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PLC & Scada: Programmable Logic Controllers & Supervisory Control and Data Acquisition

Programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems are used together for industrial automation and control. PLCs control machines and processes on the plant floor, while SCADA systems allow operators to monitor and control the entire plant from a central location. PLCs were developed as a more flexible alternative to relay-based control systems and can be programmed to perform control functions using various programming languages like ladder logic. SCADA systems provide visualization of industrial processes by connecting to PLCs using tags to collect data and allow remote supervision and control. Together, PLCs and SCADA systems automate industrial operations and processes.

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218 views45 pages

PLC & Scada: Programmable Logic Controllers & Supervisory Control and Data Acquisition

Programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems are used together for industrial automation and control. PLCs control machines and processes on the plant floor, while SCADA systems allow operators to monitor and control the entire plant from a central location. PLCs were developed as a more flexible alternative to relay-based control systems and can be programmed to perform control functions using various programming languages like ladder logic. SCADA systems provide visualization of industrial processes by connecting to PLCs using tags to collect data and allow remote supervision and control. Together, PLCs and SCADA systems automate industrial operations and processes.

Uploaded by

Ram Ram
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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PLC & SCADA

Programmable Logic Controllers


&
Supervisory Control And Data Acquisition
A Programmable Logic Controllers (PLC)
is a miniature industrial grade computer
that contains hardware and software –
What is a PLC ? capable of being programmed to perform
control functions
Programmable Logic Controller

The first PLC was developed by a group of engineers


at General Motors in 1968, when the company were
looking for an alternative to replace complex relay
control systems.
Before the PLC.

How were machines and industrial processes


controlled before PLC?

One of the means for controlling machines was


through the use of

Power Relays

Control Relays
Before the PLC.

What are the disadvantages of relay based


control systems?

Complexity,
Costly
Hardwiring,
Troubleshooting problems
Strict Maintenance routine
Not easy to modify
PLC – Configurations
Modular Configuration
PLCs are of two main configurations.

• Modular Configuration

• Fixed Configuration .
Parts of a PLC.

(Courtesy: Hitachi)
. PLC – Configurations
• Fixed Configuration

Fixed Configuration
Communication Modules
• Used to establish point-to-point connections
with other intelligent devices for the
exchange of data.

• Such connections are normally established


with computers, operator stations, process
control systems, and other PLCs.

• Communication modules allow the user to


connect the PLC to high-speed local
networks that may be different from the
network communication provided with
the PLC.
Basics Concepts of PLC

Inputs to PLC

Push Button

Push buttons Key Switch Selector Switch

1
Outputs of PLC

Power Contactor Contactor

Relays
PLC Outputs ‐ Actuators
Solenoid Coils Servo Motors

Manifold Block

1
PLC operation sequence
1)Self test: Testing of its own hardware and
software for faults.

2)Input scan: If there are no problems, PLC Self test


will copy all the inputs and copy their values
into memory.

3)Logic solve/scan: Using inputs, the ladder Input scan


logic program is solved .

4)Output scan: After solving logic the output Logic scan


values are updated only in memory when
ladder scan is done.
Output
scan
PLC Programming Languages

The standard IEC (International Electro-technical Commission) was established


to standardize the multiple languages associated with PLC programming by
defining the following five standard languages:

• Ladder Diagram (LD) —a graphical process with rungs of logic, similar to the relay ladder
logic schemes that were replaced by PLCs.
• Function Block Diagram (FBD) —a graphical process flow using simple and complex
interconnecting blocks.
• Sequential Function Chart (SFC) —a graphical process of interconnecting steps, actions, and
transitions.
• Instruction List (IL) —a low-level, text-based language that uses mnemonic instructions.
• Structured Text (ST) —a high-level, text-based language such as BASIC, C, or PASCAL specifically
developed for industrial control applications.
Ladder program execution :

Power Ground
Rail ( Rung 1 ) Rail

( Rung 2 )

( Rung 3 )

( Rung 4 )

( Rung 5 )
Why this programming language is called ladder
programming ?

Power Ground
Rail ( Rung 1 ) Rail

( Rung 2 )

( Rung 3 )

( Rung 4 )

( Rung 5 )
Ladder Logic

AND

Two limit switches connected in series


and used to control a solenoid valve
Ladder Logic

OR
Ladder Logic

limit Pressure
switches switch
Ladder Logic
Ladder Logic
Ladder Logic
JUMP CONTROL
DATA HANDLING INSTRUCTIONS

• Moving data
• Comparison of data( greater than, equal
to, less than)
• Arithmetic operation (Addition &
subtraction)
MOVE INSTRUCTION
DATA COMPARISON

EQUAL TO NOT EQUAL TO

GREATER THAN
GREATER THAN OR EQUAL
DATA COMPARISON

LESS THAN LESS THAN OR EQUAL


ARITHMETIC OPERATION

ADDITION SUBTRACTION

MULTIPLICATION DIVISION
Counters

 Counter Relays must “Count” a pre-determined


number of events before changing contact status.
 Can Count Up (UpCounter) or Count Down
(DownCounter)
 e.g. An UpCounter is set to 8 and is programmed to
detect every occurrence of a 5 Volt pulse. When it
has detected 8 such occurrences, the NO Contacts
close and the NC contacts open.
 Great for making Real-Time Clocks, etc
Programming the PLC
The system to be controlled by
the PLC is first described in ladder
logic.

Next the ladder logic is compiled


and translated into basic
instructions that are uploaded into
the PLC memory by the
programmer.

The programming is done while


the PLC is set to TERMINAL OR
PROGRAMMING MODE.

Programming can be done through


a PLC Programmer or a PC that
has the programming software.
SCADA

• Supervisory Control And Data Acquisition


• It is a software through which we can create visualization of any industrial
process.
• The problem- no one knew what’s happening inside the PLC.
• Solution= PLC+SCADA
TAG’s

• It is the address of the memory location where signals are being saved.
• We define aTAG in order to use it in the SCADAsoftware(Intouch
wonderware).
• TYPES: 1)Analog 2) Digital 3) Strings
• These are further associated with either “Memory” or “I/O” type tags.
• PLC-SCADA – Memory analog/digital/stringtag
• PLC-SCADA- I/O analog/digital/string tag
FEATURESOF SCADA
• Dynamic processgraphic
• Alarm
• Database connectivity
• Real time trend and historical trend view
• Security
• Device connectivity
SCADA Architecture
 First generation: "Monolithic“

 Second generation: "Distributed“

 Third generation: "Networked"


Monolithic SCADA Systems
Minicomputers are used earlier for computing the SCADA
systems.

In earlier times, during the time of first generation, monolithic


SCADA systems were developed wherein the common
network services were not available.

Hence, these are independent systems without having any


connectivity to other systems.
Distributed SCADA Systems

The processing was distributed across multiple stations


which were connected through a LAN and they shared
information in real time.

Each station was responsible for a particular task thus making


the size and cost of each station less than the one used in First
Generation.
Networked SCADA Systems
Open system architecture.
Multiple networked systems, sharing master station functions.
 Distribute SCADA functionality across a WAN
Open standards eliminate multiple limitations
Easier to connect to third party peripheral
devices to the system or the network
Disaster survivability
Application of SCADA system
 Electric power generation, transmission and distribution
 Water treatment plant
 Oil and Gas Distributions
 Food processing industry
 Traffic signals
 And many more………
SCADA Software
• Wonderware- Intouch
• Rockwell- RSview32
• Siemens- winCC
• GE- Intellation
QUERIES ???

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