COMPONENTS

Components used in Project:

Here we will give a brief introduction to the different types of components used in this
project. They are explained as follows.

PLC (Programmable Logic Controller)

A Programmable Logic Controller (PLC) or programmable controller is an industrial

digital computer which has been used for the control operation of machines and other
equipment. This is an advanced microcontroller which is more reliable and easy to
operate.

Its advanced features include:

1. Run time debugging: User can fix or change the program in the run time i.e.
operation is easily controllable and accessible.
2. Remote access: With the integration of SCADA system we can see and control
the things remotely. This thing will provide security assurance and quality
operation.
3. Speed of operation: Response time of PLC program is very less hence its speed of
operation is very high.

Figure 1: plc panel

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 SMPS (SWITCH MODE POWER SUPPLY)

A SMPS is an electronic power supply that incorporates a switching regulator to convert

electrical power efficiently. Like other power supplies, an SMPS transfers power from a
source, like mains power, to a load, such as personal computer, while converting voltage
and current characteristics. Unlike a linear power supply, the pass transistor of switching
mode supply continually switches between low dissipation, full on and full off states, and
spends very little time in the high dissipation transitions, which minimizes wasted energy.
Ideally, SMPS dissipates no power. Switching regulators are used as replacements for
linear regulators when higher efficiency, smaller size or lighter weight is required. They
are, however, more complicated, their switching currents can cause electrical noise
problems if not carefully suppressed and simple designs may have a poor power factor.

Emergency Stop

An emergency stop , also known as a kill switch; is a safety mechanism used to shut off a
device in an emergency state of affairs in which it cannot be shut down in the usual
manner. Unlike a normal shut down switch/procedure, which shuts down all systems in
an orderly fashion and turns the machine off without damaging it, a kill switch is
designed and configured to a) completely and as quickly as possible abort the operation,
even if this damages equipment and b) be operable in a manner that is quick, simple, and
usually, c) be obvious even to an untrained operator or a bystander.
Kill switches are featured especially often as part of mechanisms whose normal operation
or foreseeable misuse may cause injury or death; designers who include such switches
consider damage to or destruction of the mechanism to be an acceptable cost of
preventing that injury or death.

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 Indicating Lamp

Indicator consisting of light to indicate whether power is on or motor is in operation.

TERMINAL CONNECTOR

It connects multiple wires individually to a single terminal point in an enclosed housing.

They are available in many sizes, but they lack the circuit protection and connection
simplicity of other connectors. Connection includes PCB terminal blocks, multiple
terminal connectors (MTC), pluggable terminal blocks, and barriers trips. Application

Includes printed circuit boards (PCB’s) and various electrical devices

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 PROGRAMMABLE LOGIC CONTROLLER
HISTORY OF PLC:
In the 1960's Programmable Logic Controllers were first developed to replace relays and
relay control systems. Relays, while very useful in some applications, also have some
problems. The primary reason for designing such a device was eliminating the large cost
involved in replacing the complicated relay based machine control systems for major
U.S. car manufacturers. These controllers eliminated the need of rewiring and adding
additional hardware for every new configuration of logic. These, along with other
considerations, led to the development of PLCs. plc was more improved in 1970’s. In
1973 the ability to communicate between PLCs was added. This also made it possible to
have the controlling circuit quite a ways away from the machine it was controlling.
However, at this time the lack of standardization in PLCs created other problems. This
was improved in the 1980's.The size of PLC was also reduced then, thus using space even
more efficiently. The 90's increased the collection of ways inwhich a PLC could be
programmed (block diagrams, instruction list, C, etc.).

INTRODUCTION OF PLC:
A programmable logic controller (PLC) is an industrial computer control system that
continuously monitors the state of input devices and makes decisions based upon a
custom program to control the state of output devices.

It is designed for multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact.

They are used in many industries such as oil refineries, manufacturing lines, conveyor
systems and so on, wherever there is a need to control devices the PLC provides a
flexible way to "soft wire" the components together.

