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PLC & SCADA, a Case Study: -Autoclave Automation

Conference Paper · January 2008

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 PROCEEDINGS OF INTERNATIONAL CONFERENCE-PSACO-2008, 13-15th MARCH 2008, ANDHRA UNIVERSITY, VISAKHAPATNAM, AP, INDIA
830

PLC & SCADA, a Case Study: - Autoclave

Automation
Prof. D. P. Kadam, Prof. P.M. Sonwane, Mr. S. C. Landge, Prof. V. P. Dhote, Prof. S. S. Thorat

Abstract -
Automation generally refers to the science and technology of process control and includes
the control of chemical and petrochemical plants, Oil refineries, iron and steel plant, Power plants,
cement mills, Paper pulp and paper mills water and waste water treatment plants and many like all
this. The basic objective of automation is identifying the information flow and manipulates the
material and energy flow as given process in a desired way. PLC & SCADA plays an important role
in automating industrial system.
This work shows how automation is carried & implemented with software interface, PLC &
Micro-SCADA in C.G. Ltd. Nashik, Maharashtra, India for CVT autoclave. The whole process is of
121 hrs consisting of number of cycles, which is automated using PLC & SCADA for all process
parameters.

Key Words:- PLC, SCADA, Automation, Case Study-Autoclave Automation.

