Principles of SCADA-system Development

Stanislav V. Moshko1, Anastasiia D. Stotckaia2

Faculty of Electrical Engineering and Automatics; Department of Automatic Control Systems
Saint-Petersburg Electrotechnical University “LETI”
Saint Petersburg, Russia
1
[email protected], [email protected]

Abstract— The paper deals with principles of control software Such circuit lets adjust physical parameter with some ways: on
design. Such a software tools are widely used in modern paper deflection, on initiation and combined way [3]. Present
production enterprise. Siemens SIMATIC Step-7 environment is designing implements adjustment on deflection from fixed
implemented for software development (SCADA system value.
(Supervisory Control And Data Acquisition)). Basic concept of
program operation could be described as follows: control signal Creating ACS for coarse swirl purification sector demands
is generated by using real-time sensors’ data. Example of formation the 4 control loops. Two of them must maintain
creation operator panel interface with the overview its structure, pressure on the input and the output of centricliner. The two
are also included. This HMI (human-machine interface) contains others regulate pulp consumption after the first machine pool
schemes of production processes and helps operator to respond to and pulp concentration before second machine pool
untypical changes in manufacturing. respectively. All these circuits work on the same principle.
Therefore, it can be concluded that the mathematical models of
Keywords—SCADA; control loop; Siemens Step-7; PI the regulating circuits have the same structure. Controller itself
(proportional-integral) controller; automated system; operator is described by program which is designed in Step-7 Simatic
interface Manager. This program is loaded to PLC connected with
I. INTRODUCTION sensor, executing device and operator panel. The scheme of the
simplest regulating circuit is shown in the Fig. 1 (without
Resent years, while technical progress becomes one of the connecting to panel).
most expanding area in the world, each enterprise demands
modifications in working process. Automated control systems Control software which is loaded to PLC is consisted from
(ACS) which decline human’s participation in production some program parts which process signals in demanded ways.
process and enhance efficiency, let fulfill this task in the best Firstly, signal from sensor should be transformed from analog
way. Nevertheless, robotic devices can’t be self-sustained to numeric form. Then, it is compared with fixed value from
entirely. For operator controlling production processes SCADA operator panel. If there is a difference, PI controller
system was created. This software package lets design compensates deflection of measuring value from fixed. One of
programs which assemble and process information from the the main tasks is to limit signal from operator panel, because
control object and send from operator required control signals no one insured from human mistake. After compensation
to executing mechanisms. SCADA system usually is control signal is sent from PI controller to digital analog
implemented with such devices as: operator panels, converter and then to executing device. Furthermore, there are
programmable logic controllers (PLC), frequency converters, some program parts described below. The functional scheme of
electrical engines and sensors. the typical regulating circuit is shown on the Fig. 2.
The pattern of designing automated control system is Each block of processing signal is a mathematical function.
represented in this paper. It is based on the SCADA-system All of them are presented further.
structure and simulated in the Siemens SIMATIC Step-7
environment which includes application WinCC Flexible for
creating operator panel interface.
Similar ACS was implemented in one of the main pulp and
paper mills in Russia, namely in coarse swirl purification
sector. Such sector is consisted from 2 machine pools,
centricliner and mass pump.
II. CONTROL LOOP AND HIS MATHEMATICAL DESCRIPTION
Almost every production cycle is consisted from several Fig.1. Sheme of the simpliest regulation circuit.
technical operations. All of them require regulation physical
parameters [1]. Thus, any ACS includes control loops which
realize the link between sensors and executing devices [2].

