CHAPTER-1

INTRODUCTION TO COMPANY
1.1 GOEDUHUB TECHNOLOGY:-
Goeduhub Technologies-Jaipur is Training partner with the Government of Rajasthan.
Goeduhub's trainers are some of the most knowledgeable in the industry with profound empirical
knowledge and an enviable proficiency in theoretical concepts.

We provide Summer, winter, regular training in Artificial Intelligence(AI), Machine

Learning(ML), Deep Learning(DL), Python, Big Data Hadoop, Internet of Things(IoT), Cloud
Computing, Salesforce, Embedded Systems & Robotics, Mobile Apps Development, Industial
Automation(PLC-SCADA),AUTOCAD, MATLAB, Programming (PHP, Java, C, C++),
Networks & Database.

We are providing a broad foundation for a revolution in higher education worldwide. The advent
of the Internet and other information technologies can make teaching and research readily
available to scholars and students across the globe.

With the changing global scenario and India is turning out to be a knowledge based economy
like US, there is a huge requirement of technology professionals worldwide. The Need of
interactive learning and maintaining high quality standards in technology education is the need
of the hour. With over 10 million upcoming new jobs in emerging technology sectors like AI,
Machine Learning, Deep Learning, Big Data HADOOP, Cloud Computing, Embedded systems
and Robotics, young India must opt for technology training that comes from the premier
education schools-training that is high quality, reliable and cutting edge. Such training will not
only equip students to participate in the job-rich emerging sectors, it will also allow existing
professionals to re-skill themselves with more up-to-date technology knowledge.

AIET/DOEE/2017-21/ 1
Goeduhub Technologies-Jaipur is Training partner with the Government of Rajasthan.
Goeduhub's trainers are some of the most knowledgeable in the industry with profound empirical
knowledge and an enviable proficiency in theoretical concepts.

We are a pool of experienced IT professionals providing world class Hands-On Projects Oriented
Corporate & Technical trainings through Classroom / Virtual Trainings for Organizations (Govt.
& Public Listed) Clients, Individuals in the domains of Data Science, Artificial Intelligence,
Machine Learning, Internet of Things(IoT), Big Data and Open Source Technologies. Goeduhub
is committed to provide research based practical training through its experts

AIET/DOEE/2017-21/ 2
 CHAPTER-2

INTRODUCTION
2.1 AUTOMATION
Automation is the use of machines, control systems and information technologies to optimize
productivity in the production of goods and delivery of services. The correct incentive for
applying automation is to increase productivity, and/or quality beyond that possible with current
human labor levels so as to realize economies of scale, and/or realize predictable quality levels.
The incorrect application of automation, which occurs most often, is an effort to eliminate or
replace human labor. Simply put, whereas correct application of automation can net as much as 3
to 4 times original output with no increase in current human labor costs, incorrect application of
automation can only save a fraction of current labor level costs. In the scope of industrialization,
automation is a step beyond mechanization. Whereas mechanization provides human operators
with machinery to assist them with the muscular requirements of work, automation greatly
decreases the need for human sensory and mental requirements while increasing load capacity,
speed, and repeatability. Automation plays an increasingly important role in the world
economy and in daily experience.

Automation has had a notable impact in a wide range of industries beyond manufacturing (where
it began). Once-ubiquitous telephone operators have been replaced largely by
automated telephone switchboards and answering machines. Medical processes such as primary
screening in electrocardiography or radiography and laboratory analysis of
human genes, sera, cells, and tissue sare carried out at much greater speed and accuracy by
automated systems. Automated teller machines have reduced the need for bank visits to obtain
cash and carry out transactions. In general, automation has been responsible for the shift in the
world economy from industrial jobs to service jobs in the 20th and 21st centuries.

AIET/DOEE/2017-21/ 3
The term automation, inspired by the earlier word automatic (coming from automaton), was not
widely used before 1947, when General Motors established the automation department. At that
time automation technologies were electrical, mechanical, hydraulic and pneumatic. Between
1957 and 1964 factory output nearly doubled while the number of blue collar workers started to
decline.

2.2 ADVANTAGES AND DISADVANTAGES:-

The main advantages of automation are:
 Increased throughput or productivity.
 Improved quality or increased predictability of quality.
 Improved robustness (consistency), of processes or product.

The following methods are often employed to improve productivity, quality, or robustness.
Install automation in operations to reduce cycle time.
 Install automation where a high degree of accuracy is required.
 Replacing human operators in tasks that involve hard physical or monotonous work.
 Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes,
nuclear facilities, underwater, etc.)
Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc.
Economy improvement: Automation may improve in economy of enterprises, society or most of
humanity. For example, when an enterprise invests in automation, technology recovers its
investment; or when a state or country increases its income due to automation
like Germany or Japan in the 20th Century.
 Reduces operation time and work handling time significantly.
 Frees up workers to take on other roles.

