PROJECT REPORT ON

SCADA CONTROLLING AUTOMATIC BOTTLE FILLING PLANT

PREPARED BY: HARDIK GOHEL (04MC11) KAMIN PATEL (04MC37) KETAN PATEL (04MC39)

DEPARTMENT OF MECHATRONICS ENGINEERING U.V. PATEL COLLEGE OF ENGINEERING,

GANPAT UNIVERSITY, KHERVA - 382711.
CERTIFICATE
SCADA CONTROLLING AUTOMATIC BOTTLE FILLING SYSTEM
SUBMITTED BY:HARDIK GOHEL KAMIN PATEL KETAN PATEL (04MC11) (04MC37) (04MC39)

Towards partial fulfillment of requirement for the award of Degree of Bachelor in

MECHATRONICS ENGINEERING of GANPAT UNIVERSITY. This is the record of candidates own
work carried out by them under our supervision & guidance. In our opinion the work
submitted has reached a level required for being accepted for exam. The matter
embodied in this project has not been submitted to any other university or
institute.

GUIDE:

Mr. N. J. Thakkar,
Lecturer, Mechatronics Department, U. V. Patel College of Engg. Mehsana.

COUNTERSIGNED:

Prof. S. M. Patel,
Head of Department, Mechatronics & Mechanical Engg. U. V. Patel College of Engg.
Mehsana.
ACKNOWLEDGEMENT
Our hard work never shines if we do not convey our heart felt gratitude to those
people from whom we have got considerable support and encouragement during this
project. Many people have helped and provide direction, technical information and
advice at all stages of our project and it’s our pleasure to say a vote of thanks
to all of them Firstly we are thankful to our college to give us opportunity to
represent our ability. We are deeply indebted to Mr. Nehul Thakkar, Prof. J.P.Patel
& also Mechatronics staff for this motivation of support and provision of all
necessary facilities of our project work. We will always remain grateful to those
who has been a consistence source of our encouragement and whose constant care
about as provided us a new direction to work.

HARDIK R. GOHEL KAMIN K. PATEL KETAN J. PATEL

(04MC11) (04MC37) (04MC39)

PREFACE
Automation, now a days have become in integral part of the industry, say any
production as well as process industry, it is progressively increasing the
productivity and the profitability of most large organization by rapidly becoming
more efficient and competitive by their methods of production and management. Small
industries with small exceptions, is not progressing to the same extended and their
profitability is far too low for stability and growth. The efficiency of small
industries is however, of vital importance to the economy of the country. They
represent 90% of all industries, employ about half of those engaged in large
industries and produce nearly half of the manufactured goods. For rapid industrial
growth in developing countries like India which is basically a nucleus of small
industries, it is of primary importance to put the wheels of efficiency of these
small industries properly geared to accelerate productivity, to increase
profitability and to achieve this goal at present juncture is Low Cost Automation
as High cost Automation is not within the reach of developing countries. SCADA
vendors release one major version and one to two additional minor versions once per
year. These systems evolve thus very rapidly so as to take advantage of new market
opportunities, to meet new requirements of their customers and to take advantage of
new technologies. As was already mentioned, most of the SCADA systems that were
evaluated decompose the process in "atomic" parameters to which a Tag-name is
associated. This is impractical in the case of very large processes when very large
sets of Tags need to be configured. As the industrial applications are increasing
in size, new SCADA versions are now being designed to handle devices and even
entire systems as full entities (classes) that encapsulate all their specific
attributes and functionality. In addition, they will also support multi-team
development. As far as new technologies are concerned, the SCADA products are now
adopting: • Web technology, ActiveX, Java, etc. • OPC as a means for communicating
internally between the client and server modules. It should thus be possible to
connect OPC compliant third party modules to that SCADA product. If a laborer has
to do a series of work for the completion of a certain job and it has to do the
same job repeatedly for the whole day, his involvement into the job linearly
decreases with time. The repeatability of the same type of work causes fatigue,
stress, strain and negligence and eventually decreases the quality and quantity of
production. So automating a part of his job, which involves tiring work, definitely
increases quality of work as well as result in saving of time. In such
circumstances, the person can even have the opportunity to attend other work.
Implementation of automation plays a very important role in the output efficiency.
In modern
times when there is paucity of time with one and all, the importance of Automation
with easy Controlling system needs no explanation.
INDEX
SR. NO.
1 2 3 4