The basic units have a CPU (a computer processor) that is dedicated to run one program
that monitors a series of different inputs and logically manipulates the outputs for the
desired control. They are meant to be very flexible in how they can be programmed while
also providing the advantages of high reliability (no program crashes or mechanical
failures), compact and economical over traditional control systems.

In simple words, Programmable Logic Controllers are relay control systems put in a very
small package. This means that one PLC acts basically like a bunch of relays, counters,
timers, places for data storage, and a few various other things, all in one small package.

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ARCHITECTURE OF PLC:
The PLC give output in order to switch things on or off.The PLC’s output is
proportionally activated according on the status of the system’s feedback sensors and
input terminal which is connected to PLC. The decision to activate output are based on
logic programmes. The logic programme stored in RAM or ROM memory. The PLC also
have same as computer, a CPU, data bus and address bus

Fig. : PLC internal architecture

to communicate with external devices such as programmers, display monitor The next
diagram shows a simplified diagram of PLC’s structure. The central processing unit
control everything according to a programme stored in a memory (RAM/ROM).
Everything is interconnected by two buses ,the address bus and data bus . The system
must be able and a/d converter.

Fig : Simplified PLC structure

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Fig : Basic plc sections

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 Ladder Diagram (LD)

The Ladder Diagram is also a graphics oriented programming language which

approaches the structure of an electric circuit. Ladder Diagram consists of a series of
networks. Each network consists on the left side of a series of contacts which pass on
from left to right the condition "ON" or "OFF" which correspond to the Boolean values
TRUE and FALSE. To each contact belongs a Boolean variable. If this variable is TRUE,
then condition pass from left to right.

Fig : ladder diagram

COMMUNICATION/PROGRAMMING WITH SOFTWARE

RSLINX
This explains how to program the PLC. It describes how to write a program, how the
program is structured and representation of the programming language.

PROGRAMING BY LADDER DIAGRAM:

Ladder logic is a method of drawing electrical logic schematics. It is now a graphical
language very popular for programming Programmable Logic Controllers (PLCs). It was
originally invented to describe logic made from relays. The name is based on the
observation that programs in this language resemble ladders, with two vertical "rails "and
a series of horizontal "rungs" between them. A program in the ladder logic, also called
ladder diagram is similar to a schematic for a set of relay circuits.

The Ladder Diagram is also a graphics oriented programming language which

approaches the structure of an electric circuit. The Ladder Diagram consists of a series of
networks. A network is limited on the left and right sides by a left and right vertical
current line. In the middle is a circuit diagram made up of contacts, coils, and connecting
lines.

Each network consists on the left side of a series of contacts which pass on from left to
right the condition "ON" or "OFF" which correspond to the Boolean values TRUE and

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FALSE. To each contact belongs a Boolean variable. If this variable is TRUE, then the
condition is passed from left to right along the connecting line. Otherwise the right
connection receives the value OFF.

INPUT represented by I

OUTPUT represented by O.

Addressing method:
1 slot=32 bit=2 word (1 char./word=2 byte=16 bit)

Ø Input addressing:
File letter:Slot number.Word number/Bit number

For example I:2.1/1

Ø Output addressing:
File letter:Slot number.Word number/Bit number

For example O:2.1/1

GENERALLY USED INSTRUCTIONS & SYMBOL FOR

PLC PROGRAMMING:
Input Instruction:
1. --[ ]-- This Instruction is Called XIC or Examine If Closed.
ie; If a NO switch is actuated then only this instruction will be true. If a NC switch is
actuated then this instruction will not be true and hence output will not be generated.

2. --[\]-- This Instruction is Called XIO or Examine If Open

ie; If a NC switch is actuated then only this instruction will be true. If a NC switch is
actuated then this instruction will not be true and hence output will not be generated.

Output Instruction:
1. --( )-- This Instruction Shows the States of Output(called OTE).
ie; If any instruction either XIO or XIC is true then output will be high. Due to high
output a 24 volt signal is generated from PLC processor.

2. --(L)-- Output Latch (OTL)

OTL turns a bit on when the rung is executed, and this bit retain

its state when the rung is not executed or a power cycle occurs.