AIET/DOEE/2017-21/ 4
  Provides higher level jobs in the development, deployment, maintenance and running of
the automated processes.

The main disadvantages of automation are:

Security Threats/Vulnerability: An automated system may have a limited level of intelligence,

and is therefore more susceptible to committing errors outside of its immediate scope of
knowledge (e.g., it is typically unable to apply the rules of simple logic to general propositions).
Unpredictable/excessive development costs: The research and development cost of automating a
process may exceed the cost saved by the automation itself.
High initial cost: The automation of a new product or plant typically requires a very large initial
investment in comparison with the unit cost of the product, although the cost of automation may
be spread among many products and over time.
In manufacturing, the purpose of automation has shifted to issues broader than productivity, cost,
and time.

2.3 RELIABILITY AND PRECISION

The old focus on using automation simply to increase productivity and reduce costs was seen to
be short-sighted, because it is also necessary to provide a skilled workforce who can make
repairs and manage the machinery. Moreover, the initial costs of automation were high and often
could not be recovered by the time entirely new manufacturing processes replaced the old.
(Japan's "robot junkyards" were once world famous in the manufacturing industry.)
Automation is now often applied primarily to increase quality in the manufacturing process,
where automation can increase quality substantially. For example, internal combustion
engine pistons used to be installed manually. This is rapidly being transitioned to automated
machine installation, because the error rate for manual installment was around 1-1.5%, but has
been reduced to 0.00001% with automation.

AIET/DOEE/2017-21/ 5
2.4 HEALTH AND ENVIRONMENT
The costs of automation to the environment are different depending on the technology, product
or engine automated. There are automated engines that consume more energy resources from the
Earth in comparison with previous engines and those that do the opposite too. Hazardous
operations, such as oil refining, the manufacturing of industrial chemicals, and all forms of metal
working, were always early contenders for automation.

2.5 AUTOMATION TOOLS

Engineers can now have numerical control over automated devices. The result has been a rapidly
expanding range of applications and human activities. Computer-aided technologies (or CAx)
now serve the basis for mathematical and organizational tools used to create complex systems.
Notable examples of CAx include Computer-aided design (CAD software) and Computer-aided
manufacturing (CAM software). The improved design, analysis, and manufacture of products
enabled by CAx has been beneficial for industry.

Information technology, together with industrial machinery and processes, can assist in the
design, implementation, and monitoring of control systems. One example of an industrial control
system is a programmable logic controller (PLC). PLCs are specialized hardened computers
which are frequently used to synchronize the flow of inputs from (physical) sensors and events
with the flow of outputs to actuators and events.
2.6 HUMAN MACHINE INTERFACE
Human-machine interfaces (HMI) or computer human interfaces (CHI), formerly known asman-
machine interfaces, are usually employed to communicate with PLCs and other computers.
Service personnel who monitor and control through HMIs can be called by different names. In
industrial process and manufacturing environments, they are called operators or something
similar. In boiler houses and central utilities departments they are called stationary engineers. [6]

Different types of automation tools exist:

AIET/DOEE/2017-21/ 6
 ANN - Artificial neural network
 BPM - Bonita Open Solution
 DCS - Distributed Control System
 HMI - Human Machine Interface
 SCADA - Supervisory Control and Data Acquisition
 PLC - Programmable Logic Controller
 PAC - Programmable automation controller
 Instrumentation
 Motion control
 Robotics
2.7 LIMITATIONS TO AUTOMATION

 Current technology is unable to automate all the desired tasks.

 As a process becomes increasingly automated, there is less and less labor to be saved or
quality improvement to be gained. This is an example of both diminishing returns and
the logistic function.
 Similar to the above, as more and more processes become automated, there are fewer
remaining non-automated processes. This is an example of exhaustion of opportunities.

2.8APPLICATION

Automated mining involves the removal of human labor from the mining process.[7] The mining
industry is currently in the transition towards automation. Currently it can still require a large
amount of human capital, particularly in the third world where labor costs are low so there is less
incentive for increasing efficiency.

AIET/DOEE/2017-21/ 7
2.8.1 AUTOMATED VIDEO SURVEILLANCE

The Defense Advanced Research Projects Agency (DARPA) started the research and
development of automated visual surveillance and monitoring (VSAM) program, between 1997
and 1999, and airborne video surveillance (AVS) programs, from 1998 to 2002. Currently, there
is a major effort underway in the vision community to develop a fully automated tracking
surveillance system. Automated video surveillance monitors people and vehicles in real time
within a busy environment. Existing automated surveillance systems are based on the
environment they are primarily designed to observe, i.e., indoor, outdoor or airborne, the amount
of sensors that the automated system can handle and the mobility of sensor, i.e., stationary
camera vs. mobile camera. The purpose of a surveillance system is to record properties and
trajectories of objects in a given area, generate warnings or notify designated authority in case of
occurrence of particular events.