TOPIC
PRINCIPLE OF PROJECT ABOUT THE PROJECT INTRODUCTION CONCEPTUAL OVERVIEW

PAGE NO.
01 02 03 04

COMPONENTS o INPUT COMPONENTS o OUTPUT COMPONENTS PLC PROGRAMMING o ELECTRICAL

DIAGRAM o FLOW CHART o PHYSICAL LADDER DIAGRAM INTERFACE TO SERVER o CONFIGURING
I/O SERVER o CONFIGURING COMMUNICATION PORT o CONFIGURING TOPIC DEFINITION
DESIGNING

06

07 08 10

11 12 13 15

PROGRAMMING o TAGS o PROCEDURE DESCRIPTION

18 20
10

BIBLIOGRAPHY

24
FIGURE INDEX
SR. NO.
1 2 3 4 5 6 7

FIGURES
CONCEPTUAL OVERVIEW OF SCADA ELECTRICAL DIAGRAM FLOW CHART PHYSICAL LADDER DIAGRAM
DESING OF INITIAL POSITION HALF FILLED BOTTLE FULLY FILLED BOTTLE

PAGE NO.
04 07 08 10 16 22 23
1. PRINCIPLE OF PROJECT
The main motive of project is to automatic filling of the liquid bottle from the
tank with the help by controlling through the SCADA software. The main
concentration of the whole system is on the SCADA.

SCADA
It can control the overall action of the system in the field plant. It examines the
status of the input and in responses control the overall process through the
output. Combination of the input and output data are referred to as logic. Several
logic combinations are usually required to carry out program. This program is
stored in the memory and is periodically changed as per the requirements of the
party by an order given to an operator, usually run the programs in predetermined
order for SCADA. Hence, an industrial SCADA system will be used for the development
of the controls of the four experimental terms. This describes the SCADA systems in
terms of their architecture, their interface to the process hardware, the
functionality and the application development facilities they provide. Some
attention is also paid to the industrial standards to which they abide their
planned evolution as well as the potential benefits of their use. Thus we get a
perfect idea through its name itself as Supervisory Control And Data Acquisition.

SCADA systems have made substantial progress over the recent years in terms of
functionality, scalability, performance and openness such that they are an
alternative to in house development even for very demanding and complex control
systems.
2. ABOUT THE PROJECT
The technology has been developing even since the Stone Age. The ancient man
applied their minds towards the techniques to have comfort and betterment in their
life. The same phenomenon is continuing even till today. Always there is tendency
and thirsty with human beings to develop a better technique in any working process
to attain or to provide less fatigue and mental stress and more comfort to the
operators. There will be always a desire to-do things in a better way and speedy.
The project “SCADA CONTROLLING AUTOMATIC BOTTLE FILLING PLANT” is also based on the
above-mentioned as facts. The industries, which are having manual process of
filling, can be automated using Automation & Controlling techniques. Application of
Automation components as per requirement resulted the project of automatically
filling and transporting. In this plant there are following major operations are
performed. The first one is designing the whole plant as it is in the field and
secondly filling of the bottle to the required level and then transporting it with
help of conveyor. For this a programming is done in SCADA system accurately via I/O
drivers of the specific types like ABKF2, SIEMENS2, etc... The Automation
components used in the plants are conveyor system, sensors, and solenoid operated
direction control valves and drain valves. After the end of a process, the filled
bottle is collected and the bottle is now ready to be transported further for
sealing and packing purpose. The manual error in filling operation, due to repeated
similar operation, can be eliminated. The fatigue and mental stress of the operator
is removed. The operation cycle is also increased considerably.
3. INTRODUCTION
Acronym for Supervisory Control And Data Acquisition indicates a computer system
for gathering & analyzing real time data. As such, it is a purely software package
that is positioned on top of hardware to which it is interfaced, in general via
Programmable Logic Controllers (PLCs), or other commercial hardware modules. SCADA
systems are used to monitor and control a plant or equipment in industries such as
telecommunications, water and waste control, energy, oil and gas refining and
transportation. The 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 are used not only in
industrial processes: e.g. steel making, power generation (conventional and
nuclear) and distribution, chemistry, but also in some experimental facilities such
as nuclear fusion. The size of such plants range from a few 1000 to several 10
thousands input/output (I/O) channels. 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. The server I/O
communication drives those are used for an application program that acts as a
communication protocol server. It allows the application programs access to data in
PLCs.
4. CONCEPTUAL OVERVIEW
To get an overview of the SCADA system that how it can be processed by an operator
as per the required application of the party or industrial plant; the conceptual
overview of SCADA gives the basic idea of whole process expressed in Fig. 1.

