SEMINAR REPORT

On

Study of "SCADA" system and "PLC"

Submitted in partial fulfillment for bachelor of technology degree at
Rajasthan Technical University, kota
.

(2019-2020)

Submitted to: Submitted by:-

Department of electrical engineering Shivam Bohra
B.Tech (7 sem.)
16EVEEE014

Department of Electrical Engineering

VYAS INSTITUTE OF ENGINEERING AND TECHNOLOGY
JODHPUR(RAJ.)
 VYAS INSTITUTE OF ENGINEERING AND
TECHNOLOGY , JODHPUR(RAJ.)
Department of Electrical Engineering

CERTIFICATE
This is to certify that the student Shivam Bohra of final year, have
successfully completed the seminar report titled “PLC & SCADA
Automation” towards the partial fulfillment of the degree of Bachelor
Of Technology (B.TECH) in the Electrical Engineering of the
Rajasthan Technical University during academic year 2019-2020.
Finally, I also express my gratitude to other faculty members of MERC
for their intellectual support throughout the course of PLC
PROGRAMMING. It is a wonderful experience and I am deeply
thankful to all the staff of MERC.

Guided by:- HEAD OF DEPARTMENT

Mr. Rahul Narang Prof. Manish Bhati
 ABSTRACT
Supervisory control and data acquisition (SCADA) allows a utility operator to
monitor and control processes that are distributed among various remote sites.
SCADA, is a system for gathering real time data, controlling processes, and
monitoring equipment from remote locations. Many companies are implementing
an open SCADA architecture through the Internet to monitor critical infrastructure
components such as power plants, oil and gas pipelines, chemical refineries, flood
control dams, and waste and water systems. This report provides an overview of
SCADA, outlines several vulnerabilities of SCADA systems, presents data on
known and possible threats, and provides particular remediation strategies for
protecting these systems.

PLCs are used in many different industries and machines such as packaging and
semiconductor machines. A programmable logic controller (PLC) or
programmable controller is a digital computer used for automation in industry such
as control of machinery on factory assembly lines, amusement rides, or lighting
fixtures. PLCs are used in many industries and machines. The PLC is designed for
multiple inputs and output arrangements, extended temperature ranges, immunity
to electrical noise, and resistance to vibration and impact.

Automation is the use of control systems in concert with other applications of

information technology ([CAD, CAM, CAx]), to control industrial machinery and
processes, reducing the need for human intervention. Plc is also one of the tool of
automation which reduces the heavy wiring used in relay for industry.
 AKNOWLEDGEMENT

First and foremost, I would like to thank my parents, who always

encouraged me to think and work out innovetively what so ever would
be the field of my life.
Secondly, the thanks goes to my seminar in charge Mr. Rahul sir.Who
gave his all efforts to the completion of my entire seminar related
work .Without his inspiration and great motivation I could not be able to
complete such task given to me. I would also like to give thanks him for
his prodigious guidance, prudential suggestion throughout my seminar
work.

Also I would like to pay sincere thanks to Mr Manish Bhati sir, and to
all my teaching and nonteaching staff for excellent corporation in entire
seminar session.

Shivam Bohra .
B.Tech (7 sem,EE)
16EVEEE014
 TABLE OF CONTENTS
CHAPTER 1.

INDUSTRIAL AUTOMATION …………………..………………………………….9-13

1.1 INTRODUCTION………………………………………………………...................09

1.2 TYPES OF AUTOMATION …………………………………………………. ……10

1.2.1 FIXED AUTOMATION………………………………………………… … ...11

1.2.2 PROGRAMMABLE AUOTMATION………………………………………...11

1.2.3 FLEXIBALE AUTOMATION …………………………………………..........11

1.3 INDUSTRIAL AUTOMATION TOOLS …. ………………………………...…….12

1.3.1 PLC- PROGRAMMABLE LOGIC CONTROLLER………………......…13

1.3.2 SCADA- SUPERVISORY CONTROL AND DATA ACQUISITION….… 13

1.3.3 HMI- HUMAN MACHINE INTERFACE…………………………………….13

1.3.4 ANN- ARTIFICIAL NEURAL INTERFACE…………………………..…….13

1.3.5 DCS- DISTRIBUTED CONTROL SYSTEM…………………………….…..14

CHAPTER-2.