2.8.2 AUTOMATED HIGHWAY SYSTEMS

As demands for safety and mobility have grown and technological possibilities have multiplied,
interest in automation has grown. Seeking to accelerate the development and introduction of
fully automated vehicles and highways, the Congress authorized more than $650 million over six
years for intelligent transport systems (ITS) and demonstration projects in the 1991Intermodal
Surface Transportation Efficiency Act (ISTEA). Congress legislated in ISTEA that
“the Secretary of Transportation shall develop an automated highway and vehicle prototype from
which future fully automated intelligent vehicle-highway systems can be developed. Such
development shall include research in human factors to ensure the success of the man-machine
relationship. The goal of this program is to have the first fully automated highway roadway or an
automated test track in operation by 1997. This system shall accommodate installation of
equipment in new and existing motor vehicles." [ISTEA 1991, part B, Section 6054(b)].

AIET/DOEE/2017-21/ 8
2.9 AUTOMATED MANUFACTURING
Automated manufacturing refers to the application of automation to produce things in the factory
way. Most of the advantages of the automation technology have its influence in the manufacture
processes.

The main advantages of automated manufacturing are higher consistency and quality, reduced
lead times, simplified production, reduced handling, improved work flow, and increased worker
morale when a good implementation of the automation is made.

2.10 HOME AUTOMATION

Home automation (also called domotics) designates an emerging practice of increased
automation of household appliances and features in residential dwellings, particularly through
electronic means that allow for things impracticable, overly expensive or simply not possible in
recent past decades.

2.11 INDUSTRIAL AUTOMATION

Industrial automation deals with the optimization of energy-efficient drive systems by precise
measurement and control technologies. Nowadays energy efficiency in industrial processes are
becoming more and more relevant. Semiconductor companies like Infineon Technologies are
offering 8-bit microcontroller applications for example found in motor controls, general purpose
pumps, fans, and ebikes to reduce energy consumption and thus increase efficiency. One of
Infineon`s 8-bit product line found in industrial automation is the XC800 family.

Agriculture: Now that we’re moving towards automated orange-sorting[1] and autonomous
tractors[2], the next step in automated agriculture is robotic strawberry pickers[3].

2.12 AGENT-ASSISTED AUTOMATION

Agent-assisted Automation refers to automation used by call center agents to handle customer
inquiries. There are two basic types: desktop automation and automated voice solutions. Desktop
automation refers to software programming that makes it easier for the call center agent to work

AIET/DOEE/2017-21/ 9
across multiple desktop tools. The automation would take the information entered into one tool
and populate it across the others so it did not have to be entered more than once, for example.
Automated voice solutions allow the agents to remain on the line while disclosures and other
important information is provided to customers in the form of pre-recorded audio files.
Specialized applications of these automated voice solutions enable the agents to process credit
cards without ever seeing or hearing the credit card numbers or CVV codes.

The key benefit of agent-assisted automation is compliance and error-proofing. Agents are
sometimes not fully trained or they forget or ignore key steps in the process.

AIET/DOEE/2017-21/ 10
 CHAPTER-3

SCADA
An industrial SCADA system will be used for the development of the controls of the four LHC
experiments. This paper describes the SCADA systems in terms of their architecture, their
interface to the process hardware, the functionality and the application development facilities
they provide.

3.1 INTRODUCTION
Widely used in industry for Supervisory Control and Data Acquisition of industrial processes,
SCADA systems are now also penetrating the experimental physics laboratories for the controls
of ancillary systems such as cooling, ventilation, power distribution, etc.

SCADA systems have made substantial progress over the recent years in terms of functionality,
scalability, performance and openness such that they are an alternative to in house development
even for very demanding and complex control systems as those of physics experiments.

3.2 TYPES OF SCADA

1. D+R+N (Development +Run + Networking)
2. R+N (Run +Networking )

3.3 FEATURES OF SCADA

1. Dynamic process Graphic
2. Alarm summery
3. Alarm history
4. Real time trend
5. Historical time trend
6. Security (Application Security)

AIET/DOEE/2017-21/ 11
7. Data base connectivity
8. Device connectivity
9. Scripts
10. Recipe management

3.4 MANUFACTURE OF SCADA

Modicon (Telemecanique) Visual look
Allen Bradley: RS View
Siemens: win cc
Gefanc:
KPIT : ASTRA
Intelution : Aspic
Wonder ware: Intouch

AIET/DOEE/2017-21/ 12
 CHAPTER-4

MEANING OF SCADA
SCADA stands for Supervisory Control and Data Acquisition. As the name indicates, it is not a
full control system, but rather focuses on the supervisory level. As such, it is a purely software
package that is positioned on top of hardware to which it is interfaced, in general via
Programmable Logic Controllers (PLCs), or other commercial hardware modules.