Figure 1: Conceptual Overview of SCADA

Hence for detailed process; it is discussed later on in the report. Here only the
basic idea gets from Fig. 1 as predetermined above. SCADA systems used to run on
DOS, VMS and UNIX; in recent years all SCADA vendors have moved to NT and some also
to Linux based OS. AS shown in figure 1 the server communicates with Allen-Bradley
either directly or indirectly using the Data Highway, Data Highway Plus, or DH485
with the appropriate AllenBradley communications interface. Therefore the
communication interface is anyone from PLC2, PLC-3, PLC-5, and SLC-500 PLCs or the
SIEMENS & ABB.
So to build up the whole design plant in the industry, several points should be
taken into consideration are as follows: o o o o o o o o Defining Components (I/O)
PLC Programming Flow Chart PLC Ladder Diagram Interface to Server Initial Design of
Layout Continue Process to the end At last achieve the required result….
5. COMPONENTS
The components which are on the field designed or planted, that type of designing
layout must be done in SCADA. The input and output components are derived below
with different symbols which are representing the PLC symbols, normally open or
close.

Input Components
Sr. no 1 Inputs Start button Symbols /

Stop button

Proximity sensor (bottle sense)

Proximity sensor (Liquid level sense)

Output Components
Sr. no 1 Outputs Solenoid valve 1 (Vin) Symbols

Solenoid valve 2 (Vout)

Conveyor motor
6. PLC PROGRAMMING
The overall programming of model is done in Urologic PLC software for Allen
Broadly. We can use the electrical diagram for basic plant layout and with the help
of this electrical diagram as shown in Fig. 2 below.
Figure START 2: Electrical Diagram

FILL TANK

IS TANK FULLY
Figure 3: Flow Chart
The logic for simplifying the electrical diagram, the flow chart is used to show in
which way the process is going and is likely to be the Fig. 3 as shown above. Once
the electrical diagram and flow chart is completed then the remaining thing in PLC
is the ladder diagram which is used for representing the symbolic programming of
the process and will be further shown. Therefore the overall programming of model
is done in Urologic PLC software for Allen Broadly. We can use the ladder diagram
as programming language. During programming we can generate the symbolic ladder
diagram and then giving address to the electrical diagram. This ladder diagram is
shown in Fig. 4.
Figure 4: Physical Ladder Diagram
7. INTERFACE TO SERVER
In this section the serial I/O server of the Allen – Bradley is interfaced with an
appropriate drives to communicate different protocols. So, the server that will be
accessing the data element. In this case, the data is out coming or going to ABPLC
equipment via the server. The application portion of the server is known to be
namely as ABKF2 for the specific ABPLC. Hence using this server an item can be
trend, counter, level checked, register, etc…, in the SCADA.

Configuring I/O Server

Once the server has been installed, a small amount of configuration is required.
Configuring the server automatically creates a configuration file named, ABKF2.CGF.
This will store the information for the communication ports.

To perform the required configurations, start up the server by double clicking on

its icon and then to open the server’s window.