1. INTRODUCTION
PLC: - (PROGRAMMABLE LOGIC CONTROLLERS)
Automation of many different processes, such as
controlling machines or factory assembly lines, is done
through the use of small computers called as
Programmable Logic Controller (PLC). This is actually a
control device that consists of a programmable
microprocessor, and is programmed using a specialized
computer language. Fig No. 1 PLC block Diagram
Today, programmable logic controllers deliver a 2.1 PLC Operation & Working Principle
wide range of functionality, including basic relay control, A PLC works by continually scanning a
motion control, process control, and complex networking, program. The scan cycle consists of three important steps.
as well as being used in Supervisory Control and Data There are typically more than three but we focus on the
Acquisition Systems and Distributed Control Systems. important parts.
• Check Input Status: First the PLC takes a look at each
2. PLC PROGRAMMING input to determine if it is on or off. In other words, is
Previously programmable logos controller were the sensor connected to the first input on? How
programmed in ladder logic, which is similar to a about the second input? And so on it checks all the
schematic of relay logic. Modern programmable logic connected inputs. It records this data into its
controller is usually programmed in any one of several memory to be used during the next step.
languages, ranging from ladder logic to Basic or C.
• Execute Program: Next the PLC executes your
Typically the program is written in a development
program, one instruction at a time.
environment on a personal computer, and then is
• Update output Status: Finally the PLC updates the
downloaded onto the programmable logic controller
status of the outputs based on which inputs were on
directly through a cable connection.
during the first step and the results of executing your
Recently, the International standard IEC 61131-3
program during the second step.
has become popular currently defines 5 programming
2.2 PLC Selection
languages for programmable control systems:
Some of the Key factors for the selection of PLC
FBD (Function Block Diagram),
• Number of I/O required
LD (Ladder Diagram),
ST (Structured Text, Pascal type lang.) • Expandability
IL (Instruction List) • Cost
SFC (Sequential function chart) • Serviceability/ Support
• Flexibility
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2.2 Ordering Specifications etc. As incoming data changes the screen is updated.
Power Supply: AC/DC, 220V AC/24 V DC. Figure shows the examples of inputs from the MTU and
Configuration: Total Input and Output Details- Digital field devices.
and Analog. 3.4 Remote Terminal Unit
Remote terminal units gather information from
their remote site from various input devices, like valves,
2.3 User Interface pumps, alarms, sensors, meters, etc. Essentially, data is
PLC's may need to interact with people for the either analog ( real numbers), digital (on/off),or pulse
purpose of configuration, alarm reporting or everyday data(e.g., counting revolutions of meters). Many remote
control. A Human- Machine interface (HMI) is employed terminal units hold the information gathered in their
for this purpose. A simple system may use buttons and memory and wait for a request from the MTU to transmit
lights to interact with the user. Text displays are available the data. Other more sophisticated remote terminal units
as well as graphical touch screens. Most modern PLCs have microcomputers and PLC that perform direct control
can communicate over a network to some other system, over a remote site without the direction of the MTU. The
such as a computer running SCADA system. RTU central processing unit receives a binary data stream
in accordance with the communication protocol. Protocols
3. S.C.A.D.A can be open, like Transmission Control Protocol and
3.1 S.C.A.D.A- (SUPERVISORY CONTROL AND Internet Protocol (TCP/IP) or proprietary. Figure shows
DATA ACQUISITION) can mean many things to many an example of outputs of the RTU to MTU and field
people. The acquisition of data, the processing of those devices. Output to f ield devices
data for use by the operator, and operator control of • Contact1 Closure or 0-24V controls
remote devices are the fundamental building blocks upon Inputs from MTU • Analog control
P ulse Train stepping Motor Control
which all modern utility control systems are based. The • Discrete Control order •
• Analog setting Instructions • Serial Message to field Equipment
system to accomplish these functions is known as • Stepping Motor Pulses •
SCADA system. As the name indicates, it is not a full • Orders to response
control system, but rather focuses on the supervisory RTU
level. As such, it is a purely software package that is Output to MTU
• Field Analog Signal
positioned on top of hardware to which it is interfaced, in
Inputs from field devices • Alarms
general via Programmable Logic Controllers, or other • Field Analog Signal • Equipment status
commercial hardware modules. • Alaram switch Signal • Totaled Meter signals
• Equipment Message
3.2 Basic SCADA Elements • Equipment status signal
• Pulse Meter Signal
There are four major elements to a SCADA • Serial Message from field
system, master terminal unit (MTU), communications,
and remote terminal unit (RTU). The operator exercises
control through information that is depicted on a video Fig. No.2 :-Inputs & Outputs for RTU
display unit (VDU). Input to the system normally initiates The data acquisition part of SCADA is getting
from the operator via the master terminal unit’s keyboard. more PC-Based than stand-alone hardware. Many of
The MTU monitors information from remote sites and today’s RTU is either a Personal Computer or a
displays information for the operator. The relationship Programmable Logic Controller (PLC)
between MTU and RTU is analogous to master and slave.
SCADA systems are capable of communicating using a 3.5 Why SCADA System & Functions
wide variety of media such as fiber optics, dial-up, or Some basic needs are listed below
dedicated voice grade telephone lines, or radio. • Save Time: The time taken to travel remote sites to
3.3 Master Terminal Unit gather information or issue controls, to sift through
At the heart of the system is the master terminal manually entered data, write out a report or perform
unit (MTU). The master terminal unit initiates all any of the functions that a SCADA system does as a
communications, gathers data, stores information, sends matter of course is considerable. Time saving
information to other systems, and interfaces with benefits go far beyond the man hours saved-
operators. The major difference between the MTU and timeliness of alarms, actions, control have high
RTU is that the MTU initiates virtually all monetary value as well.
communications by its programming and people. Almost • Avoid Trouble: A SCADA system’s primary purpose
all communication is initiated by the MTU. The MTU is to give advance warning of trouble. Hence action
also communicates with other peripheral devices in the can be taken before it swallows the whole system
facility like monitors, printers or other information and creates problem.
systems. The primary interface to the operator is the
monitor that portrays a representation of valves, pumps,
PROCEEDINGS OF INTERNATIONAL CONFERENCE-PSACO-2008, 13-15th MARCH 2008, ANDHRA UNIVERSITY, VISAKHAPATNAM, AP, INDIA
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• Achieve System wide Processes: edited as required. The products include a library of
SCADA systems afford the user an opportunity to standard graphical symbols, many of which would
monitor and control processes that take place over a however not be applicable to the type of applications
wide geographical area. e.g., A sewage treatment encountered in the experimental physics community.
plant or energy management system. These
applications can cause considerable financial Standard windows editing facilities are provided:
savings in running cost and capital cost which can zooming, re-sizing, scrolling... On-line configuration and
pay for the cost of SCADA in itself. customization of the MMI is possible for users with the
• Save Manpower: Before SCADA systems were appropriate privileges. Links can be created between
implemented; remote sites such as substations and display pages to navigate from one view to another.
pumping stations were either manned or inspected
frequently. The need for this was eliminated or • Trending :- The products all provide trending
greatly reduced by the implementation of wide area facilities and one can summarize the common
SCADA. This was the primary economic driver for capabilities as follows:
SCADA system implementation in the first great
wave of comprehensive systems in the 1970’s and
1980’s. • The parameters to be trended in a specific chart
can be predefined or defined on-line
• A chart may contain more than 8 trended
parameters or pens and an unlimited number of
charts can be displayed (restricted only by the
readability)
• Real-time and historical trending are possible,
although generally not in the same chart
• Historical trending is possible for any archived
parameter
• Zooming and scrolling functions are provided
• Parameter values at the cursor position can be
displayed

