A SUMMER TRAINING REPORT

ON
“AUTOMATION”

In partial fulfillment for the award of the Degree of

BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING

Submitted by

Name: Satyam Raghuvanshi

Roll. No: 1714321048

Submitted to
Prof. Sameer Anand &
Prof. Raj Kumar Singh

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

ENGINEERING
IMS ENGINEERING COLLEGE
NH-24, ADHYATMIK NAGAR, DASNA, GHAZIABAD

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 ACKNOWLEDGEMENT

I express my profound sense of gratitude to my mentor, Mr. Yash Pal

Singh (Trainer), PLC Automation, for their systematic guidance,
valuable advices, encouragement and suggestions were of immense help
to me throughout my Summer Training in the company.
I would like to express my sincere gratitude to Prof. Annu
Govind, Head of the Department of Electrical and Electronics
Engineering, IMS Engineering College Ghaziabad, for his valuable
advices and motivational support during my presentation.
I would also like to thank all the faculty and staff members of
Electrical and Electronics Engineering Department, who extended full
cooperation for completion of the presentation.
I take this opportunity to thank all my friends who helped me
through their patient discussions and suggestion and for their help at
various stages in completion of this seminar.

Candidate name: Satyam Raghuvanshi

Roll.no:1714321048

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 TABLE OF CONTENTS

Page No.
Automation i
Need for Automation
Companies
Evolution of Control System

Manual Control
Drawbacks

Pneumatic Control
Drawbacks

Hard wired logic control

Drawbacks
Electronic Control using Logic Gates
Advantages
Drawbacks
PLC(Programmable Logic Controller)
PLC History
INTRODUCTION TO FIXED AND MODULAR PLC HARDWARE
THE CENTRAL PROCESSING UNIT

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 AUTOMATION
WHAT IS INDUSTRIAL AUTOMATION?
Automation is the technique to make the process a ‘self sustain’.
 Minimizing direct human intervention in Industrial Plant operation.
 Adding intelligence to Energy Management.

Need for Automation

 Higher productivity.
 Shorter process change times.
 Stability and accuracy of control.
 Greater reliability and equipment life.
 To add flexibility to process.

Companies
 L&T  ALSTOM
 Schneider  FESTO
 Siemens  Fuji Electric
 Allen Bradley  Toshiba
 Messung  TATA Honeywell
 Modicon  Omron
 Mitsubishi  Fanuc
 Asia Automation

Evolution of Control System

 Manual control
 Pneumatic Control
 Hardwire Logic control
 Electronic Gate control
 PLC (Program logical Control)

1. Manual Control
All the actions related to process control are taken by the operators
Drawbacks

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  Like human errors and consequently its effect on quality of final product. The
production, safety, energy consumption and usage of raw material are all
subject to the correctness and accuracy of human action.

2. Pneumatic Control
Industrial automation, with Its machine and process control, had its origin in the
1920s with the advent of "Pneumatic Controllers". Actions were controlled by a
simple manipulation of pneumatic valves, which in turn were controlled by relays
and switches.
Drawbacks
 Bulky and Complex System
 Involves lot of rework to implement control logic
 Longer project time

3. Hard wired logic control

The contactor and Relays together with hardware timers and counters were used in
achieving the desired level of automation.
Drawbacks
 Bulky panels
 Complex wiring
 Longer project time
 Difficult maintenance and troubleshooting

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4. Electronic Control using Logic Gates
In 1960s with the advent of electronics, the logic gates started replacing the relays
and auxiliary contactors in the control circuits. The hardware timers & counters
were replaced by electronic timers.
Advantages
• Reduced space requirements
• Energy saving
• Less maintenance & greater reliability
Drawbacks
• Changes in control logic not possible
• More project time

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5. PLC (Programmable Logic Controller)
A PLC is a user friendly, micro-processor based specialized computer that carries out
control functions of many types and levels of complexity.
PLC (Programmable logic controller) is a device that is designed for use in an
industrial environment, which uses its programmable memory for the internal storage
of instructions for implementing specific functions to control various types of process