To access the option used for the various configurations, open the Configure menu
as shown below.
Configuring Communication Port
Use the Communication port settings option from the configure menu to configure
communication ports that will be used to communication with AB device. When this
option is selected the dialog box will appear as below:

So with the help of this and defining all necessary data as an appropriate baud
rate or serial bit rate which is in bit per second and for SLC-500 it is 9600bps to
communicating with port1. The default, Full Duplex is preferred setting. Then
select the number of data bits that will match the configuration of AB device.
Configuring Topic Definition
Use the topic definition option from the configure menu to create new, modify or
delete topic definitions. Each topic definition must contain unique name for the
PLC associated with it.

Enter a unique name up to 32 characters long with the first character being
alphabetic. After giving the topic definition name, then new dialog box will appear
for ABKF2 topic definition as below:
Select the connect type appropriate for the PLC network configuration.

After that the supporting Network addressing option will be activated for the
selection and dialog box will appear as below:

The network addressing is a dynamic field. The applicable option appears according
to the PLC family type and Connect type selected. In the example, network
addressing is defined as follows:

The Host computer is directly connected to a 1770KF2 by a RS232 cable.

This network addressing shown

here is for the SLC-500 with a direct connects type. In this networking address is
simple. The Host computer is directly connected to the SLC-500 by a RS232 cable.
8. DESIGNING
The objects or a layout can be designed by using the tool box available in SCADA
system window maker. We can choose the following toolbars as per our requirements.
General Toolbar The general toolbar is populated with toolbar buttons that execute
most of the window commands located on the File menu and some of the object editing
commands located on the Edit menu. Arrange Toolbar The Arrange toolbar is populated
with toolbar buttons that execute most of the object arranging commands located on
the Arrange menu. Draw Object Toolbar The Draw Object toolbar is populated with all
the tools that you will use to draw both simple graphic objects or text objects
and, complex objects such as alarm windows, real-time trends, historical trends,
bitmap boxes and 3-dimensional buttons with labels in your windows. View Toolbar
The View toolbar is populated with toolbar buttons that execute most of the window
commands located on the View menu. These commands are used to control the state of
the Window Maker window.

For designing the objects click on the object and drag it on the screen. The links
for showing the values memory/IO can be made by creating text "#. ##" and assigning
display value properties to it. The level indication can be made by selecting the
tanks wizard and assigning the % fill property to it. Similarly the indication of
the pumps and other components can be done using the discrete colour property.
The components which are on the field designed or planted, that type of designing
must be done via symbol factory mentioned in SCADA software. For this project we
have note down the components or parts are as below: • • • • • • • Push Buttons
Conveyor Belt Bottles Tank Bottle Sensor Liquid Level Sensor 2 – Solenoid Valves

The initial design is made similarly as in the Fig. 5. It is defining the

initialized position at the field location plant which is operated through PLC &is
interfaced with the ABKF2 server in SCADA system.
Figure 5: Design of Initial Position
After designing the initial position of the plant; next step is to make an
appropriate interfacing with PLC via ABKF2 server to access the data. This data
will be controlled or modified by doing changes directly in the main SCADA system.
This is more beneficial point of view for achieving the higher accuracy & better
output. So a programming part done in the memory discrete is referred in the next
coming section.
9. PROGRAMMING
Tags:
A tag is a logical name for a variable in a device or local memory (ram). Tags that
receive data from some external device such as programmable logic controllers or
servers are referred to as I/O tags (input/ output). Tags that receive data
internally from SCADA system is referred to as memory tags. Tags are stored in tag
name directory and their names are then used in other parts of the program. The
various tag types are described for the different data elements as specified on
PLC, input/output drives related to its communicated addresses. Choose the types
from below: • • • Memory Discrete: Internal discrete tagname with a value of either
0 (False, off) or 1 (True, on). Memory Integer: A 32-bit signed integer value
between -2,147,483,648 and 2,147,483,647. Memory Real: Floating (decimal) point
memory tagname. The floating point value may be between -3.4e38 and 3.4e38. All
floating point calculations are performed with 64-bit resolution, but the result is
stored in 32-bit. Memory Message: Text string tagname that can be up to 131
characters long.

