IoT ENABLED PLC-SCADA BASED

TEMPERATURE CONTROL SYSTEM

Sachin Sonawane Saurav Tiwari Ajay Upadhyaya
Electronics Engineering Electronics Engineering Electronics Engineering
Sardar Patel Institute of Technology Sardar Patel Institute of Technology Sardar Patel Institute of Technology
Mumbai-400058 Mumbai-400058 Mumbai-400058
[email protected] [email protected] [email protected]

Abstract—This paper presents the implementation of an A. ON-OFF control Proportional Control

automation plant for controlling the temperature of process
fluid using Programmable Logic Controller(PLC) Supervisory In case of ON-OFF control the controlled variable has the
control and data acquisition (SCADA). A prototype system is largest value when the error is positive and the controlled
developed in which a temperature control unit accepts a the variable has the smallest value when the error is negative. It is
input from RTD, to perform PID control. The desired set point simple and there are no parameters to choose. ON-OFF control
is provided by the user through SCADA GUI and the PID often succeeds in keeping the process variable close to the set-
controller within the PLC would try to maintain the required point, but it will typically result in a system where the variable
set point. The sole purpose is to optimize the heating profile of oscillates. The ON-OFF control oscillates because the
the given process fluid as per the requirement. PID algorithm is controlled variable overreacts even when there is a small
necessary to implement in order to stabilize the response of the change in the error which will make the controlled variable
system- minimize transient time and reduce overshoot and to change over the full range. This is eliminated by using
ensure the process variable agrees with the set point. Thus a proportional controller, where the controlled variable is made
prototype model comprising of PLC, SCADA temperature proportional to the control error for small errors. To get high
control unit was developed for remote control monitoring. This performance output gain must be increased, however it is well
was achieved using PLC Ladder Logic PLC was configured known that higher gain results into oscillation whereas small
using Ethernet Protocol with Remote Control loop gain results in small output response. Its biggest drawback
Station(SCADA).The proposed system allows user to change is Controlled variable never reaches set-point there always exist
the set point remotely monitor the characteristics / variations Offset Error.
via GUI. System response is obtained and analyzed by using
various parameters of PID controller and the most efficient
response is chosen. B. Integral control
Keywords-Programmable Logic The main function of Integral Action is to make sure
Controller(PLC),Supervisory control and data acquisition that the process output agrees with the set point. With
(SCADA), Proportional-Integral-Derivative(PID) controller Integral action, a small positive error will always lead to
Internet of Things(IoT). an increasing control signal negative error will give a
decreasing control signal, no matter how small the error
I. INTRODUCTION is. However it can cause the present value to overshoot
Temperature control has a very important role in the set-point value, since the integral term is responding
industrial/home applications and is difficult to be to accumulated errors from the past.
implemented through ordinary control techniques. PID
controllers are widely used in temperature control.PID C. Derivative control
Proportional, Integral Derivative Controller are in itself a
separate controller, but when combined together gives Derivative action is used to improve the close loop
optimized control for the system.[1]. Though the effect of stability. Because of load changes process dynamics, it will
individual parameter Proportion Gain(Kp) , Integral take some time before a change in control variable is
Gain(Ki) Derivative Gain(Kd) are known, to demonstrate its noticeable in process output. Thus system will be late in
effect, Automation plant consisting of PLC SCADA is correcting errors. Adding a derivative term can improve the
developed. stability, reduce the overshoot that rises when proportional
or high gain integral terms are used, and improve response
The purpose of the automation plant is to heat up a
speed by predicting changes in the error.
particular solution to a desired temperature with the mini-
mum overshoot and in minimum time, in other word the
D. Graphical User Interface & Internet of Things
optimum result. It is necessary to operate the system in
closed loop to ensure the system temperature meets with
SCADA and IoT Application is used for creation of
the desired set-point.System is implemented using negative
feedback principle where the controlled variable is Graphical User Interface as well as control and monitor of
increased when the process variable is smaller than the set- the System Process Remotely. Thus providing the user to
point and vice verse. This is referred to as Negative safely operate the system without actually going into the
feedback principle because the controlled variable moves in field. The disadvantage of a SCADA Screen is that it
opposite direction to that of process variable. requires wired communication with PLC for its action. Thus
an option of IoT enabled Application overcomes this
disadvantage and provides wireless global control.