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PLC History
In the late 1960's PLCs were first introduced. The primary reason for designing such a
device was eliminating the large cost involved in replacing the complicated relay
based machine control systems. Bedford Associates (Bedford, MA) proposed
something called a Modular Digital Controller (MODICON) to a major US car
manufacturer.
When production requirements changed so did the control system. This becomes very
expensive when the change is frequent. Since relays are mechanical devices they also
have a limited lifetime which required strict adhesion to maintenance schedules.
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Troubleshooting was also quite tedious when so many relays are involved. Now
picture a machine control panel that included many, possibly hundreds or thousands,
of individual relays.
What is a programmable logic controller (PLC)?
A programmable controller is an industrial computer in which control devices such as
limit switches, push buttons, proximity or photoelectric sensors, float switches, or
pressure switches, to name a few, provide incoming control signals into the unit. An
incoming control signal is called an input.
Incoming control signals, or inputs, interact with instructions specified in the user
ladder program, which tells the PLC how to react to the incoming signals. The user
programs also direct the PLC on how to control field devices like motor starters, pilot
lights, and solenoids. A signal going out of the PLC to control a field device is called
an Output.
Why use a PLC?
The question, “why use a PLC?” really should be rephrased to, “Why automate?” The
PLC is the tool that provides the control for an automated process. What will
automating a process do for a company? Automation will help a manufacturing
facility to:
 Gain complete control of the manufacturing process
 Achieve consistency in manufacturing
 Improve quality and accuracy
 Work in difficult or hazardous environments
 Increase productivity
 Shorten the time of market
 Lower the cost of quality, scrap, and rework
 Offer greater product variety
 Quickly change over from one product to another
 Control inventory

HOW DO PLCS KNOW WHAT THEY ARE SUPPOSED TO DO?

A PLC simply follows the instructions stored in memory. To retain user program
instructions, they are stored in the memory of the PLC for future used and reference.
Think of an instruction as a sentence. Each instruction that is entered will be placed in
memory in ascending order. The list of instructions is called the user ladder program.
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The instructions you wish your PLC to carry out of transferred to the memory of the
controller from either handheld programmer is created by the operating pushing the
correct sequence of buttons on a handheld programmer.
A PLC user program user can also be created using a personal or industrial computer.
When using a personal or industrial computer to develop the user ladder program, a
PLC ladder development software package is used. The primary difference between a
personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment. For now we will use the term
“personal computer” for both. When the entire user ladder program has been
developed, entered, and verified for correctness, the next step is to download the
program into the processor’s memory. Transferring the PLC program for a personal
computer’s memory of PLC memory is called downloading the program.

SECTION OF PLC:-
 Sensing inputs or controlling hardware:- The sensing section made up of
limit switches, pressure switches, photo electric sensor. push buttons and so
forth. These incoming hardware devices provide input signals.
 PLC input hardware:- Compresses of two major areas
1. Physical screw terminals where incoming signals are attach to PLC.
2. The second portion of input section is the PLC’s internal conversion
electronics. The function of the input section’s electronic components
is to convert and isolate the high voltage input level from field devices.
 The controller or CPU:- Central processing unit is the brain that control and
supervise the entire process. The CPU solves the user program & update the
status of the output.
 Handling programming device The programming device is whereby the
operator or programmer can enter or edit the program instruction or data.
 Output PLC hardware:- The output section is simply a series of switches,
one for each output point that are controlled by the CPU and are used to turn
output field devices ON or OFF.
 Hardware output device:- The devices such as Motor , Valve , Lamps
,Hooters etc that are controlled by PLC’s output section are defined as PLC
hardware devices
INTRODUCTION TO FIXED AND MODULAR PLC HARDWARE

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PLC hardware falls into two physical configurations
1. Fixed PLC:- A fixed PLC has all of its components. The input section, CPU and
associated memory, power supply, and output section built into one self contained
unit. All input and output screw terminals are built into the PLC package and are
fixed, not removable. This style of PLC is also called a packaged controller.
2. Modular PLC:-The modular PLC comes as separate pieces. A modular PLC is
purchased piece by piece. There may be two or three power supplies to choose from, a
handful of different processors (CPUs), many separate input and output cards or
modules, and a selection of assemblies, called racks, chassis, or base plates to hold the
pieces together. When purchasing a modular PLC you select and purchase the specific
pieces you need to build the PLC specifically for the needs of your control situation.