SCADA systems are used not only in industrial processes: e.g. steel making, power generation
(conventional and nuclear) and distribution, chemistry, but also in some experimental facilities
such as nuclear fusion. The size of such plants range from a 1000 to several thousand of
input/output (I/O) channels. However, SCADA systems evolve rapidly and are now penetrating
the market of plants with a number of I/O channels of several 1 lakh: we know of two cases of
near to 1 M I/O channels currently under development. SCADA systems used to run on DOS,
VMS and UNIX; in recent years all SCADA vendors have moved to NT and some also to Linux.

4.1 ARCHITECTURE

4.1.1 HARDWARE ARCHITECTURE

One distinguishes two basic layers in a SCADA system: the "client layer" which caters for the
man machine interaction and the "data server layer" which handles most of the process data
control activities. The data servers communicate with devices in the field through process
controllers. Process controllers, e.g. PLCs, are connected to the data servers either directly or via
networks or fieldbuses that are proprietary (e.g. Siemens H1), or non-proprietary (e.g. Profibus).
Data servers are connected to each other and to client stations via an Ethernet LAN. The data
servers and client stations are NT platforms but for many products the client stations may also be
W95 machines. Fig.1. shows typical hardware architecture.

AIET/DOEE/2017-21/ 13
Figure 1:- Typical Hardware Architecture

AIET/DOEE/2017-21/ 14
However, it is possible to have dedicated servers for particular tasks, e.g. historian, data logger,
alarm handler. Fig. 2 shows a SCADA architecture that is generic for the products that were
evaluated.

4.2 COMMUNICATIONS

4.2.1 INTERNAL COMMUNICATION

Server-client and server-server communication is in general on a publish-subscribe and event-
driven basis and uses a TCP/IP protocol, i.e., a client application subscribes to parameter which
is owned by a particular server application and only changes to that parameter are then
communicated to the client application.

4.2.2 ACCESS TO DEVICES

The data servers poll the controllers at a user defined polling rate. The polling rate may be
different for different parameters. The controllers pass the requested parameters to the data
servers. Time stamping of the process parameters is typically performed in the controllers and
this time-stamp is taken over by the data server. If the controller and communication protocol
used support unsolicited data transfer then the products will support this too.
The products provide communication drivers for most of the common PLCs and widely used
field-buses, e.g., Modbus. Of the three fieldbuses that are recommended at CERN, both Profibus
and Worldfip are supported but CANbus often not [3]. Some of the drivers are based on third
party products (e.g., Applicom cards) and therefore have additional cost associated with them. A
single data server can support multiple communications protocols: it can generally support as
many such protocols as it has slots for interface cards.

AIET/DOEE/2017-21/ 15
The effort required to develop new drivers is typically in the range of 2-6 weeks depending on
the complexity and similarity with existing drivers, and a driver development toolkit is provided
for this.

4.3 INTERFACING

4.3.1 APPLICATION INTERFACES / OPENNESS

The provision of OPC client functionality for SCADA to access devices in an open and standard
manner is developing. There still seems to be a lack of devices/controllers, which provide OPC
server software, but this improves rapidly as most of the producers of controllers are actively
involved in the development of this standardThe products also provide

• An Open Data Base Connectivity (ODBC) interface to the data in the archive/logs, but
not to the configuration database,
• An ASCII import/export facility for configuration data,
• A library of apis supporting C, C++, and Visual Basic (VB) to access data in the RTDB,
logs and archive. The API often does not provide access to the product's internal features
such as alarm handling, reporting, trending, etc.

The PC products provide support for the Microsoft standards such as Dynamic Data Exchange
(DDE) which allows e.g. to visualise data dynamically in an EXCEL spreadsheet, Dynamic Link
Library (DLL) and Object Linking and Embedding (OLE).

AIET/DOEE/2017-21/ 16
4.3.2 DATABASE
The configuration data are stored in a database that is logically centralised but physically
distributed and that is generally of a proprietary format. System (RDBMS) at a slower rate either
directly or via an ODBC interface.
4.4 FUNCTIONALITY

4.4.1 ACCESS CONTROL

Users are allocated to groups, which have defined read/write access privileges to the process
parameters in the system and often also to specific product functionality.