Fig. 1: Project overview

Fig. 3: Temperature Control Setup

The most common used controllers are the P controller, PI

controller and PID controller. Proportional controller is
capable of reducing the rise time. However it never eliminates
the steady state error. Proportional-integral controller on the
other hand will eliminate the steady state error, but it also may
make the transient response worse. A Proportional-integral-
derivatives controller will increase the system stability, reduce
the overshoot, and improve the transient response. SCADA,
being an easy to use operate tool provides interactive human
machine interface. SCADA can be configured with master
controller using numerous tools techniques like using Labview
[4],wireless sensor network [5]. SCADA in developed
system is configured via Ethernet, thereby providing
remote monitoring control.

I. METHODOLOGY
The System block diagram of this project Fig 1, shows
how PLC, RTD , Temperature Transmitter (PT-100), heater
coil are related to each other. The input or set point (SP) of
the system is the desired temperature which is entered via
SCADA GUI, which is then compared with current
temperature in PLC, which then actuates the final control
element to reach the set point.

Fig. 4: Flowchart for temperature control

Fig. 2: System Block Diagram

Variation in temperature is converted into variation in

resistance by RTD, which is then converted into variation in Fig. 5: Rslogix Programming Screen
current(4-20 mA) by temperature transmitter. Its output is
fed to Analog Input of PLC . Output of plc is then fed to
SSR(Solid State Relay). SSR output is given to heater coil
according to change in input current of SSR its output
voltage changes in the range of 60-120 V.
Supervisory control and data acquisition (SCADA) is a
control system architecture that uses computers, networked
data communication and graphical user interfaces for high- Controller Proportional Integral Derivative
Type Band, PB Time, T1 Time, Td
level process supervisory management, but uses other P * 0 0
peripheral devices such as programmable logic controllers PI * * 0
to interface to the process plant or machinery. It provides PID * * *
an interface which enables monitoring and the issuing of TABLE I: PID VALUES FOR EACH MODE
process commands, such as controller set point changes,
System On - Off as well as can present process related
parameters graphically for analysis purpose.
alone. Fig 7 shows us the response of the system when the
proportional gain has been set to 150 and Fig 8 corresponds to
the proportional gain of 600. The following figure also shows
us the system is First order system and hence the response of
the system increases from its OFF state value to the one in
steady state. From the figure it is clear that there is a finite
steady state error in the process output. The steady state error
usually reduces with increasing proportional gain however
increasing proportional gain with give rise to oscillations[2].
Hence the response of the system with proportional gain of
600 will reduce the steady state error however it will give rise
to oscillations which makes the system unstable. The Offset
error for proportional gain of 15 is greater as compared to
proportional gain of 600. The offset with proportional gain of
15 is 4.6 (48.7-44.6) is greater as compared to the response of
Fig. 6: SCADA Home Screen the system with proportional gain of 600 1(48.7-47.7).

Fig 6 shows GUI developed on SCADA for controlling the

Temperature System ON and OFF whereas System Status denotes
whether System is ON or OFF. Numeric Entry text is provided to
insert desired set point. Current Temperature of the fluid / Room
in process is displayed ON Digital LCD as well as plot of
Temperature Vs Time is obtained which is further used to
determine various system parameters like Rise time, Fall Time and
Overshoot.

III.RESULTS AND ANALYSIS

In this section various effects of Proportional gain,
Integral gain and the Derivative gain are observed on the
process variable. The basic function of this section is to
identify the most optimum response for the system. The
result and analysis section has been divided into three Fig. 7: Proportional Gain with 150
sections which are proportional analysis, proportional and
integral analysis and Proportional integral and derivative
analysis.All the set-point in experiment has set to 48.7 and
data for the experiment has been taken until the system
becomes stable or in other words the settling time has been
elapsed. The parameters used for analysis are as follows
 Rise time (Tr)seconds
 Peak time (Tp) seconds
 Delay time (Td) seconds
 Percent Overshoot (OS)
 Offset error or steady state error