Architecture of PLC:-

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 Programming
Device

User
I/P table Program O/P table

Data
storage

I/P Device I/O System O/P Device

THE CENTRAL PROCESSING UNIT

The central processing unit is built into the single-piece, fixed PLC. When
working with modular PLC’s, the CPU is typically a plug-in module just like with an
I/O modular unit. The CPU work like the human brain work to direct the rest of the
body. In actuality, the CPU is a solid-state, microprocessor integrated circuit chip.
The microprocessor integrated chip is placed on a printed circuit board with other
supporting and interface chips to build the PLC’s CPU, or processor module.
The CPU comprises of Two Components.
 Controller
 Memory System

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Controller :- The microprocessor, or brain, that supervises all operations in the
system. The CPU reads, or gathers information from external sources like input
devices and stores this information in memory for later use by the CPU. When done
solving the user program, the CPU will write, or send, data out to external devices
like output modules and field hardware devices.
Memory System:-
The memory system has to provide the following:
1. Storage for the user program.
2. Storage of the input status file data: The input status file consists of memory
location that store the ON or OFF status of each field input device.
3. Storage of the output status file data: The output status file consist of
memory locations that store the ON or OFF status of field hardware devices as
the result of solving the user program. Data in the output status file is waiting
to be transferred to the output module’s switching device. The output
module’s switching device for each output point will turn power on or off to
each field output device.
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 4. Data storage:- The data storage area of memory is used to store numerical
data that may be used in math calculations, recipe ingredient weight, bar code
data being input to the PLC, and similar functions.

Programming
Device

Input User Output

Table Program Table

Data
Storage

Input Input/Output Output

Devices System Devices

I/O Module
The real world input & output devices are of two types:
 Discrete.
 Analog.
Discrete I/O devices are either ON or OFF, OPEN or CLOSED. Limit switches,
push button etc. are the examples of discrete input devices.
Analog devices have an infinite number of possible values such as temperature
probes. Pressure, indicators etc.

INPUT MODULES
Input modules serve as the link between field devices and the PLCs CPU. Each
input modules has a terminal block for attaching input wiring from each individual
field input device. Typical input modules have 8, 16, 32, 64 and so on input terminals.
 The main function of an input module is to take the field device input signals,
convert it to a signal level on which, CPU can work with, electrically insolate
it, and send the signal, by way of the backplane board, to the CPU.
 The input signal, once received on the CPU module must be stored
somewhere to wait processing by the CPU. The memory storage area input
signals is called that input status file (sometime called the input status table).
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 Each input screw terminals on each input module has one memory location in
the input status file. Each memory location stores the binary equivalent of the
ON or OFF status of its associated input signal.
 Discrete input modules : come in a wide range of voltages for various
applications, i.e. 120 V AC, 240V AC, 24VDC, 12-24V DC. Some
manufactures also give their module on AC/DC rating to increase their
flexibility. Input modules come with a wide range of input channels such as 4,
8, 16, 32, and 64 that determines the number of field devices that can be
connected to the module.
 Analog Input Modules: are used to convert analog signal from analog
devices that sense such variable as Temp, light intensity, speed, pressure etc.
and convert to 16 bit binary coded decimal. The conversion from analog to
digital is accomplished with an analog to digital converter.
For e.g……
 Switches and Pushbuttons
 Sensing Devices
 Limit Switches
 Photoelectric Sensors
 Proximity Sensors
 Condition Sensors
 Pressure Switches
 Level Switches
 Temperature
 Switches/ Vacuum Switches
 Float Switches
 Encoders

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 

OUTPUT MODULES
Output Module serve as the link between the PLCs microprocessor and hardware
field devices. Each output module has a terminal block for attaching output wiring to
go to each individual field output devices. Typical output modules have 8, 16, 32, 64
and so on output terminals.
 The output signal, once received from the CPU, must be stored before being
sent to each output modules output screw terminals. The storage area for
output signals is called the output status file. Each output screw terminal on
each output module has one memory location in the output status file.
 Discrete output modules : are used to control the current flow to real world
devices such as motor relay coils, lights, and control relays and solenoids

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 valves. This also works on a digital or ON and OFF basis. The output modules
works like a remote control switch that is controlled by the processor for
turning output devices ON or OFF. Output modules are sized by the number of
output devices that can be connected to them. They have a current rating for
each channel or connection point as well as overall rating for the module. The
individual current rating indicates the maximum current or load that can be
controlled.
 Analog Output Module: When the processor decides that the output is to be
turned On and sends a signal then the analog module changes the 16 bit
binary value used by the processor into analog signal using a digital to analog
converter. These analog signals can be used for speed controllers, signal
amplifiers or valve petitioners.
 Valves
 Motor Starters
 Solenoids
 Actuators
 Control Relays
 Horns & Alarms
 Stack Lights
 Fans/ Pumps
 Counter/Totalizer/ Printers

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 Remote I/O Racks
They allow the input and output modules to be installed closed to the actual operating
equipment. This saves the amount of cable and other associated wiring and labour
cost. Only wiring needed for communication back to the processor is a shielded
twisted pair, twin axial cable, fiber optic cable. The status lights on output module
close to the actual equipment shortens troubleshooting time increase production, eases
maintenance and increases efficiency.