The trending feature is either provided as a separate

module or as a graphical object (ActiveX), which can then
be embedded into a synoptic display. XY and other
statistical analysis plots are generally not provided.
Fig. No.4: - Graphical Screen Of Process
• Alarm Handling :- Alarm handling is based on limit
and status checking and performed in the data servers.
SCADA Functions
More complicated expressions (using arithmetic or logical
expressions) can be developed by creating derived
• Access Control: - Users are allocated to groups, parameters on which status or limit checking is then
which have defined read/write access privileges to performed. The alarms are logically handled centrally,
the process parameters in the system and often also i.e., the information only exists in one place and all users
to specific product functionality. see the same status (e.g., the acknowledgement), and
• MMI: -The products support multiple screens, which multiple alarm priority levels (in general many more than
can contain combinations of synoptic diagrams and 3 such levels) are supported.
text. They also support the concept of a "generic"
graphical object with links to process variables. It is generally possible to group alarms and to handle
These objects can be "dragged and dropped" from a these as an entity (typically filtering on group or
library and included into a synoptic diagram. acknowledgement of all alarms in a group). Furthermore,
it is possible to suppress alarms either individually or as a
Most of the SCADA products that were evaluated complete group. The filtering of alarms seen on the alarm
decompose the process in "atomic" parameters (e.g. a page or when viewing the alarm log is also possible at
power supply current, its maximum value, its on/off least on priority, time and group. However, relationships
status, etc.) to which a Tag-name is associated. The Tag- between alarms cannot generally be defined in a
names used to link graphical objects to devices can be straightforward manner. E-mails can be generated or
PROCEEDINGS OF INTERNATIONAL CONFERENCE-PSACO-2008, 13-15th MARCH 2008, ANDHRA UNIVERSITY, VISAKHAPATNAM, AP, INDIA
833

