
place in any of the PLCs shall be updated in both the servers automatically and
simultaneously. In the other HMI stations, only client software shall be loaded.
Both servers shall update relevant data (process, configurations, history etc.)
continuously. Necessary
Dual redundant network interface modules shall be provided for
communication with PLCs and other peripherals. Other operator station, shall log
on to these servers for system & process operation, data access and other
operations. Servers shall be considered with Oracle database. The system
software shall support 10000 tags.

PROGRAMMING SOFTWARE:

Each LAP TOP PC shall be loaded with licensed programming software. All
software shall be licensed version. The programming software shall be windows
based and shall be compatible with the systems proposed. The Programming
software shall be suitable to program all the RTUs. In addition to above one
licensed RTU/PLC programming software shall be loaded in the HMI (Telecom)
also. It shall be ensured that the healthiness and fault diagnosis of PLC/RTU cards
can be checked / accessed from HMI (Telecom) only.

60 PLASMA Screen:

The HMI shall connect to the 60 PLASMA screen (Video mimic) for viewing
of mimic pages in the control room. The offered mimic screen shall be selfstanding type.

INTELLIGENT COMMUNICATION INTERFACE UNIT :

The intelligent communication interface unit shall be serving the purpose

of interfacing between Master station and PLCs with high speed.
The PLCs shall be connected to the Master station utilizing existing
telephone cables with modems at the RTU/PLC end and at Master station end. In
the control room of E&T centre the modems shall be connected to the Intelligent
Communication Interface unit. The data of the PLCs shall be transferred by the
intelligent Interface unit to the server without affecting the process requirement.
The communication
from each RTU shall be connected to the Intelligent Interface unit through
separate module. The retrieval of data from the PLCs shall be configured by the
servers of Master station. The intelligent communication interface unit shall be
connected to the dual ETHERNET. The offered interface unit shall connect to all
RTUs and 3 no.s work station. Over and above the above 20% spare cards to be
provided for future expansion. If the offered interface unit is not capable of
handling all the cards then required number of Intelligent Interface units shall be
included in the scope of work. All the interface units to be connected to the dual
ETEHRNET switch.
ETHERNET SWITCH:

The ETEHRNET SWITCHES shall be redundant. It shall have 24 ports in

each switch. Layer-3 Ethernet switch supporting 10/100/1000 MBPS shall be
considered. It shall be mounted in suitable metallic enclosure.

DIGITAL ENERGY METERS :

The digital Energy Meters shall be with serial interface (RS485) to connect
to the PLC. The energy meters shall be mounted in the field and the maximum
distance shall be considered from the RTU location
This covers design, engineering, manufacture, assemble, inspection and testing
before supply of 110V, 5A/1A and 3 element 4 wire CT

Meters of accuracy class 0.5 capable of performing the functions of metering in

all 4 quadrants .The scope also includes commissioning of the meters by
dismantling the existing electromechanical meters, TTB and suitably installing,
wiring new meter and commissioning of the meters at VSP site. Connection to
RTU for SCADA connectivity using MODBUS protocol or otherwise by ensuring 10
meters per serial loop also is included in the scope of the supplier. The supplier is
expected to bring all tools/tackles and instrument etc. required for
commissioning as mentioned in the specifications.
MODEMS:

The modems located at site shall be suitable for interfacing the PLCs to
Master Station over existing telephone cables. The selected Modem shall be able
to send the signals up to a distance of 15 KM over telephone cables. For this
purpose the existing 5 pair PJF telephone cables of RTUs shall be utilized for
connecting the modems as well. Point to point modems shall be considered. The
modems shall be housed in suitable metallic enclosure and mounted in the
RTU/PLC panel in the field and separate panel in E&T centre. The modems shall
be duplex type The modems shall be suitable for the ambient temperature of 45
Deg C and shall be UL certified. The modems shall be dedicated line type for
industrial applications. The interface shall be as required to connect to the RTU.
The modems shall be suitable for SCADA applications.
UPS SYSTEM:

For RTUs and remote work stations separate UPS systems shall be
provided. Total 26 nos UPS systems shall be provided. A feeder with 230V +10% /
- 10%,1Phase,

50Hz+/-3% will be made available. UPS rating shall be as per the

requirement of complete equipment covered in tenderer scope + 25% spare
capacity. In the proposed UPS system the batteries should be sealed
maintenance free lead acid type. In case of power failure the backup time of the
UPS to be 30 minutes with resistive load (Unity Power factor). The AH rating of
the offered batteries shall be selected accordingly. The batteries shall be
mounted in a suitable metallic enclosure.
COMMUNICATION CABLES:

The communication cables like ETHERNET bus network and Modbus cable
shall be industry standard for process control. All these communication cables
shall be routed through suitable size GI conduits and GI conduits to be included
in the scope of work. The OFC cable between proposed SCADA server and the
existing IBM server shall support 1Gbps data transfer. Same shall be single
mode, 6-core armored type. The specifications of PJF armored cables shall be
same as the existing cables.

CONTROL CABLES:

All the control cables shall have spare cores of 20%. The control cable
shall be of 1.5 sq.mm size, 1100 V grade,Annealed tinned Copper core,
multistrand conductor, PVC insulated, PVC sheathed, un-armoured cables
conforming to IS 1554.
The size of the cables/wires considered for the internal wiring of the PLC
panels unto the terminal blocks shall be as per the PLC manufacturer's standard
only.
POWER CABLES:

The power cables shall be ATC copper core, multistrand,PVC insulated, PVC
sheathed, un-armoured cables conforming to IS 1554. The size and voltage grade
of power cables shall be done as per the requirement and PLC manufacturer's
standard only.

Advantages of SCADA system are:

High availability of front-end processors to dual access hardware.

Scalability due to provision for expansion for Field Remote terminal units,
front end processors, intermediate serial port cards and memory /
processors of the host and other computer systems.

Upgradability of hardware and software

Standard interfaces like RS 232, LAN etc are provided for interfacing with
other systems and applications.

Availability of standard interfaces for interoperability with other systems

like central computer, power plant computer, etc.

Thus SCADA is system has proven that a better technology establishment

is a one time cost but the fruits we see from this are continuous and
encouraging.

Summary :
The Supervisory Control And Data Acquisition system is a
versatile network of intelligent sub systems, which has broad revolution in the
field of monitoring and controlling systems. Earlier due to lack of sophisticated
equipment it was very difficult to predict whether the channel corrupted the data
coming to the monitoring station or it is the date pertaining to a functional error
in a particular department. Further it was very time consuming process to undo
the effect causing the problem( Only after making sure the data received is
correct ). In the mean time a lot of energy is wasted and sometimes even
unacceptable hazards also used to take place. Also there was no privilege to
track the position that is responsible for the error.
The Supervisory Control And Data Acquisition systems overcomes
all the above bottlenecks. It has host computer in the master station to store the
data for a long period of time so that it can be used to take strategic decisions
sat the time of crisis.
The proposed SCADA systems for Vizag Steel Plant shall acquire
various electrical and utility parameters for effective monitoring and control
operations. The various parameters acquired shall be such as electric power,
voltages, currents etc., and electrical monitoring and parameters such as flows ,
temperatures pressures etc., under utility monitoring.

These parameters are locked into the systems using a suitable

database management system. The data is processed and presented in the plant
to the concerned officials and operators using user-friendly graphical interfaces.