If you do not assign the tag name to a specific Alarm Group, by default, InTouch
will assign it to the root group, $System. Once you create a tag name and assign it
to an Alarm Group, if you do not close the dialog box, all subsequent tag names
that you define will be assigned to the same Alarm Group, unless you change it. For
I/O type tag names, select Read Write to grant the tag name read and write
capabilities in runtime.
If the tag you defined is I/O type then define access name and the item name for
connecting the tag to the hardware. The procedure for access name is as follows: •
• •

• •

Click Access Names, the Access Names dialog box appears. Click Add. The Add Access
Name dialog box appears. In the Access Name box type the name you want InTouch to
use to this Access Name. (For simplicity, use the same name that you will use for
the topic name here.) InTouch uses Access Names to reference real- time I/O data.
Each access Name equates to an I/O address, which contains a Node, Application, and
Topic. In the Application Name box, type the actual program name for the I/O Server
program from which the data value will be acquired. Do not enter the .exe extension
portion of the program name. In the Topic Name box, type the topic name you want to
access. The Topic Name is an application-specific sub-group of data elements. In
the case of data coming from a Wonderware I/O Server program, the topic name is the
exact same name configured for the topic in the I/O Server program. Select advice
all items if you want the server program to poll for all data whether or not it is
in visible windows, alarmed, logged, trended or used in a script. Selecting this
option will impact performance, therefore its use is not recommended. Select Advise
only active items if you want the server program to poll only points in visible
windows and points that are alarmed, logged, trended or used in any script. Click
OK to accept the new Access Name and close the dialog box. The Access Names dialog
box will reappear displaying the new Access Name selected in the list.

At last give the item name i.e. address of the I/O. The item names will differ from
server to server.
Procedure Description:
First of all design the initial position then its time to do a program as it is as
done in the memory discrete; shown below with defining various tags of the
components. For the application of bottle filling plant as mentioned earlier that
programming is done in the memory discrete; the program is done without confusion
by using the window type script. At the primary stage W.S. has On Show & While
Showing scripts are presented. Hence for that, all the different components should
be specified by unique tag names. So first initialize the On Show by using
different tag names as decided individually below: B1 = Push Button B2 = Conveyor
Belt B3 = Filling Bottle B4 = Bottle Sensor B5 = Tank B6 = Lower Solenoid Valve B7
= Liquid Level Sensor B9 = Bottle Movement B10 = Upper Solenoid Valve B11 = No. of
Bottles B12 = Initial Condition for next Bottle. After that the script While
Showing has been made as shown below: IF b1==1 AND b12==0 AND b4==0 THEN b9=b9+5;
ENDIF; IF b9==345 THEN b9=345; b4=1; ENDIF; IF b4==1 THEN b6=1; b5=b5 -1; b3=b3+1;
ENDIF;

IF b3==100 AND b1==1 THEN b9=b9+5; b2=b2+5; b6=0; b5=b5; b4=0; ENDIF; IF b9==710
THEN b11=b11+1; b2=0; b9=0; b3=0; ENDIF; IF b11==2 THEN b12=1; b9=0; b11=0; b10=1;
ENDIF; IF b10==1 THEN b5=b5+1; ENDIF; IF b5==200 THEN b10=0; b12=0; ENDIF;

Thus the operator can derive the require output predetermined & get good results.
The various images of the runtime and development time; it is taken in between the
operations as shown in Fig. 6 & Fig. 7.
Figure 6: Half Filled Bottle
Figure 7: Fully Filled Bottle
10. BIBLIOGRAPHY

www.sciencedirect.com www.howstuffworks.com

BOOKS: CERN-CNL-2000-003 Vol. XXXV, issue no 3 SCADA INTOUCH GUIDE.

SOFTWARES: WONDARWARE INTOUCH, Version 9.0 ABKF2 I/O Server.