The Guts Inside

The PLC mainly consists of a CPU, memory areas, and appropriate circuits to receive
input/output data. We can actually consider the PLC to be a box full of hundreds or
thousands of separate relays, counters, timers and data storage locations. Do these
counters, timers, etc. really exist? No, they don't "physically" exist but rather they are
simulated and can be considered software counters, timers, etc. These internal relays
are simulated through bit locations in registers. (more on that later)

What does each part do?

 INPUT RELAYS-(contacts)These are connected to the outside world. They
physically exist and receive signals from switches, sensors, etc. Typically they
are not relays but rather they are transistors.
 INTERNAL UTILITY RELAYS-(contacts) These do not receive signals
from the outside world nor do they physically exist. They are simulated relays
and are what enables a PLC to eliminate external relays. There are also some

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 special relays that are dedicated to performing only one task. Some are always
on while some are always off. Some are on only once during power-on and are
typically used for initializing data that was stored.
 COUNTERS-These again do not physically exist. They are simulated counters
and they can be programmed to count pulses. Typically these counters can
count up, down or both up and down. Since they are simulated they are limited
in their counting speed. Some manufacturers also include high-speed counters
that are hardware based. We can think of these as physically existing. Most
times these counters can count up, down or up and down.
 TIMERS-These also do not physically exist. They come in many varieties and
increments. The most common type is an on-delay type. Others include off-
delay and both retentive and non-retentive types. Increments vary from 1ms
through 1s.
 OUTPUT RELAYS-(coils) these are connected to the outside world. They
physically exist and send on/off signals to solenoids, lights, etc. They can be
transistors, relays, or triacs depending upon the model chosen.
 DATA STORAGE-Typically there are registers assigned to simply store data.
They are usually used as temporary storage for math or data manipulation.
They can also typically be used to store data when power is removed from the
PLC. Upon power-up they will still have the same contents as before power
was removed. Very convenient and necessary!!

Programming Language
A Programmer use to develop series of instruction or commands that directs the PLC
to execute action. Types of Language:-
 Ladder Diagram (LD):- A PLC programming system that contains relay
logic (NO, NC) in the form of ladder.
 Functional Block diagram (FBD):- A programming system that uses large
function block for portion of program.
 Structured text (ST):- structure text (ST) is a PLC programming system that
uses a series of steps and description to define a program. Structure text uses a
lots of IF, Else, and TRUE or FALSE.
 Instruction List (LT):- A PLC programming system that consists of series of
sequential statement which define a program.

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  Sequential Functional Chart (SFC):- A programming system that uses
vertical and parallel connected blocks and gates used in programming.

A Programming Language rules for combining the instruction so that they produce
the desired action. The most common language used for programming Language is
“LADDER LOGIC”.
Why ladder logic preferred?
Ladder Logic is a graphical system of symbol and term even those not familiar with
relay wiring diagram can easily learn it.

SOURCING vs. SINKING

RULES
1.) Field devices on the positive side (+VDC) of the field power supply are sourcing
field devices.
2.) Field devices on the negative side (DC COM) of the field power supply are
sinking field devices.
3.) Sourcing field devices must be connected to sinking I/O cards and vice versa.
4.) Sinking field devices must be connected to sourcing I/O cards and vice versa.

SOURCING Pushbutton SINKING Pushbutton

(PNP) (NPN)

+VDC

+
+ DC
Power
DC Supply
Power
Supply
-
- DC COM

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 SOURCING SINKING
(PNP) (NPN)

+VDC
Field
Device IN1 +
DC DC
+ DC Power
Input
DC Supply
Power Module
Input
Supply
Module -
Field
- DC COM Device IN1

Electrical Ladder Diagram

 Ladder logic is evolved from electrical logic, which represents how electrical
current flow through the device to complete an electric circuit.
 An electrical diagram consists of two vertical bus lines or power lines, with
current flowing from left to right bus.
 Each electrical circuit in the diagram is considered a RANG.
 Every rang has two components:-
 It contains at least one device that is controlled.
 It contains the condition that controls the device.