4.4.2 MMI
The products support multiple screens, which can contain combinations of synoptic diagrams
and text. They also support the concept of a "generic" graphical object with links to process
variables. These objects can be "dragged and dropped" from a library and included into a
synoptic diagram.

Most of the SCADA products that were evaluated decompose the process in "atomic" parameters
(e.g. a power supply current, its maximum value, its on/off status, etc.) to which a Tag-name is
associated. The Tag-names used to link graphical objects to devices can be edited as required.
The products include a library of standard graphical symbols, many of which would however not
be applicable to the type of applications encountered in the experimental physics community.
Standard windows editing facilities are provided: zooming, re-sizing, scrolling... On-line
configuration and customization of the MMI is possible for users with the appropriate privileges.
Links can be created between display pages to navigate from one view to another.

4.4.3 TRENDING

AIET/DOEE/2017-21/ 17
The products all provide trending facilities and one can summarize the common capabilities as
follows:
• the parameters to be trended in a specific chart can be predefined or defined online
• 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.

4.4.4 ALARM HANDLING

Alarm handling is based on limit and status checking and performed in the data servers. More
complicated expressions (using arithmetic or logical expressions) can be developed by creating
derived parameters on which status or limit checking is then performed. 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.

It is generally possible to group alarms and to handle these as an entity (typically filtering on
group or acknowledgement of all alarms in a group). Furthermore, it is possible to suppress
alarms either individually or as a complete group. 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. However,
relationships between alarms cannot generally be defined in a straightforward manner. E-mails
can be generated or predefined actions automatically executed in response to alarm conditions.

AIET/DOEE/2017-21/ 18
4.4.5 LOGGING/ARCHIVING
The terms logging and archiving are often used to describe the same facility. However, logging
can be thought of as medium-term storage of data on disk, whereas archiving is long-term
storage of data either on disk or on another permanent storage medium. Logging is typically
performed on a cyclic basis, i.e., once a certain file size, time period or number of points is
reached the data is overwritten. Logging of data can be performed at a set frequency, or only
initiated if the value changes or when a specific predefined event occurs. Logged data can be
transferred to an archive once the log is full. The logged data is time-stamped and can be filtered
when viewed by a user. The logging of user actions is in general performed together with either a
user ID or station ID. There is often also a VCR facility to play back archived data.

4.4.6 REPORT GENERATION

One can produce reports using SQL type queries to the archive, RTDB or logs. Although it is
sometimes possible to embed EXCEL charts in the report, a "cut and paste" capability is in
general not provided. Facilities exist to be able to automatically generate, print and archive
reports.

4.5 APPLICATION DEVELOPMENT

4.5.1 CONFIGURATION
The development of the applications is typically done in two stages. First the process parameters
and associated information (e.g. relating to alarm conditions) are defined through some sort of
parameter definition template and then the graphics, including trending and alarm displays are
developed, and linked where appropriate to the process parameters. The products also provide an
ASCII Export/Import facility for the configuration data (parameter definitions), which enables

AIET/DOEE/2017-21/ 19
large numbers of parameters to be configured in a more efficient manner using an external editor
such as Excel and then importing the data into the configuration database.

However, many of the PC tools now have a Windows Explorer type development studio. The
developer then works with a number of folders, which each contains a different aspect of the
configuration, including the graphics. The facilities provided by the products for configuring
very large numbers of parameters are not very strong. However, this has not really been an issue
so far for most of the products to-date, as large applications are typically about 50K I/O points
and database population from within an ASCII editor such as Excel is still a workable option.
On-line modification to the configuration database and the graphics is generally possible with the
appropriate level of privileges.

4.5.2 DEVELOPMENT TOOLS

The following development tools are provided as standard:
• A graphics editor, with standard drawing facilities including freehand, lines, squares circles,
etc. It is possible to import pictures in many formats as well as using predefined symbols
including e.g. Trending charts, etc. A library of generic symbols is provided that can be
linked dynamically to variables and animated as they change. It is also possible to create
links between views so as to ease navigation at run-time.
• A data base configuration tool (usually through parameter templates). It is in general possible
to export data in ascii files so as to be edited through an ascii editor or excel.
• A scripting language
• An application program interface (api) supporting C, C++, VB a driver development toolkit
to develop drivers for hardware that is not supported by the SCADA product.

4.5.3 OBJECT HANDLING

The products in general have the concept of graphical object classes, which support inheritance.
In addition, some of the products have the concept of an object within the configuration

AIET/DOEE/2017-21/ 20
database. In general the products do not handle objects, but rather handle individual parameters,
e.g., alarms are defined for parameters, logging is performed on parameters, and control actions
are performed on parameters. The support of objects is therefore fairly superficial.