PLC (PROGRAMMABLE LOGIC CONTROLLER) ………...…………………….14-24

2.1 INTRODUCTION OF PLC……………………………………………………….…14

2.2 DEVELOPMENT AND HISTORY…………………………………………………14

2.3 FEATURES OF PLC…………………………………………………………….16

2.3.1 HIGH RELIABILITY……………………………………………………….…16

2.3.2 FLEXIBILITY…………………………………………………………………16

2.3.3 QUALITY OF STRONG – EASY OPERATION…………………………..…17

 2.3.4 EASY PROGRAMMING AND MODIFICATION…………...…………...17

2.3.5 LONGER LIFE……………………………………………………….........…16

2.3.6 VAST APPLICATIONS………………………....……………………… 17

2.4 ARCHITECTURE………………………………………………………………… 17

2.4.1 CPU…………………………………………….………………………… 18

2.4.2 THE BUSES………………………………………………..……………… 18

2.4.3 MEMORY……………………………………………………..… ………. 18

2.4.4 INPUT/OUTPUT UNIT…………………………………………………….…18

2.5 PLC OPERATION………………………………………………………………… 19

2.6 PLC PROGRAMMING……………………………………………………………. .20

2.7 PLC LANGUAGE………………………………………………………………… 20

2.8 LADDER LANGUAGE ………………………………………………….. ………..20

2.9 WORKING OF PLC…………………………………………………………………21

2.10 LADDER LOGIC AND PLC PROGRAMMING………………………………… 22

CHAPTER-3.

SCADA (SUPERVISORY CONTROL AND DATA ACQUISITION) ……………25-32

3.1 WHAT IS SCADA? …………………………………...…………………………... 25

3.2 FIELD WHERE SCADA CAN BE USED……………………………………….…25

3.2.1 MANUFACTURING…………………...….…………………………………...25

3.2.2 BUILDING, FACILITIES AND ENVIRONMENT…………….……………..26

3.2.3 ELECTRICAL POWER GENERATION, TRANSMISSION AND

DISTRIBUTION…………………………………….……………………….. .26
 3.2.4 WATER AND SEWAGE……………………...…………………………….. 26

3.2.5 MASS TRANSIT…………………………………………………………….. 26

3.2.6 TRAFFIC SIGNALS…………………………………………..…………… 27

3.3 HOW DOES SCADA WORK……………………………….…………………..….27

3.4 WHY SCADA? …………………………………………………………………... 28

3.5ARCHITECTURE OF SCADA…………………………………………………… 28

3.5.1 FIRST GENERATION- “MONOLITHIC” ………………...……………….. …29

3.5.2 SECOND GENERATION- “DISTRIBUTED”. ………………………………. 29

3.5.3 THIRD GENERATION- “NETWORKED” ……………………….…………. 29

3.6 COMPONENTS OF SCADA …………………………..……………………...… . 30

3.7 APPLICATION OF SCADA………………………………………………………. 30

3.7.1 BUILDING MAINTAINANCE……………………………………………..… 30

3.7.2 ENERGY …………………………………………………………………..… 30

3.7.3 MANUFACTURING ……………………………………………………… .31

3.7.4 WATER AND WASTE WATER………………………………………….……31

3.7.5 HEALTH-CARE………………………………………………………………...31

3.7.6 PETROCHEMICAL…………………………………………………………. .31

3.7.7 DIGITAL SIGINAGE

SOLUTION……………………………………………………………………………...31

3.8 ADVANTAGES OF SACDA…………………………………………………… .32

3.9 DISADVANTAGES…………………………………………………………..… .32

CHAPTER 4
PROJECT USING SCADA………………………………………………..….33-39
5.1 Project Objective…………………………………………………..32
5.2 SOFTWARE USED……………………………………………….35
5.3 PROGRAMMING…………………………………………………37
5.4 RESULT …………………………………………………………..38
5.5 FUTURE SCOPE………………………………………………….39
CHAPTER 6
CONCLUSION……………………………………………………….40
 FIGURE OF INDEX

S.NO. FIGURE NAME PAGE NO.