L1 L2
PB2 Start
PB1 Motor
Stop
Rung M1
M1

Auxiliary Holding
Power
Power Bus Contact
Bus

Ladder diagram
 Ladder Logic closely resembles electrical ladder diagrams
 A Ladder logic program exists only in the PLC’s software.

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  In ladder Logic it is not the actual flow of current thru circuits.
 In electrical diagram the devices are described as open or closed(ON or
OFF), where as in Ladder Logic, instructions are either TRUE or FALSE.
 In Ladder Logic Program must contain at least one control instruction
(output) and usually contains one or more conditions (inputs).

L1
Condition Control L2
Instruction
PB1 Stop PB2 Start Motor- M1
Instruction
%Q1
%I1 %I2
Run
g %Q1

Auxiliary Contact

Scan Time
A PLC works by continually scanning a program. We can think of this scan cycle as
consisting of 3 important steps.

Step 1-CHECK INPUT STATUS-First the PLC takes a look at each input to
determine if it is on or off. In other words, is the sensor connected to the first input
on? How about the second input? How about the third... It records this data into its
memory to be used during the next step.
Step 2-EXECUTE PROGRAM-Next the PLC executes your program one
instruction at a time. Maybe your program said that if the first input was on then it
should turn on the first output. Since it already knows which inputs are on/off from
the previous step it will be able to decide whether the first output should be turned on

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based on the state of the first input. It will store the execution results for use later
during the next step.

PLC Operating Cycle

START

Housekeeping Input Scan

Internal checks on The status of external inputs
memory, speed and (terminal block voltage) is written
operation. Service to the Input image (“Input file”).
any communication
requests, etc.

Program Scan
Each ladder rung is scanned
using the data in the Input
Output Scan file. The resulting status
The Output Image data is (Logic being solved) is
transferred to the written to the Output file
external output circuits, (“Output Image”).
turning the output
devices ON or OFF.

Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the status of the
outputs. It updates the outputs based on which inputs were on during the first step and
the results of executing your program during the second step. Based on the example in
step 2 it would now turn on the first output because the first input was on and your
program said to turn on the first output when this condition is true.
After the third step the PLC goes back to step one and repeats the steps continuously.
One scan time is defined as the time it takes to execute the 3 steps listed above.

Response Time
The total response time of the PLC is a fact we have to consider when shopping for a
PLC. Just like our brains, the PLC takes a certain amount of time to react to changes.
In many applications speed is not a concern, in others though...
If you take a moment to look away from this text you might see a picture on the wall.
Your eyes actually see the picture before your brain says "Oh, there's a picture on the
wall". In this example your eyes can be considered the sensor. The eyes are connected

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to the input circuit of your brain. The input circuit of your brain takes a certain
amount of time to realize that your eyes saw something. (If you have been drinking
alcohol this input response time would be longer!) Eventually your brain realizes that
the eyes have seen something and it processes the data. It then sends an output signal
to your mouth. Your mouth receives this data and begins to respond to it. Eventually
your mouth utters the words "Gee, that's a really ugly picture!".
Notice in this example we had to respond to 3 things:
INPUT- It took a certain amount of time for the brain to notice the input signal from
the eyes.
EXECUTION- It took a certain amount of time to process the information received
from the eyes. Consider the program to be: If the eyes see an ugly picture then output
appropriate words to the mouth.
OUTPUT- The mouth receives a signal from the brain and eventually spits (no pun
intended) out the words "Gee, that's a really ugly picture!"

Logic Gates
INTRODUCTION OF LOGIC GATES USED IN PLC PROGRAMMING
 A Digital Gate is a device that analyzes the digital states of its inputs and puts
out an approximate output state

 digital gate logic keys such as

o AND
o OR
o NOT and others.

 Once logic terms are understood. PLC programming using them can be easily
accomplished.
 Boolean algebra is a shorthand way of writing digital gate diagrams.
 The Boolean algebra symbols are :-

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 o Dot
o +
o –
o 0
o =

 Some computer-trained persons understand PLC programming best using

digital logic
 All gates have one output.