4.6 EVOLUTION
SCADA vendors release one major version and one to two additional minor versions once per
year. These products evolve thus very rapidly so as to take advantage of new market
opportunities, to meet new requirements of their customers and to take advantage of new
technologies.

As was already mentioned, most of the SCADA products that were evaluated decompose the
process in "atomic" parameters to which a Tag-name is associated. This is impractical in the case
of very large processes when very large sets of Tags need to be configured. As the industrial
applications are increasing in size, new SCADA versions are now being designed to handle
devices and even entire systems as full entities (classes) that encapsulate all their specific
attributes and functionality. In addition, they will also support multi-team development.

4.7 ENGINEERING
Whilst one should rightly anticipate significant development and maintenance savings by
adopting a SCADA product for the implementation of a control system, it does not mean a "no
effort" operation. The need for proper engineering cannot be sufficiently emphasized to reduce
development effort and to reach a system that complies with the requirements, that is economical
in development and maintenance and that is reliable and robust. Examples of engineering
activities specific to the use of a SCADA system are the definition of:

AIET/DOEE/2017-21/ 21
A library of objects (PLC, device, subsystem) complete with standard object behavior (script,
sequences, ...), graphical interface and associated scripts for animation, templates for different
types of "panels", e.g. Alarms, instructions on how to control e.g.

A mechanism to prevent conflicting controls (if not provided with the SCADA), alarm levels,
behavior to be adopted in case of specific alarms.

4.8 POTENTIAL BENEFITS OF SCADA

The benefits one can expect from adopting a SCADA system for the control of experimental
physics facilities can be summarized as follows:

• A rich functionality and extensive development facilities. The amount of effort invested
in SCADA product amounts to 50 to 100 p-years!
• The amount of specific development that needs to be performed by the end-user is
limited, especially with suitable engineering.
• Reliability and robustness. These systems are used for mission critical industrial
processes where reliability and performance are paramount. In addition, specific
development is performed within a well-established framework that enhances reliability
and robustness.
• Technical support and maintenance by the vendor.

For large collaborations, as for the CERN LHC experiments, using a SCADA system for their
controls ensures a common framework not only for the development of the specific applications
but also for operating the detectors. Operators experience the same "look and feel" whatever part
of the experiment they control. However, this aspect also depends to a significant extent on
proper engineering.

AIET/DOEE/2017-21/ 22
 CHAPTER-5

PLC
5.1 INTRODUCTION
Control engineering has evolved over time. In the past humans were the main method for
controlling a system. More recently electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relays to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution, the Programmable
Logic Controller (PLC). The advent of the PLC began in the 1970s, and has become the most
common choice for manufacturing controls.

PLCs have been gaining popularity on the factory floor and will probably remain predominant
for some time to come. Most of this is because of the advantages they offer.

• Cost effective for controlling complex systems.

• Flexible and can be reapplied to control other systems quickly and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.

5.1.1 LADDER LOGIC

Ladder logic is the main programming method used for PLCs. As mentioned before, ladder logic
has been developed to mimic relay logic. The decision to use the relay Topics: Objectives:

AIET/DOEE/2017-21/ 23
• Know general PLC issues
• To be able to write simple ladder logic programs
• Understand the operation of a PLC
• PLC History
• Ladder Logic and Relays
• PLC Programming
• PLC Operation

Modern control systems still include relays, but these are rarely used for logic. A relay is a
simple device that uses a magnetic field to control a switch. When a voltage is applied to the
input coil, the resulting current creates a magnetic field. The magnetic field pulls a metal switch
(or reed) towards it and the contacts touch, closing the switch. The contact that closes when the
coil is energized is called normally open. The normally closed contacts touch when the input coil
is not energized. Relays are normally drawn in schematic form using a circle to represent the
input coil. The output contacts are shown with two parallel lines. Normally open contacts are
shown as two lines, and will be open (non-conducting) when the input is not energized.
Normally closed contacts are shown with two lines with a diagonal line through them. When the
input coil is not energized the normally closed contacts will be closed (conducting).

Relays are used to let one power source close a switch for another (often high current) power
source, while keeping them isolated. An example of a relay in a simple control application is
shown in Figure 4. In this system the first relay on the left is used as normally closed, and will
allow current to flow until a voltage is applied to the input A. The second relay is normally open
and will not allow current to flow until a voltage is applied to the input B. If current is flowing
through the first two relays then current will flow through the coil in the third relay, and close the
switch for output C. This circuit would normally be drawn in the ladder logic form

AIET/DOEE/2017-21/ 24
 Figure 2:- A Simple Relay Controller

The example in Figure 2 does not show the entire control system, but only the logic. When we
consider a PLC there are inputs, outputs, and the logic. Figure 2.3 shows a more complete
representation of the PLC. Here there are two inputs from push buttons.