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 3. --(U)-- Output Unlatch(OTU)
OTU turns a bit off when the rung is executed, and this bit retains its state when the rung
is not executed or when power cycle occurs.

Rung:
Rung is a simple line on which instruction are placed and logics are created

E.g.; ---------------------------------------------

Timer:
Timer has three bit:

Ø EN: Enable bit :

The Timer Enable (EN) bit is set immediately when the rung goes true. It stays set until
the rung goes false.

Ø TT: Timer timing bit :

The Timer Timing (TT) bit is set when the rung goes true. It stays set until the rung goes
false or the Timer Done (DN) bit is set (i.e. when accumulated value equals preset value).

Ø DN: Done bit:

The Timer Done (DN) bit is not set until the accumulated value is equal to the preset
value. It stays set until the rung goes false.

Timer is three type:

1. TON 2. TOF 3. RTO

1. TON: Timer On
Counts time base intervals when the instruction is true.

Fig : Timer on

2. TOF: Timer off

Delay Counts time base intervals when the instruction is false.

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 Fig : Timer off

3. RTO: Retentive Timer

This type of timer does NOT reset the accumulated time when the input condition goes
false. Rather, it keeps the last accumulated time in memory, and (if/when the input goes
true again) continues timing from that point.

Fig : Retentive Timer

Addressing of timer:

Fig : Addressing of timer

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 Table : Status of bits in timer

Set When Accumulated value wraps around to +32,768 (from: 32)

Counter:
Counter has three bit:

Ø Count Up bit (CU):

Set When Rung conditions are true and remains set till rung conditions go false or a RES
instruction that has the same address as the CTD instruction is enabled.

Ø Done bit ( DN):

Set when the accumulated value is => the present value and remains set till the
accumulated value becomes less than the present value.

Ø Overflow ( OV):
continues counting from there and remains set till a RES instruction that has same
address as the CTD instruction is executed or the count is incremented greater than or
equal to +32,767 with a CTU instruction.

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Counter is two type:
1. CTU
2. CTD

1. CTU: Count Up
Increments the accumulated value at each false-to true transition and retains the
accumulated value when the instruction goes false or when power cycle occurs.

Fig : Count Up

2. CTD: Count Down

Decrements the accumulate value at each false-to true transition and retains the
accumulated value when the instruction goes false or when power cycle occurs.

Fig: Count Down

Addressing of counter:

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 Fig: Addressing of timer

3. RESET: --(RES)--
Reset the accumulated value and status bits of a timer or counter.

A C5:0

-------[ ]---------------------(RES)--------------------------

When A is true than counter C5:0 is reset.

BOOLEAN LOGIC DESIGN BY LADDER DIAGRAM:

Ø AND logic:
Y0=X0.X1

Fig 3.5: AND logic ladder diagram

Ø OR logic:
Y1=X0+X1

Fig 3.6: OR logic ladder diagram

Ø NOT logic:

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Y3=X0

Fig 3.7: NOT logic ladder diagram

Ø NAND logic:
Y0=X0.X1

Fig : NAND logic ladder diagram

Ø NOR logic:
Y1=X0+X1

Fig : NOR logic ladder diagram

Ø X-OR logic:
Y2=X0 + X1

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 Fig : XOR logic ladder diagram

Ø X-NOR logic:
Y2=X0 + X1

Fig : X-NOR logic ladder diagram

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 APPLICATIONS OF PLC:

The PLC can be programmed to function as an energy management system

for boiler control for maximum efficiency and safety.

Ø In automation of blender recliners

Ø In automation of bulk material handling system at ports.
Ø Automation for wagon loaders.
Ø For blast furnace charging controls in steel plants.
Ø In automation of brick molding press in refractory.
Ø In automation for galvanizing unit.
Ø For chemical plants process control automation.
Ø In automation of a rock phosphate drying and grinding system.
Ø Modernization of boiler and turbo generator set.
Ø Process visualization for mining application.
Ø Criteria display system for power station.