 The outputs are either ON (1) or OFF (0), depending on the logic status of their
inputs, ON (1) or OFF (0).

 A gate on condition is typical when +5 volts DC comes from the output

terminal. Off is typically 0 volts output

AND Gate:- For the AND gate output to be ON (1), all inputs must be ON
(1).

A
B OUTPUT
C

Truth Table foe two input:-

A*B=O

A B O
0 0 0
0 1 0
1 0 0
1 1 1

OR Gate:- For an OR gate output to be on (1), any one or more of the input must
be on (1). For the output to be off (0), all input must be off (0).

B O
C

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 Truth table for OR Gate:-
A+B=O

A B O
0 0 0
0 1 1
1 0 1
1 1 1

NOT Gate: - It reverse the input logic status, on or off, from the input to the
CPU

B
O
C

Truth Table:-
A=Ā

A O
0 1
1 0

EXCLUSIVE OR: - Its outputs are on (1) when one, and only one, of its two
input is on (1). If both inputs are on, the output is off

Truth table:-

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A + B

A B O
0 0 0
0 1 1
1 0 1
1 1 0

EXCLUSIVE NOR: - Its outputs are on, when both the inputs are either 0 or 1
output is off .

A
O

Truth Table:-

A + B

A B O
0 0 1
0 1 0
1 0 0
1 1 1

NAND Gate:- Output of NAND is OFF when both the input are 1 else both
output is always HIGH.

A
B
O
C

A.B

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 A B O
0 0 1
0 1 1
1 0 1
1 1 0

NOR Gate:- Output of the NOR Gate is ON when both the input are high else
output is always LOW.

A
B O
C

A+B

A B O
0 0 0
0 1 0
1 0 0
1 1 1

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 SCADA
(Supervisory Control And Data Acquisition)
What is SCADA and Why is so popular?

SCADA is “Supervisory Control and Data Acquisition” –real-time industrial process

control systems used to centrally monitor and control remote or local industrial
equipment such as motors, valves, pumps, relays, sensors, etc.
 SCADA is used to control chemical plant processes, oil and gas pipelines,
electrical generation and transmission equipment, manufacturing facilities,
water
purification and distribution infrastructure, etc.
 Industrial plant-scale SCADA is often referred to as a “Distributed Control
System” or DCS.
 SCADA nuzzles up to embedded system issues, too.
 The major attraction of SCADA to a municipality is the ability to significantly
reduce operating labor costs,.
 At the same time actually improve plant or regional system performance and
reliability.  Information gathering within a plant no longer requires personnel to
spend time wandering all over the site, and correspondingly the frequency of
field site inspections required in a regional system can be minimized.
 Costly after-hours alarm call-outs can often be avoided since a SCADA system
will indicate the nature and degree of a problem, while the ability to remotely
control site equipment may permit an operator at home to postpone a site visit
till working hours.  SCADA based alarming is also very reliable since it is in-
house and tied directly to process control.

A significant feature of a SCADA system, often not fully appreciated, is the trending
of data and nothing comes close for speed and ease of operation. When graphically
displayed, accumulated operating data often will indicate a developing problem, or an
area for process improvement. Reports can easily be generated from this data utilizing
other common software programs. 

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It should be appreciated that while a SCADA system is often complex to configure - it
is extremely easy to operate!

The term SCADA usually refers to centralized systems which monitor and control
entire sites, or complexes of systems spread out over large areas (anything between an
industrial plant and a country). Most control actions are performed automatically by
Remote Terminal Units ("RTUs") or by Programmable Logic Controllers ("PLCs").

Supervisory
 From the dictionary:
 To “supervise” means to “oversee.” An overseer watches over and sets the
direction but does not do the detailed work. Typically the overseer is charged
with seeing “the big picture” and with directing the many elements of that
picture to work in concert for maximum effect.
 Supervisory Control generally entails:
 such binary things as OPEN/CLOSE,ON/OFF, UP/DOWN etc.
 Multiple choice options like recipes and programs.
 Set points for continuously variable processes
Control
 Control means to “command”, “direct”, and” guide”.
 Control also means to “regulate”, implying careful and constant vigilance that
ensures that the regulated process remains within acceptable limits.

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Data Acquisition
 In order to make “big picture” decisions, the supervisor must be cognizant of
salient Conditions and facts about the process he is controlling. The supervisor
must have data about the status of key parameters. The supervisors tasked with
integrating that data into information that he uses to issue supervisory
commands.