A. Proportional Mode analysis

Fig. 8: Proportional Gain with 600
This mode is usually given by Ti= and Td=0 and some B. Proportional and Integral Mode analysis
finite proportional gain. The following figure shows us the
response of the system when Proportional controller is used This mode is usually given by by Td=0; and finite
proportional and integral gain. Fig 9 shows us the response of
the system when the system is subjected to PI controller while the compared to I gain. Fig 11 shows the response of system
proportional gain is kept constant at 600 and the integral gain is when PID controller is used
kept at 2.5 and Fig 10 shows the response when the integral gain is
increased to 1. In theory, integral gain (I) accumulate error from
past to correct it on present and overshoot will occur because of
this. A high integral gain yields a faster output to encourage faster
process toward SP and eliminate residual steady-state error that
occurs with a P only controller. In the system it affects how long
heater will rest before resume heating. In addition, the result also
indicates a high I gain give faster rise time but higher overshoot
and more encourage output to oscillate as well. Whereas a lower
integral gain (I) have lower rise time, overshoot produced
comparable to high integral gain (I) is low and promotes oscillating
as well. The overshoot observed when Integral gain(I) is 1 is higher
which is 7.8% as compared to the overshoot observed when the
Integral gain(I) i.e 2.5 is low which was 1.43%. Hence, a high
integral gain increases the peak overshoot and rise time(Tr). Hence Fig. 11: PID with P=600 and I=1 and D=0.05
it is recommended to keep integral gain as high as possible.

Mode Graph P I D Td(secs) Tr(secs) Tp(secs) %OS

P Figure 7 150 0 0 22 31 41 NA
Figure 8 600 0 0 27 37 68 NA
PI Figure 9 600 2.5 0 29 40 207 1.43%
Figure 10 600 1 0 33 48 108 7.8%
PID Figure 11 600 1 0.05 22 29 82 1.8%

TABLE II: OVERALL PERFORMANCE COMPARISON

Based on the above conclusion, it can be summarized as:

1) P gain: A higher P gain causes unstable system
Fig. 9: PI with P=600 and I=2.5 and oscillations and insufficient proportional
gain increases the Offset error.
2) I gain: An increased Integral gain makes the
system response undesirable and increases the rise
time and also increases the peak overshoot of the
system. However, it is necessary to use high
integral gain in order to eliminate the Offset error
which results due to the proportional controller.
3) D gain: The basic function of the derivative
controller is to improve the response of the system
and also to reduce the peak overshoot and the rise
time which results due to high integral gain.
4) PID controller with gain P=600 I=1 and D=0.05
is required in order to obtain the optimum
response of the system.

IV.CONCLUSION
Fig. 10: PI with P=600 and I=1 It has been concluded from the following observation that a
properly tuned PID controller is required in order to obtain the
optimum response of the system. The performance of the system is
C. Proportional, Integral and Derivative Mode analysis analyzed in terms of Peak Overshoot, Rise time, Delay time and
Peak time. From the observation it has also been concluded that
In this analysis, it is required to determine the gain of the best PID parameters required to obtain the desired response of
proportional integral and derivative controller in order to the system is P=600 I=1 and D=0.05
obtain the optimum response of the system. In this mode
analysis the Proportional gain has been set to 600, Integral REFERENCES
gain has been set to 1 and derivative gain of 0.05 is added. The
addition of derivative gain reduces the peak overshoot [1] J. Velagic, N. Osmic, K. Lutvica and N. Kadic, ”Incubator system
identification and temperature control with PLC HMI”
observed in the PI controller from 7.8% to 1.8%. It also makes ELMAR,2010 PROCEEDINGS, Zadar, 2010, pp. 309-312.
the response of the system stable. The D gain is usually 4 times [2] K.J.Astrom, T. Hagglund, ”Revisiting the Ziegler-Nichols step
lower as response method for PID control [J]”, Journal of Process Control
14 (2004) 634-650.
[3] R. Li, X. Du and P. Li, ”Design of low-cost acquisition sys
tem for multichannel analog signal for PLC and its application
in temperature control system,” Intelligent Control and Automation
(WCICA), 2012 10th World Congress on, Beijing, 2012, pp. 93-98,
doi:10.1109/WCICA.2012.6357846.
[4] Neeraj Khera, Sumit Balguvhar, Design of micro-controller
based wireless SCADA system for real time data, UACEE
International Journal of Advances in Electronics Engineering,
volume 2:issue 1 ISSN 2278 - 215X (Online).
[5] Siti Rohainiza BintiChe Mood, Development of SCADA system
based on wireless sensor network, Thesis, University Teknikal,
Malaysia Melaka, May 2009