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PLC based process control automation using GSM and SCADA technology

Article · July 2015

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Amala Rani Aaron James

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 S.Aaron James* et al. International Journal Of Pharmacy & Technology

ISSN: 0975-766X
CODEN: IJPTFI
Available Online through Research Article
www.ijptonline.com
PLC BASED PROCESS CONTROL AUTOMATION USING GSM AND SCADA
TECHNOLOGY
1
V.Amala Rani, 2 S.Aaron James, 3J.Adeline Sneha, 4 Bestley Joe S
1
Assistant Professor, Department of Electronics and Instrumentation, Sathyabama University, Chennai.
2
Assistant Professor, Department of Electronics and Instrumentation, Sathyabama University, Chennai.
3
Assistant Professor, Department of Electronics and Instrumentation, Sathyabama University, Chennai.
4
Assistant Professor, Department of Electronics and Instrumentation, Sathyabama University, Chennai.
E-mail: 1v.amalarani@gmail.com,2aaronjameszion@yahoo.com,3j.adelinesneha@gmail.com,4bestleyjoe@gmail.com

Received on 10-09-2015 Accepted on 28-09-2015

Abstract

There has been an important and necessity for safety measures which has always been stressed upon us, especially in,

Industries. Process control industries comprise numerous SPM (Specials Purpose Machines) boilers& furnaces etc.

Therefore every parameter measured and controlled in those industries are abundantly vital. If one thing went wide of

the mark certainly there would be an enormous loss in price. For that reason it’s necessary to provide a safety and

security conditions in all furnace application. This paper stress that many parameters such as pressure, humidity and

temperature are controlled using by PLC-(Programmable Logic Controller), analyzed through SCADA and additionally

the total mechanism comes to a power of machine-in-charge by the help of GSM Modem. In this way, huge losses in the

process control fields could be avoided and attaining the maximum accuracy in the process could also be maintained. As

a result of all this process, the head controller could be able to make the essential or the necessary steps to sustain the

field from any hazardous situation by receiving an message with the help of GSM.

Keywords: PLC, SCADA, GSM, PROCESS, SAFETY.

1. Introduction

This paper involves in control and monitoring the process taking place in industries. Herein, the most significant task is

done by GSM modem. The hardware components are interconnected together and simulated through SCADA software.

In this process, certain parameters like temperature, pressure and humidity are controlled and also its effects can be seen

on SCADA software. If any of the parameters like (pressure, temperature, humidity) fall below the respective set point

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 S.Aaron James* et al. International Journal Of Pharmacy & Technology
or if it reaches the maximum set point value, a kind of alert is been generated to the head of the supervisor with the help

of GSM modem. Based on the information, the head could consult with the supervisor for future change in the process.

This provides safety measures for the process control industries like petroleum, oil and gas etc under any hazardous

conditions. Safety is always been an important concern in any type of industries. Thus the safety sector is quite

improved by clubbing the GSM Into PLC through a communication protocol. To begin with the PLC, it is just a device

which controls the output signals based on the input signals and a ladder logic program which is being programmed.

Initially there would be a supervisor to monitor and control the entire process via his “PC” through a driver software

been linked up to a PLC and that software is called SCADA, The SCADA(supervisory control and data acquisition) is

being linked with the PLC through the driver software. This software can be installed in the supervisor’s PC and it is

used to interlink the SCADA and PLC altogether. In SCADA the entire process is being supervised and controlled

virtually by the supervisor. Then there is another important modem being connected in our process which is called GSM

(global system for mobile communication).

2. Existing System

In the prevailing process the entire process has been controlled and monitored by the supervisor. He gets the visual

output of the entire process virtually via the software SCADA. The complete process is been also programmed via PLC

software by ladder diagram format. The whole program would be in the form of ladder diagram. In this system only the

supervisor could monitor and control the entire application..In case of any abnormality is detected the supervisor alone

could observe and control the process. The disadvantage of this method is that it needs manual amount of labor to

process and the safety is comparatively less.

3. Proposed System

The virtual display of the entire process is being shown in the software of SCADA. In this, the supervisor controls and

monitors the process, if any abnormality is detected; the GSM updates the abnormality process to the head of the

supervisor. The GSM main function is to update the head of the supervisor in any abnormality condition.

The head of the supervisor turn could know the true statuses of the process.The advantage of the system are the

supervisor as well as the head of the supervisor could control the process and the whole process feedback would be

known.