We can imagine the inputs as activating 24V DC relay coils in the PLC. This in turn drives an
output relay that switches 115V AC, that will turn on a light. Note, in actual PLCs inputs are
never relays, but outputs are often relays. The ladder logic in the PLC is actually a computer
program that the user can enter and change. Notice that both of the input push buttons are
normally open, but the ladder logic inside the PLC has one normally open contact, and one
normally closed contact. Do not think that the ladder logic in the PLC needs to match the inputs
or outputs. Many beginners will get caught trying to make the ladder logic match the input types.

AIET/DOEE/2017-21/ 25
 Figure 3 A PLC Illustrated With Relays

Many relays also have multiple outputs (throws) and this allows an output relay to also be an
input simultaneously. The circuit shown in Figure 2.4 is an example of this, it is called a seal in
circuit. In this circuit the current can flow through either branch of the circuit, through the
contacts labelled A or B. The input B will only be on when the output B is on. If B is off, and A
is energized, then B will turn on. If B turns on then the input B will turn on, and keep output B
on even if input A goes off. After B is turned on the output B will not turn off.

AIET/DOEE/2017-21/ 26
5.2 PROGRAMMING
The first PLCs were programmed with a technique that was based on relay logic wiring
schematics. This eliminated the need to teach the electricians, technicians and engineers how to
program a computer - but, this method has stuck and it is the most common technique for
programming PLCs today. An example of ladder logic can be seen in Figure 2.5. To interpret
this diagram imagine that the power is on the vertical line on the left hand side, we call this the
hot rail. On the right hand side is the neutral rail. In the figure there are two rungs, and on each
rung there are combinations of inputs (two vertical lines) and outputs (circles). If the inputs are
opened or closed in the right combination the power can flow from the hot rail, through the
inputs, to power the outputs, and finally to the neutral rail. An input can come from a sensor,
switch, or any other type of sensor. An output will be some device outside the PLC that is
switched on or off, such as lights or motors. In the top rung the contacts are normally open and
normally closed.Which means if input A is on and input B is off, then power will flow through
the output and activate it. Any other combination of input values will result in the output X being
off.

Figure 4:- A Simple Ladder Logic Diagram

AIET/DOEE/2017-21/ 27
The second rung of Figure 5 is more complex, there are actually multiple combinations of inputs
that will result in the output Y turning on. On the left most part of the rung, power could flow
through the top if C is off and D is on. Power could also (and simultaneously) flow through the
bottom if both E and F are true. This would get power half way across the rung, and then if G or
H is true the power will be delivered to output Y. In later chapters we will examine how to
interpret and construct these diagrams. There are other methods for programming PLCs. One of
the earliest techniques involved mnemonic instructions. These instructions can be derived
directly from the ladder logic diagrams and entered into the PLC through a simple programming
terminal.
An example of mnemonics is shown in Figure 2.6. In this example the instructions are read one
line at a time from top to bottom. The first line 00000 has the instruction LDN (input load and
not) for input 00001. This will examine the input to the PLC and if it is off it will remember a 1
(or true), if it is on it will remember a 0 (or false). The next line uses an LD (input load)
statement to look at the input. If the input is off it remembers a 0, if the input is on it remembers
a 1 (note: this is the reverse of the LD). The AND statement recalls the last two numbers
remembered and if the are both true the result is a 1, otherwise the result is a 0. This result now
replaces the two numbers that were recalled, and there is only one number remembered. The
process is repeated for lines 00003 and 00004, but when these are done there are now three
numbers remembered. The oldest number is from the AND, the newer numbers are from the two
LD instructions. The AND in line 00005 combines the results from the last LD instructions and
now there are two numbers remembered. The OR instruction takes the two numbers now
remaining and if either one is a 1 the result is a 1, otherwise the result is a 0. This result replaces
the two numbers, and there is now a single number there. The last instruction is the ST (store
output) that will look at the last value stored and if it is 1, the output will be turned on, if it is 0
the output will be turned off.

AIET/DOEE/2017-21/ 28
 Figure 5:- An Example of a Mnemonic Program and Equivalent Ladder Logic

The ladder logic program in Figure 6, is equivalent to the mnemonic program. Even if you have
programmed a PLC with ladder logic, it will be converted to mnemonic form before being used
by the PLC. In the past mnemonic programming was the most common, but now it is uncommon
for users to even see mnemonic programs.