predefined actions automatically executed in response to Remote I/O (RIO), Devicenet, Controlnet, and a few
alarm conditions. others. Talk about an identity complex! Modicon PLCs
speak Modbus, Modbus Plus, and now Modbus TCP/IP
• Logging/Archiving: - The terms logging and (Modbus over Ethernet). Automation Direct PLCs speak
archiving are often used to describe the same facility. Directed and K-sequence protocols while some of their
However, logging can be thought of as medium-term PLCs still communicate using their old protocols. The
storage of data on disk, whereas archiving is long-term old GE PLC protocol was CCM but they now use SNP
storage of data either on disk or on another permanent and variants such as SNPX. Siemens PLCs work mainly
storage medium. Logging is typically performed on a with the Profibus protocol which is considered more of an
cyclic basis, i.e., once a certain file size, time period or open, rather than proprietary, protocol.
number of points is reached the data is overwritten. The most common "standard" protocols we see
Logging of data can be performed at a set frequency, or are DF1, Modbus, and Profibus. DF1 and Modbus are
only initiated if the value changes or when a specific popular since they have been around longer than many of
predefined event occurs. Logged data can be transferred the people using them. Profibus is popular because, in
to an archive once the log is full. The logged data is time- our humble opinion, combines the best of simplicity
stamped and can be filtered when viewed by a user. The (daisy chain, twisted pair), industrial ruggedness (RS485),
logging of user actions is in general performed together speed (12 MBaud), adaptability (you can select from
with either a user ID or station ID. There is often also a many different speeds), scalability (from simple COM
VCR facility to play back archived data. port up to communications controllers), and function
• Report Generation: - One can produce reports using (most automation devices can talk Profibus). Typically
SQL type queries to the archive, RTDB or logs. Although all PLC manufacturers will have a PLC module that will
it is sometimes possible to embed EXCEL charts in the talk these protocols.
report, a "cut and paste" capability is in general not Now that Ethernet is becoming the "most hyped"
provided. Facilities exist to be able to automatically capability in automation there are several protocols over
generate, print and archive reports. Ethernet. But remember -- just because an Allen-Bradley
• Automation: - The majority of the products allow and a Siemens PLCs are both put on the same Ethernet
actions to be automatically triggered by events. A cable -- they cannot talk to each other because they do not
scripting language provided by the SCADA products use the same protocol.
allows these actions to be defined. In general, one can 4.1 SCADA CONFIGURATION
load a particular display, send an Email, and run a user Configuration in SCADA should be done
defined application or script and write to the RTDB. The sequentially only. This is having following sequence.
concept of recipes is supported, whereby a particular 1. Protocol Configuration
system configuration can be saved to a file and then re- 2. Port Configuration.
loaded at a later date. 3. Device Configuration
4. Tag Configuration
5. Role Configuration
Sequencing is also supported whereby, as the
name indicates, it is possible to execute a more complex 4.2 APPLICATION OF SCADA
sequence of actions on one or more devices. Sequences
• Electric Utility
may also react to external events.
• Water / Waste Water Utilities
• Oil & Gas Transmission & Distribution
4. CONNECTIONS & PROTOCOLS • Communication Networks
• Industrial Process Control
As mentioned earlier that PLC is used frequently • Etc.
in a SCADA system as the RTU. We need to throw some
light on the communication between the SCADA
Computer and the PLC, There are several different types 5. CASE SYUDY – AUTOCLAVE AUTOMATION
of connections between the SCADA computers and
PLCs. For example, RS232, RS422, RS485, and Company:- Crompton Greaves Ltd. , Nashik
Ethernet. Note that these are only the electrical Address:- G.G. Ltd. Ambad, Nashik, Maharastra,
connection and do not specify the protocol or language India-422004,
used on the connection. We can call this as the Hardware Contact No.:- Mr. Shirode M.M. (+91-09422270801)
protocol. Each PLC manufacturer has their own protocol Products:-C.B.s , RELAYS, CT’S, PT’S, CVT’s
or language that the PLC speaks. For example, Allen- Process Of Study & Design :- Autoclave Automstion
Bradley (Rockwell) PLCs talk DF1, Data Highway 485
(DH485), Data Highway (DH), Data Highway + (DH+),
PROCEEDINGS OF INTERNATIONAL CONFERENCE-PSACO-2008, 13-15th MARCH 2008, ANDHRA UNIVERSITY, VISAKHAPATNAM, AP, INDIA
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A case study of “AUTOCLAVE AUTOMATION” 5.3 Device Used for Process: -