A SCADA System usually consists of the following subsystems:

 A Human-Machine Interface or HMI is the apparatus which presents process

data to a human operator, and through this, the human operator monitors and
controls the process.
 A supervisory (computer) system, gathering (acquiring) data on the process
and sending commands (control) to the process.
 Remote Terminal Units (RTUs) connecting to sensors in the process,
converting sensor signals to digital data and sending digital data to the
supervisory system.
 Programmable Logic Controller (PLCs) used as field devices because they are
more economical, versatile, flexible, and configurable than special-purpose
RTUs.
 Communication infrastructure connecting the supervisory system to the
Remote Terminal Units

SCADA runs on a PC and is generally connected to various PLCs and other

peripheral devices. It enables you to generate applications for the most demanding
requirements of plant engineers, operators, supervisors and managers tailored
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precisely to the needs of each plant. SCADA constantly gathers data from the plant in
real-time, stores and processes it in the database, evaluates and generates alarms,
displays information to plant operators to plant operators, supervisors and managers
and can issue instructions to PLCs on the plant floor.

Leading SCADA software

Company Software Country

Schneider Vejio citect France
Wonder ware In Touch USA
Siemens Win CC Germany
Modicon Moviecon France
Allen Bradley RS View USA
GE Fanuc Cimplicity USA

Usefulness of SCADA

Production Department
 Real time production status: manufacturing status is updated in real time in
direct communication to operator and control device
 Production schedules: production schedules can be viewed and updated
directly
 Production information mgt.: production specific information is distributed to
all
Quality Dept
 Data integrity and quality control is improved by using a common interface
 It is an open platform for statistical analysis
 Consolidation of manufacturing & lab data
Maintenance Dept
 Improved troubleshooting and de-bugging: direct connection to wide variety
of devices, displays improves troubleshooting reduces diagnostic/
debugging time
 Plant can be viewed remotely. Notification can include pagers, e-mails, and
phones.
 Co-ordination between maintenance and mgt. reduces unscheduled
downtime

Manufacturing Dept
 Unscheduled down time is reduced due swift alarm detection and event driven
information
 Makes operations easier and more repeatable with its real time functionality
 Secured real time operation are maintained with windows

Features of SCADA
 Dynamic process graphics
 Alarm summary
 Alarm History

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  Real time trends
 Historical trends
 Application security
 Database connectivity
 Device connectivity
 Recipe management
 Scripts

Dynamic process graphics:-

 Touch links allow the operator to input data into the system.
 Ex: operator may turn the valve on or off, enter a new alarm set point, run a
complex logic script etc.
 Touch pushbuttons are used to create object links that immediately perform
an operation when clicked with the mouse or touched. These operations can
be discrete value changes, action script executions, and show or hide window
commands.
 Color links (line color, fill color, and text color) are used to animate the line
color, fill color and text color of an object. Each of these color attributes can
be made dynamic by defining a color link for the attribute. The color attribute
may be linked to the value of a discrete expression, analogue expression,
discrete alarm status or analog alarm status.

Miscellaneous links
 Visibility used to control visibility of an object based on the value of a
discrete tag name or expression
 Blink used to make an object blink based on the value of a discrete tag
name or expression.
 Orientation used to make an object rotate based on the value of a tag
name /expression
 Disable used to disable the touch functionality of objects based on the
value of a tag name of expression. Often used as part of a security strategy.
 Value display links provide the ability to use a text object to display the
value of a discrete, analog or string tag name.
 Percent fill links used to provide ability to vary the fill level of a filled
shape according to the value of an analog tag name or an expression that
computes to an analog value.

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Alarm summery:-
Alarm handling is based on limit and status checking and performed in the data
servers. The alarms are logically handled centrally, i.e., the information only exists in
one place and all users see the same status (e.g., the acknowledgement), and multiple
alarm priority levels (in general many more than 3 such levels) are supported. The
filtering of alarms seen on the alarm page or when viewing the alarm log is also
possible at least on priority, time and group.

Trending:-
 The products all provide trending facilities and one can summaries the
common capabilities as follows:
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 o real-time and historical trending
o zooming and scrolling functions are provided
o parameter values at the cursor position can be displayed

Application security:-
It application is optional. It provides the application developer with the ability to
control whether or not specific operators are allowed to perform specific functions
within an application.

