AUTOMATION [Automatic filing with the help of scada]

P R E F AC E

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.
 IND EX

SR. TOPIC PAGE

NO. NO.

1 PRINCIPLE OF PROJECT 01

2 ABOUT THE PROJECT 02

3 INTRODUCTION 03

4 CONCEPTUAL OVERVIEW 04

5 COMPONENTS 06
o INPUT COMPONENTS
o OUTPUT COMPONENTS

6 PLC PROGRAMMING
o ELECTRICAL DIAGRAM 07
o FLOW CHART 08
o PHYSICAL LADDER DIAGRAM 10

7 INTERFACE TO SERVER
o CONFIGURING I/O SERVER 11
o CONFIGURING COMMUNICATION PORT 12
o CONFIGURING TOPIC DEFINITION 13

8 DESIGNING 15

9 PROGRAMMING
o TAGS 18
o PROCEDURE DESCRIPTION 20
10 BIBLIOGRAPHY 24
 FIGU RE IND EX

SR. FIGURES PAGE

NO. NO.

1 CONCEPTUAL OVERVIEW OF SCADA 04

2 ELECTRICAL DIAGRAM 07

3 FLOW CHART 08

4 PHYSICAL LADDER DIAGRAM 10

5 DESING OF INITIAL POSITION 16

6 HALF FILLED BOTTLE 22

7 FULLY FILLED BOTTLE 23

 1 . P R I N C I P L E O F P R O JE C T

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 . AB O U T T H E P R O JE C T

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. INTROD U CTION

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. CONCEP TU AL 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 Allen-
Bradley communications interface. Therefore the communication interface is anyone from PLC-
2, 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 Defining Components (I/O)

o PLC Programming
o Flow Chart
o PLC Ladder Diagram
o Interface to Server
o Initial Design of Layout
o Continue Process to the end
o At last achieve the required result… .
 5. COM P ONENTS

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.
I n p ut C omp on en ts

Sr. no Inputs Symbols

1 Start button /

2 Stop button /

3 Proximity sensor (bottle sense) /

4 Proximity sensor (Liquid level sense) /

O utp ut C omp on en ts

Sr. no Outputs Symbols

1 Solenoid valve 1 (Vin)

2 Solenoid valve 2 (Vout)

3 Conveyor motor
 6. P LC P ROGRAM M ING

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 2: Electrical Diagram
START

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

cable.
simple. The Host computer is directly connected to the SLC-500 by a RS232
 8 . D ESIGNING

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. P ROGRAM M ING

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. B IB LIOGRAP H Y

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

SCADA INTOUCH GUIDE.

SOFTWARES:
WONDARWARE INTOUCH, Version 9.0

ABKF2 I/O Server.