at Crompton Greaves, Nasik is considered. Demand for 1. Thermic Fluid Pump – used in heating system
Capacitive Voltage Transformer (CVT) has risen from 2. Air circulation Fan- One ON during Air Heating
past few years, because of features such as metering, 3. Roots Vacuum Pump – One ON during Fine Vacuum
protection & Carrier communication all being present in 4. Vacuum Pump 1 (Single Stage)– One ON during
one single product, also it is reparable in case of failure. Rough Vacuum
Considering the entire above thing CG wanted to increase 5. Vacuum Pump 2 (Double Stage)– One ON during
their rate of CVT production by reduction of process time Fine Vacuum
& manpower with enhanced quality. Since Autoclave 6. Hydro Power Pack – for Automatic Door Opening /
process is one of the major processes in the CVT product Closing
cycle and also takes 5 & ½ days, the need for it’s time 7. Three RTD’s – Temp. Sensing
optimization was faced, which was achievable through its 8. Pirani Vacuum Gauge – Vacuum measurement
automation. 9. Electrically operated Solenoid Valves
10. Light Flasher
5.1 Specification Of CVT Autoclaves 11. Liquid Level Sensors
1. Size – 1400mm ID X 2000mm useful Height 12. PLC & PC
2. Purpose Processing of Capacitor Tags &
Electromagnetic Units 5.4 Designed Logic for system
3. Heating System – Thermic Fluid Logic of only one cycle is mentioned & others
4. Processing Cycle has follows are on similar basis. Logic is prepared considering the
5. Hydraulic Lifting Cover for Autoclave different interlocking that needs to be satisfied for the
6. Quantity Reqd. = 03 Nos output to get activate.
7. PC / PLC with SCADA System common for all Before start of the cycle the door should be
03 Autoclaves & provision for another 03 closed that is the NO s/w of the door limit need to be
Autoclaves on the same PC. closed. This act as one of the digital I/P to the PLC.
8. During FINE VACUUM Stage we must get 50
microns Vacuum on Pirani Gauge in first 24 5.4.1 AH 1: -
Hours for both type of cycles. • Open Thermic Fluid Line Valves
9. Oil Heat exchanger with flow meter for temp. • Start Air circulation Fan
Controlled oil flow rate. (Max 200 Lts/hr) at 50 • Vacuum Valve should be Closed
deg. Cent. • Start Timer at the cycle start (The Set Value for the
10. Automatic vacuum control between 100 to 200 timer is 18 Hrs.)
microns during oil impregnation state
11. Control through PLC & monitoring through 5.4.2 Switching from AH 1 to RV 1 conditions -
SCADA system. • Job Temp. 105 deg. Cels. & AH 1 Time completed
12. Activated alumina for vacuum braking. • Chilling Pump ON
5.2 Process Description TABLE NO. 1 VACUMM DETAILS
As mentioned in specification the process cycle
consist of alternate cycles of Air Heating & Rough
Stage Temp Vacuum Duration Duration
Vacuum followed by Fine Vacuum & impregnation Deg. Hrs. for Hrs for
cycles. Since capacitive voltage Transformer consists of Celc Capacitor EMU
mix dielectric, there is the need of heating the product to Cycle Cycle
remove moisture from the paper in the form of vapors. AH 1 105 - 18 08
RV 1 105 35 mbar 06 04
This is done in air heating cycle. The moisture in the form
AH 2 110 - 04 -
of vapors is sucked from the autoclave in the rough RV 2 115 25 mbar 12 -
vacuum cycle. The Air Heating & rough vacuum cycle AH 3 115 - - -
are alternatively till a temp. Of 115 deg. Cles. & Vacuum RV 3 115 15 mbar - -
of 15 mbar is achieved. The duration for the cycles is FVH 115 50 60 12
microns
mentioned in the table. After this Fine Vacuum Heating is
FVC 60 100 25 12
carried out in which Vacuum of 50 microns is achieved, microns
then the Fine Vacuum Cooling in which the temp. is OI 60 100 – 200 06 06
brought to 60 deg. Cels. & the Vacuum levels of 100 microns
microns are achieved. The end cycle is Oil Impregnation, RV – Rough Vacuum FVC – Fine Vacuum Cooling
which is carried out under vacuum of greater than 100 OI – Oil Impregnation FVH – Fine Vacuum Heating
microns. AH – Air Heating
PROCEEDINGS OF INTERNATIONAL CONFERENCE-PSACO-2008, 13-15th MARCH 2008, ANDHRA UNIVERSITY, VISAKHAPATNAM, AP, INDIA
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5.5 Autoclave Monitoring Screens

Design Software: -
Basic Design Software: - Complicity
Front End Design: - Visual Basic, VC++.
Back End Design: - Oracle, SQL
Report Generation: -Excel, Access.