1 Automation machines…………………. 10

2 Home automation……………………... 12

3 View of plc……………………………. 15

4 Archetechture of plc ………………….. 17

5 SCAN CYCLE………………………... 22

6 Input energized………………………. 23

7 HOW TO PROGRAM……………….. 24

8 Control panel of SCADA……………. 25

9 Architecture of SCADA………………. 27

10 schematic of object properties………… 35

11 SCRIPT FOR PLANT………………… 36

12 WINDOWS WONDERWARE……….. 36

13 Sedimantaion of water………………… 37

14 Program for automatic lift control……. 38

15 Automatic bottle filing plant…………... 39

 CHAPTER 1

INDUSTRIAL AUTOMATION

1.1 INTRODUCTION TO AUTOMATION -

Automation is the control of machines and processes by independent systems through the use of
various technologies which are based on computer software or robotics. Industry implements
automation to increase productivity and reduce labor costs.

Industrial automation utilizes various industrial communication devices such as programmable

logic controllers (PLCs), programmable automatic controllers (PACs) which are used to control
the industry. In industries, control strategies use a set of technologies implemented to achieve the
desired result, making automation systems necessary in industries. Automation is the use of
control systems in concert with other applications of information technology to control industrial
machinery and processes, reducing the need for human intervention.

1.2 Types of automation:

Fig 1.(Automation machines)

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1.2.1 Fixed Automation - In fixed automation, the sequence of processing operations is set
by the equipment parameters. Each of the operation in a fixed or hard automation sequence is
usually simple; it is the combination and coordination of many operations into one piece of
equipment that makes the system more complicated.

1.2.2 Programmable Automation

The production equipment is designed to be able to modify the sequence of operations to the
different product configurations in this automation. The sequence of operation is controlled by a
programming, which is a set of coded instructions allowing the system to read and interpret them.

1.2.3 Flexible Automation

A flexible or soft automated system is a system that is capable of producing a wide range of
products with essentially no time for changes from one product to another. It is a fully
programmable automation. There is no loss of production time when reprogramming the
automation system and changing the physical parameter of the product., automobiles and CNC
machines

1.2.4 Home Automation

A home automation system is a technological solution that enables automating the bulk of
electronic, electrical and technology-based tasks within a home. It uses a combination of
hardware and software technologies that enable control and management over appliances and
devices within a home. Home automation is also known as domotics, and a home with an
automation system is also known as a smart home. Devices within the home automation system
connect and communicate with each over a local wired or wireless network. The entire home
automation system usually requires system management software, installation of
device/appliance controllers, motion and temperature sensors and other components.

11
 Fig2 (home automation)

Some of the processes within home automation system in design are

 Installation of computer control for heating, ventilation and air conditioning systems
 Installation and maintenance of network-enabled surveillance cameras and physical
security systems
 Central control and management capabilities over electrical fixtures and electrical system

1.3 INDUSTRIAL AUTOMATION TOOLS

Current technology is unable to automate all the desired tasks, unpredictable Development cost
of automatic process is difficult to predict accurately beforehand. Since this cost can have a large
impact on profitability, it's possible to finish automating process only to discover that there's no
economic advantage in doing so. Initial costs are relatively high. The automation of a new
product required a huge initial investment in comparison with the unit cost of the product,
although the cost of automation is spread in many product batches. The automation of a plant
required a great initial investment too, although this cost is spread in the products to be produced.
Automation tools different types automation tools exist:

1.3.1 PLC - Programmable Logic Controller –

It is a digital computer used for automation of electromechanical process such as control of
machinery on the factory assembly lines, amusement rides, or lighting fixtures PLCs are used in
many industries and machines. Unlike general-purpose computers, the PLC is designed for

multiple inputs and output arrangements.

1.3.2 SCADA - Supervisory Control and Data Acquisition –SCADA (supervisory control and
data acquisition) is a type of industrial control system (ICS). Industrial control system are
12
computer controlled systems that monitor and control industrial processes that exists in the
physical world. SCADA systems historically distinguish themselves from other ICS systems be
being large scale processes that can include multiple sites, and large distance.

1.3.3 HMI-Human Machine Interface - Human Machine interface is the part of the
machine that handles the Human-machine interaction. Membrane Switches, Rubber Keypads and
Touch screens are examples of that part of the Human Machine interface which we can see and
touch.