Sequential Function Charts (SFCs) have been developed to accommodate the programming of
more advanced systems. These are similar to flowcharts, but much more powerful. The example
seen in Figure 8 is doing two different things. To read the chart, start at the top where is says
start. Below this there is the double horizontal line that says follow both paths. As a result the
PLC will start to follow the branch on the left and right hand sides separately and
simultaneously. On the left there are two functions the first one is the power up function. This

AIET/DOEE/2017-21/ 29
function will run until it decides it is done, and the power down function will come after. On the
right hand side is the flash function, this will run until it is done. These functions look
unexplained, but each function, such as power up will be a small ladder logic program. This
method is much different from flowcharts because it does not have to follow a single path
through the flowchart.

5.3 PLC Connections

When a process is controlled by a PLC it uses inputs from sensors to make decisions and update
outputs to drive actuators, as shown in Figure 2.9. The process is a real process that will change
over time. Actuators will drive the system to new states (or modes of operation). This means that
the controller is limited by the sensors available, if an input is not available, the controller will
have no way to detect a condition.

Figure 6:- The Separation of Controller and Process

The control loop is a continuous cycle of the PLC reading inputs, solving the ladder logic, and
then changing the outputs. Like any computer this does not happen instantly. Figure 7 shows the

AIET/DOEE/2017-21/ 30
basic operation cycle of a PLC. When power is turned on initially the PLC does a quick sanity
check to ensure that the hardware is working properly.

If there is a problem the PLC will halt and indicate there is an error. For example, if the PLC
backup battery is low and power was lost, the memory will be corrupt and this will result in a
fault. If the PLC passes the sanity check it will then scan (read) all the inputs. After the inputs
values are stored in memory the ladder logic will be scanned (solved) using the stored values -
not the current values. This is done to prevent logic problems when inputs change during the
ladder logic scan. When the ladder logic scan is complete the outputs will be scanned (the output
values will be changed). After this the system goes back to do a sanity check, and the loop
continues indefinitely. Unlike normal computers, the entire program will be run every scan.
Typical times for each of the stages is in the order of milliseconds.

Figure 7:- The Scan Cycle of a PLC

5.4 Ladder Logic Inputs

PLC inputs are easily represented in ladder logic. In Figure 2.11 there are three types of inputs
shown. The first two are normally open and normally closed inputs, discussed previously. The
IIT (Immediate InpuT) function allows inputs to be read after the input scan, while the ladder

AIET/DOEE/2017-21/ 31
logic is being scanned. This allows ladder logic to examine input values more often than once
every cycle.

Figure 8:- Ladder Logic Inputs

5.5 Ladder Logic Outputs

In ladder logic there are multiple types of outputs, but these are not consistently available on all
PLCs. Some of the outputs will be externally connected to devices outside the PLC, but it is also
possible to use internal memory locations in the PLC. Six types of outputs are shown in Figure
2.12. The first is a normal output, when energized the output will turn on, and energize an output.
The circle with a diagonal line through is a normally on output. When energized, the output will
turn off. This type of output is not available on all PLC types. When initially energized the OSR
(One Shot Relay) instruction will turn on for one scan, but then be off for all scans after, until it
is turned off. The L (latch) and U (unlatch) instructions can be used to lock outputs on. When an

AIET/DOEE/2017-21/ 32
L output is energized the output will turn on indefinitely, even when the output coil is
deenergized. The output can only be turned off using a U output. The last instruction is the IOT
(Immediate Output) that will allow outputs to be updated without having to wait for the ladder
logic scan to be completed.

Figure 9:- Ladder Logic Outputs

AIET/DOEE/2017-21/ 33
 CONCLUSION

 Automation is the use of machines, control systems and information technologies to optimize
productivity in the production of goods and delivery services.
 The correct incentive for applying automation is to increase productivity, and/or quality
beyond that possible with current human labor levels so as to realize economies of scale,
and/or realize predictable quality levels.
 The incorrect application of automation, which occurs most often, is an effort to eliminate or
replace human labor
 As we all know that the branch instrumentation plays a very important role in the
management of automation in any industry or process plant. Each and every process requires
the need of certain specific instruments for their controlling.
 When the word automation comes into play, instrumentation automatically involves in it.
Without the help of instrumentation it is not possible to apply automation in any industry.
 A feedback system is applied in the industry, i.e. a set point is given and the input is feedback
according to the current output and the set point applied.
 When PLC i.e. programmable logic control type automation is applied in any industry, it
requires the continuous reading of these parameters.

AIET/DOEE/2017-21/ 34
 REFERENCES

 http://www.google.co.in/#hl=en&sclient=psy- bih=667
 http://www.google.co.incement+wikipedia&oq=instruments+of+
+SCADA+wikipedia&gs
 http://www.google.co.in/automation==241
 http://www.google.co.in/PLC==441

AIET/DOEE/2017-21/ 35