937 978-1-5386-4340-2/18/$31.00 ©2018 IEEE

 • Limiter (limit function) – this is a function that limits
the setpoint signal from the operator panel. The
formula describing the function is represented by the
number (4).
­y
°° max
y = ®kx + b (4)
°
°̄ y min
Where y – is the output signal; ‫ݕ‬௠௔௫ - the upper limit of the
restriction; ‫ݕ‬௠௜௡ - the lower limit of the restriction; k is the
slope coefficient of the straight line; b - displacement of a
straight line with respect to the Y axis.
III. CREATING PROGRAM
The basis of Siemens SIMATIC Step-7 is project concept.
Fig.2. Functional scheme of the typical regulation circuit.
Control software is created in the main application Simatic
• Scaling (zoom function) – this is a function that Manager. The main principle of control software is blocks
converts an input data set into an output set in a given structure [5].
range [4]. The formula describing the function is Firstly, creating program starts from the Organization block
represented by the number (1). (OB1) [6]. This unit communicates between the controller
max − min operating system and the user program. After that, the
out = * N + min (1) programming language is chosen by user. There are only three
N max − N min programming languages: LAD (Ladder Diagram), STL
(Statement List), FBD (Function Block Diagram) [7]. In this
Where out is the output value; max - the upper limit of the project LAD language has been applied due to its visibility and
output range; min - the lower limit of the output range; N is the convenience.
input value; ܰ௠௔௫ - the upper limit of the input range; ܰ௠௜௡ - the
lower limit of the input range. Organization block contains such blocks as FB, DB, FC.
• FB – is a function block containing that part of the
• Smooth (filter function) – this is a function that program that can be repeatedly called in OB1. The FB
smoothes a signal using a simple moving average has an internal memory that is stored in the DB
algorithm. The formula describing the function is assigned to the function block. The basic meaning of
represented by the number (2). FB is that it includes a voluminous, repeatable
application program and makes it easier to use.

y =y + (x − y )∗ T (2)
• DB – is a data block. There are two types of such
blocks. Global - blocks, which can be accessed from all
i i +1 i −1
K +T
f logical blocks in the program. Instances are blocks that
communicate with specific function blocks. They store
Where ‫ݕ‬௜ – is the processed signal at the current step; ‫ݕ‬௜ିଵ all the static and dynamic FB data to which they are
- the processed signal in the previous step; x – is the signal to attached [8].
be processed; T - signal processing time; ‫ܭ‬௙ – is the filter
• • FC is a function. It differs from the functional block in
coefficient.
that you can’t use static data in it.
• PI (pi controller) – this is a function that compares
The main elements of the control software are the
the current value of the input signal with a specified
regulating circuits, the program of which is described in the
value and eliminates the control mismatch. The
functional blocks. This software solution allows storing static
formula describing the function is represented by the
circuit data and continuously asking them in the OB1 block.
number (3).
The regulating circuits consist of a structure of functions. The
1 t
scheme of hierarchy control software is shown on the Fig. 3.
T ³
U (t ) = K ∗ ε (t ) + ε (t )dt (3)
0
ɢ Functions which are realized in function blocks consist of
simple elements of comparison, appropriation, bit logic,
Where ܷሺ‫ݐ‬ሻ – is the output signal; K - coefficient of mathematical operations and etc. Moreover, there are blocks of
proportionality; İ (t) – is the error signal, the difference timers and counters. Blocks are differed in the type of data
between the input signal and the reference; ܶˋ - constant of being processed. Regarding the data, it situates in variables
integration; t – is the processing time of the signal. which are also created in function blocks. The example of

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control loop being realized in function block is shown on the IV. CREATING PANEL INTERFACE
Fig. 4.
After choosing a relevant operator panel for given system it
should be connected with PLC through the communication
protocol. Connection is carried out as between devices as in the
project. Further, all of the variables from control software
might be open in WinCC application. There is a window in this
application which is intended for drawing objects describing
industrial cycle. Each object can be assigned by variables from
control software. As it is necessary to play simulation of
product process, some actions with objects can be added to the
interface. Designed operator interface is shown in the Fig. 5.
This interface of the operator panel contains all the
necessary elements for monitoring and controlling the
technological process. The form of objects corresponds to their
description in the schematic diagrams.

Fig.3. Scheme of hierarchy control software. IV. CONCLUSIONS

Integration of designed control software, operator interface,
devices of automation and operator itself constitute SCADA
system. Obtained system allows simulate controlling
production process and observe necessary physical parameters.
As for interface, it contains all essential objects corresponded
with the ergonomic requirements.

Fig.5. Operator interface.

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