Screens Which Designed For Monitoring Process:-

1. Front Monitoring Screen SCADA Workbench view
2. Autoclave Control Screen
3. Front End Of A-9 Autoclave Menu
4. A-9 Subsystem Screen
5. A-9 Vacuum System Fig. No. 7 :- Front End Of A-9 Autoclave Menu
6. Heating System

Fig. No. 5 :- Front Monitoring Screen SCADA Work bench Fig. No.8 :- A-9 Subsystem Screen
view

Fig. No.6 :-Autoclave Control Screen Fig. No. 9 :-A-9 Vacuum System
 PROCEEDINGS OF INTERNATIONAL CONFERENCE-PSACO-2008, 13-15th MARCH 2008, ANDHRA UNIVERSITY, VISAKHAPATNAM, AP, INDIA
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Acknowledgement
SCADA SYSTEMS We are thankful to Prof. Dr. B. E. Kushare (H. O. D.
Electrical Engg. Dept. K. K. W. I. E. E. & R. Nashik. ) for his
valuable guidance & help through out the paper. We are also
thankful to Mr. P. P. Patil & Mr. M. M. Shirode , CG Nashik for
their guidance & cooperation for the case study.

7. REFERENCES
[1]Sonawane Y.D. , Patil P.M., Thorat S.C. Landeg S.C.,
CISCON-2005, Manipal, Karnataka, India, 95-101, 11-12 Nov.
2005, “Advance Techniques Of Energy Conservation &
Management”
[2]Lester Abbey, SCADA conference 2003. 75 80 “Evolution
of SCADA systems”
[3] Dennis J. Gausheel & Henry T. Darlington, IEEE paper. 25-
Fig. No 10 :- Heating System 31 “Supervisory Control & Data Acquisition”
[4] Duong trung 1995 IEEE paper , 120-125 “The Design of
next Generation SCADA systems”
5.6 PLC & SCADA Requirements
[5] Abhijit Hazara, Kaushik Ghosh , “Embeded Micro
As per the Logic requirement 40 Digital signals SCADA” , in ICSCI-06 Int. Conf., Jan. 2006, pp. 163-168.
are required. There are total 5 Analog Signal I/P’s. GE [6] Samual C. Scacca, “Advanced SCADA Concept” IEEE
Fanuc 64 Points micro PLC is used for this purpose. It has transaction , 1995 , 95-99.
total 40 digital I/P’s & 24 digital O/P’s. Two expansion [7] Armin Biere, "Resolve and Expand", Proc. of SAT
units are added to main PLC, first one is a Digital 2004, 2004.
expansion block & second one is Analog expansion unit. [8] Cimplicity , "SCADA”, ABB manual, 1986.
Cimplicity SCADA software is used for [9] P. G. Paulin, C. Liem, M. Cornero, F. Nacabal, and G.
developing the SCADA systems. The SCADA system Goossens, “Embedded software in real-time signal
processing systems: application and architecture trends,”
will be consisting of numerous graphical screens (Like
Proc. IEEE, vol. 85, no. 3, pp. 419-435, Mar. 1997.
Main menu, Vacuum system, Heating system, Chilling
system) through which the operator is visualize as well as
initiate some activities of the cycle.

6. CONCLUSION
The case study of Autoclave Automation is
described briefly because of the space constraint. The
SCADA system for the case is design as per the customer
requirement. Because of this automation both the product
as well as process time is optimized. This work shows
how automation is carried & implemented with software
interface, PLC & Micro-SCADA in C.G. Ltd. Nashik,
Maharashtra, India for CVT autoclave. The whole process
is of 121 hrs. Consisting of number of cycles, which is
automated using PLC & SCADA for all process
parameters.

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