Database & Device connectivity:-

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 Application Scripts are linked to entire applications and are used to start
other applications, create process simulation, calculate variables and so on: 3
types of application scripts are on start up, while running, on shut down.
 Window Scripts are linked to specific window. 3 types of window scripts are
on show, while showing, on hide.

 Script:-
o Key script touch pushbutton action scripts are similar to key scripts,
except they are associated with an object that you link to a touch link
action pushbutton. 3 types are on key down, while down, on key up.

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 o Condition Scripts are linked to a discrete tag-name or expression that
equates to true or false. You can also use discrete expressions that
contain analog tag names. 4 types of scripts that you can apply to a
condition are on true, on false, while true, while false.
o Data change Scripts are linked to a tag-name and / or tag-name field
only. They are executed one time when the value of a tag-name or tag-
name field changes by a value greater than a dead band that you
defined for the tag name in the tag-name dictionary.
o Application security to an application is optional. It provides the
application developer with the ability to control whether or not
specific operators are allowed to perform specific functions within an
application. Security is based on the concept of operator logging on to
the application and entering his user name and password and access
level. For each operator access to any protected function is granted
upon verification of his password and access level.

 Recipe Management:-
o The Recipe Manager Configuration Utility provides the system
administrator with setup functions for each client PC. This is a small
program that can be run from a secure networked drive, an installation
CD-ROM or even a USB-based flash drive unit. For security
purposes, the utility is typically removed from the PC once
configuration is complete. It is easy-to-use and provides three key
functions:
o It configures the client PC to communicate with the database server.
o It configures user name and password verification for the run-time
program. This is Windows-based, and both local and domain accounts
may be configured. It creates the entire recipe database (SQL Server
or Oracle) on the server machine from the push of a button. All the
system administrator needs to do is supply the relevant information
for database connection, and a Database Administrator-level username
and password. Once the main database is created, another push of a
button creates the configuration required for the current computer to
be able to communicate with the database and also to
create/modify/delete recipes.

How to Program RSView32?

Creating a New Screen

In the Project window, expand the “Graphics” folder. Double-click on “Display”.

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A new window with an “untitled” display is created. Right-click on the new window and
select “Display Settings”. This will appear:

Display Type:-It is less confusing for the operator if you use “Replace”. This keeps windows
from getting stuck behind other windows.

Allow Multiple Running Copies:-For our application, there is no need for this.

Cache after Displaying:-In large applications, this could help speed things up. It will
consume extra RAM on the PC that is running RSView, though.

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Title Bar:-You want to leave this on during development, with the “System Menu” and
“Minimize Buttons” enabled. However, at runtime (when RSView is actually running in a
live plant environment), you will probably disable this, as it allows more access than the
operators need. Check “Size to Main Window at Runtime” and “Show Last Acquired Value”.

Size:-Specify the correct size of the monitor.

Resize:-Check “Allow Display to be Re-sized”. This will compensate for minor hardware
variations and make sure that the screen will resize to fill the monitor.

Position:-In most cases, set this to 0, 0.

Create a Tag:-Next, create a tag or tags to access the data in the devices.
10. In RSView32 click on the System folder and then click on Tag Database in the Project
Control and open the Tag Database dialog box.

The Final Results

Let’s take a look at how the screens look in actual operation.

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A Net work setup for total system:-

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 HMI
(Human Machine Interface)
H.M.I:-Human machine interface
M.M.I:-Man machine interface
It consists of a Display (16*1/16*2/20*1/20*2/20*4 line alpha-numeric LCD/LED
display and a user definable key pad with arrow keys & 4/8/16/32 keys keypad.
It is use to change the variable in a control program.
It is not use to change the PLC program itself (the program in side the PLC is
normally changed using HHT/ HHP/laptop or a PC).

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Human Machine interface (HMI) is operator interface terminals with which users
interact in order to control other devices. Some human machine interfaces include
knobs, levers, and controls. Others provide programmable function keys or a full keys
pad. Device that include a processor or interface to PC (Personal computer) are also
available. Many human machine interfaces include alphanumeric or graphic display.
For ease of use, these displays are often backlit or use standard messages. When
selection human machine interface, important considerations include device support
and devices controlled. Device dimensions, operating temperature, operating
humidity, and vibration and shock ratings are other important factor.

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