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 SCADA
(SUPERVISORY CONTROL AND
DATA ACQUISITION)
INTRODUCTION
SCADA stands for Supervisory Control And Data Acquisition. As the name indicates, it
is not a full control system, but rather focuses on the supervisory level. 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. These systems encompass the transfer of data between a SCADA central
host computer and a number of Remote Terminal Units (RTUs) and/or Programmable
Logic Controllers (PLCs), and the central host and the operator terminals. A SCADA
system gathers information (such as where a leak on a pipeline has occurred), transfers
the information back to a central site, then alerts the home station that a 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 consist of:

Ø One or more field data interface devices, usually RTUs, or PLCs, which interface
to field sensing devices and local control switchboxes and valve actuators
Ø A communications system used to transfer data between field data interface
devices and control units and the computers in the SCADA central host. The
system can be radio, telephone, cable, satellite, etc., or any combination of these.
Ø A central host computer server or servers (sometimes called a SCADA Center,
master station, or Master Terminal Unit (MTU)
Ø A collection of standard and/or custom software [sometimes called Human
Machine Interface (HMI) software or Man Machine Interface (MMI) software]
systems used to provide the SCADA central host and operator terminal
application, support the communications system, and monitor and control
remotely located field data interface devices.

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 Fig. Typical SCADA System

SCADA Software
o Rockwell – RS view32
o Siemens – winCC
o Wonderware – Intouch
o GE – Intellation

ARCHITECTURE:
Generally SCADA system is a centralized system which monitors and controls entire
area. It is purely software package that is positioned on top of hardware. A supervisory
system gathers data on the process and sends the commands control to the process. For
example, in the thermal power plant the water flow can be set to specific value or it can
be changed according to the requirement. The SCADA system allows operators to change
the set point for the flow, and enable alarm conditions incase of loss of flow and high
temperature and the condition is displayed and recorded. The SCADA system monitors
the overall performance of the loop. The SCADA system is a centralized system to
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communicate with both wire and wireless technology to Clint devices. The SCADA
system controls can run completely all kinds of industrial process.

EX: If too much pressure in building up in a gas pipe line the SCADA system can
automatically open a release valve.

Hardware Architecture:
The generally SCADA system can be classified into two parts:

· Clint layer
· Data server layer

The Clint layer which caters for the man machine interaction. 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 unit.

Fig 5.5: Hardware Architecture

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Software Architecture:
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.

EX: alarm checking, calculations, logging and archiving; polling controllers on a set of
parameter, those are typically connected to the server.

Human machine interface:

The SCADA system uses human machine interface. The information is displayed and
monitored to be processed by the human. HMI provides the access of multiple control
units which can be PLCs and RTUs. The HMI provides the graphical presentation of the
system. For example, it provides the graphical picture of the pump connected to the tank.
The user can see the flow of the water and pressure of the water. The important part of
the HMI is an alarm system which is activated according to the predefined values.

Fig : Human machine interface

For example: The tank water level alarm is set 60% and 70% values. If the water level
reaches above 60% the alarm gives normal warning and if the water level reach above
70% the alarm gives critical warning.

Monitoring/Control:

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The SCADA system uses different switches to operate each device and displays the status
at the control area. Any part of the process can be turned ON/OFF from the control
station using these switches. SCADA system is implemented to work automatically
without human intervention but at critical situations it is handled by man power.

APPLICATIONS OF SCADA:
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 monitors and controls industrial, infrastructure, or facility-based

processes, as described below:

v Infrastructure processes may be public or private, and include water

treatment and distribution, wastewater collection and treatment, oil
and gas pipelines, electrical power transmission and distribution, wind
farms, civil defence siren systems, and large communication systems.
v Facility processes occur both in public facilities and private ones,
including buildings, airports, ships, and space stations. They monitor
and control HVAC, access, and energy consumption.
v Automotive
v Building Automation
v Chemical
v Electronics
v Food and Beverages
v Aerospace & Defence
v Metals & Mining
v Oil & Gas
v Pharmaceutical
v Machines and Manufacturing
v Transportation
v Water & Wastewater

ADVANTAGES:
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1. The SCADA system provides on board mechanical and graphical
information
2. The SCADA system is easily expandable. We can add set of control
units and sensors according to the requirement.
3. The SCADA system ability to operate critical situations.

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