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Year & Branch: TY Electronics

Subject: Industrial Automation Subject Code: EL 3023

Experiment 6
Title: Real Time operation management in SCADA environment.
Aim: To develop model the plant floor using automation objects.
Objective: To develop simulation of automatic bottle filling plantwith trends and alarms.
Problem Statement: Implement an automatic bottle filling plant show how much bottles
have been filled, show histogram trend of bottle filling and reduction of water from tank and
also the show level of water in tank using alarm configuration.

Equipment:
PC, Wonderware Intouch simulation software.

Theory:
Write in short
a. Architecture of SCADA.
The generally SCADA system can be classified into two parts:
1)Clint layer
The Clint layer which caters for the man machine interaction.
2)Data server layer
The data server layer which handles most of the process data activities.

The SCADA station refers to the servers and it is composed of a single PC. The data servers
communicate with devices in the field through process controllers like PLCs or RTUs. The PLCs are
connected to the data servers either directly or via networks or buses. The SCADA system utilizes a
WAN and LAN networks, the WAN and LAN consists of internet protocols used for communication
between the master station and devices. The physical equipments like sensors connected to the PLCs or
RTUs. The RTUs convert the sensor signals to digital data and sends digital data to master. According
to the master feedback received by the RTU, it applies the electrical signal to relays. Most of the
monitoring and control operations are performed by RTUs or PLCs as we can see in the figure.

Most of the servers are used for multitasking and real time database. The servers are responsible for
data gathering and handling. The SCADA system consists of a software program to provide trending,
diagnostic data, and manage information such as scheduled maintenance procedure, logistic
information, detailed schematics for a particular sensor or machine and expert system troubleshooting
guides. This means the operator can sea a schematic representation of the plant being controlled.
Architecture of SCADA

b. Distributed Control System.


A distributed control system (DCS) is a computerized control system for a
process or plant usually with a large number of control loops, in which
autonomous controllers are distributed throughout the system, but there is central
operator supervisory control. This is in contrast to systems that use centralized
controllers; either discrete controllers located at a central control room or within a
central computer. The DCS concept increases reliability and reduces installation
costs by localizing control functions near the process plant, with remote
monitoring and supervision.
Distributed control systems first emerged in large, high value, safety critical
process industries, and were attractive because the DCS manufacturer would
supply both the local control level and central supervisory equipment as an
integrated package, thus reducing design integration risk. Today the functionality
of SCADA and DCS systems are very similar, but DCS tends to be used on large
continuous process plants where high reliability and security is important, and the
control room is not geographically remote.
Procedure:
Write a step by step procedure to execute problem statement.
1. Pick up all equipments which are necessary for the problem statement
2. Break all the components and assign tag name and functionality.
3. Bottle will have two tag name first for filling and second for horizontal movement
4. Take an analog i/o module to display values in runtime.
5. Set a counter in the script.
6. Take a histogram trend graph which shows mathematical values in the graphical format.
7. Write script for meter panel to show the level of the tank.
8. Set alarm configuration to get the status of tank (low or high).

Observation:
From above experiment we can observed that when bottle is under tank at that
time only water will fill in the bottle and after each iteration counter will count
how many bottles have been filled. After level of the tank redcued to its minimum
level then we can manually fill the tank again without interrupting the process.
Result:

Conclusion:
From the experiment we can conclude that we can built or simulate any kind of
industrial application using this software is easy to handle and user friendly.

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