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 S.Aaron James* et al. International Journal Of Pharmacy & Technology
4. Block Diagram Description

Right Margin
1.25

Figure 1: Block Diagram

The inputs for the parameters are sent through the variator and this gives the value for the process. The input module

acts as an isolation barrier for having a smooth flow and not to affect the PLC devices. PLC gets the input from the input

module unit and controls the process. SCADA monitors and supervises the functions in the process. The whole process

status is send through the GSM MODEM to the head personal as a message in the form of SMS. The head personnel of

the supervisor would be able to make change if necessary by replying (command) the SMS. The GSM receives the

status from the head of the supervisor and this status is given to the PLC and in turn it controls the system. The major

materials used in the system are DELTA PLC DVP 14SS (Programmable Logic Controller), ASTRA .SCADA

(Supervisory Control and Data Acquisition), GSM SIM 300_V7.03 (Global System for Mobile Communication), SMPS

(Switch Mode Power Supply).

4.1 Programmable Logic Controller (DELTA PLC DVP 14SS)

In this type of PLC there are normally 8 type of input and 8 type of output. The PLC’s output depends upon the input of

the PLC. The delta PLC (programmable logic controller’s) are also referred as programmable controller, and also in the

family of computer .The delta PLC are used in the commercial purposes and industrial application and moreover the

delta PLC act’s as a controllers in our process. They monitor the inputs and make decision with respect to the input and

control the output in order to automate machines and process. The output of the delta PLC generally depends upon the

input of the PLC. The output is activated by the decision based on the status of the system’s feed-back sensors and these

are connected to the input terminals of the PLC.

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 S.Aaron James* et al. International Journal Of Pharmacy & Technology
4.2 Supervisory Control and Data Acquisation (ASTRA SCADA)

An industrial measurement and control system comprising of a central host or master terminal unit, remote terminal

units and a compilation of customary software used to observe and manage distantly located field data elements.

Modern SCADA systems demonstrate principally open-loop control characteristics and make use of long distance

communications, even though some elements of closed-loop control and short distance communications also be there

.Systems similar to SCADA systems are routinely seen in factories, treatment plants etc. They are regularly referred to

as Distributed Control Systems (DCS). They include related functions to SCADA systems, except the field data

gathering or control units are generally sited within a more confined area. Communications might be by the use of a

local area network (LAN), and normally be dependable and high rate. A DCS system generally employs important

amount of closed loop control. SCADA systems alternatively cover bigger geographic areas, and rely on a mixture of

communications systems that are normally less dependable than a LAN. Closed loop control in this situation is less

advantageous. SCADA is used to supervise and control plant or equipment. The control could be involuntary or initiated

by operator commands. The data acquisition is obtained by the RTU's scanning the field inputs connected to the RTU (it

may be also called a PLC - programmable logic controller). This is done at a fast rate. The central host would scan the

RTU's (usually at a slower rate.) The data is processed to sense alarm conditions, and if an alarm is there, it will be

displayed on special alarm lists.The ladder diagram is shown below.

Figure 2: Ladder Diagram 1.

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 S.Aaron James* et al. International Journal Of Pharmacy & Technology

Figure 4: Ladder Diagram Continuation.

First set PLC,Rs232 communication for GSM modem. And set the GSM Modem for Text mode.Initialize the GSM

modem and send AT+CMGF=1<ENTER>.

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 S.Aaron James* et al. International Journal Of Pharmacy & Technology

Figure 5:SCADA Output.

This diagram shows the output page of our project by ASTRA SCADA software. At first we need to select the start

button to start the process. Next the variators can be adjusted for required status. The changes happened in the variator is

shown in the ASTRA SCADA. We can able to see the three parameters used in this project. Three parameters has three

different status conditions i.e low, normal, high. If any of the parameter is changed the status is immediately shown in

the result page. In addition to that a warning sms will also be sent to the predefined mobile number.

5. GSM Output

Figure 6: GSM Output.

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 S.Aaron James* et al. International Journal Of Pharmacy & Technology
6. Summary and Conclusion

This report shows the complete working of PLC based process control automation using GSM and SCADA technology.

The various hardware and software used in this project is thoroughly seen along with their working principle. In this

paper we have effectively completed the GSM based process control automation using SCADA.

Thus in the end of the process the supervisor could see the visual output of the process via SCADA and he could in-turn

control the process similarly the head person of the process could get the output of the process in irregularity condition.

Thus the whole project has been executed successfully and the desired result has been obtained through the end of the

process.

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Corresponding Author:
S.Aaron James*,
Email: aaronjameszion@yahoo.com

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