1.3.4 ANN -Artificial neural network–

An artificial neural network is a computational simulation of a biological neural network. These
models mimic the real life behavior of neurons and the electrical messages they produce between
input (such as from the eyes or nerve endings in the hand), processing by the brain and the final
output from the brain (such as reacting to light or from sensing touch or heat). There are other
ANNs which are adaptive systems used to model things such as environments and population.

1.3.5 DCS –
Distributed Control System –A distributed control system(DCS) refers to a control system
usually of a manufacturing system, process or any kind of dynamic system, in which the
controller elements are not in location (like a brain) but are distributed throughout the system
with each component sub-system controlled by one or more controllers. It is a computerized
control system used to control the production line in the industry.

1.4 APPLICATIONS OF AUTOMATION-

 Automated retail- food and drink, stores
 Automated mining
 Automated video surveillance
 Automated highway systems

13
 CHAPTER-2
PLC(Programmable logical controller)

2.1 INTRODUCTON OF PLC

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control system
that continuously monitors the state of input devices and make decisions based upon a custom
program to control the state of output devices. It is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact. Almost any production process can greatly enhanced using this type of
control system, the biggest benefit in using a PLC is the ability to change and replicate the
operation or process while collecting and communicating vital information. Another advantage
of a PLC is that it is modular. i.e. you can mix and match the types of input and output devices to
best suit your application. A programmable logic controller (PLC) or programmable controller is
a digitalcomputer used for automationof electromechanical processes, such as controlof
machinery on factory aassembly lines, amusement rides, or lighting fixtures.PLCs are used in
many industries and machines. Unlike general-purposecomputers, the PLC is designed for
multiple inputs and output arrangements,extended temperature ranges, immunity to electrical
noise, and resistance tovibration and impact. Programs to control machine operation are
typicallystored in battery-backed or non-volatile memory. A PLC is an example of areal time
system since output results must be produced in response to inputconditions within a bounded
time, otherwise unintended operation will result.A PLC (i.e. Programmable Logic Controller) is
a device that was invented toreplace the necessary sequential relay circuits for machine control.

2.2 DEVELOPMENT AND HISTORY

Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles
was mainly composed of relays, cam timers, drum sequencers, and dedicated closed-loop
controllers. Since these could number in the hundreds or even thousands, the process for
updating such facilities for the yearly model changeover was very time consuming and expensive,
14
as electricians needed to individually rewire the relays to change their operational characteristics.
Digital computers, being general-purpose programmable devices, were soon applied to control of
industrial processes. Early computers required specialist programmers, and stringent operating
environmental control for temperature, cleanliness, and power quality. Using a general-purpose
computer for process control required protecting the computer from the plant floor conditions.
An industrial control computer would have several attributes: it would tolerate the shop-floor
environment, it would support discrete (bit-form) input and output in an easily extensible manner,
it would not require years of training to use, and it would permit its operation to be monitored.

Fig 3 ( view of programmable logic controller)

The response time of any computer system must be fast enough to be useful for control ;the
required speed varying according to the nature of the process.[1] Since many industrial processes
have timescales easily addressed by millisecond response times, modern (fast, small, reliable)
electronics greatly facilitate building reliable controllers, especially because performance can be
traded off for reliability.In 1968 GM Hydra-Matic (the automatic transmission division of
General Motors issued a request for proposals for an electronic replacement for hard-wired relay
systems based on a white paper written by engineer Edward R. Clark. The winning proposal
came from Bedford Associates of Bedford, Massachusetts.

2.3 FEATURES OF PLC :-

PLC control system is that it regards PLC as control key component, utilize special I/O module
to form hardware of control system with a small amount of measurement and peripheral circuit,
to realize control to the whole system through programming.

15
2.3.1 HIGH RELIABILITY
Strong anti-interference quality and very high reliability are the most important features of PLC.
In order to make PLC work stably in strong interferential circumstance. Many techniques are
applied in PLC. Software control instead of relay control mode can decrease faults which are
brought about by original electric contact spot outside working badly. Industrial grade
components made by advance processing technology can resist interferences, and self-diagnosis
measures of watchdog circuit for protecting memory can improve performance of PLC greatly.

2.3.2 FLEXIBILITY
There are several programming languages for PLC including ladder diagram, SFC, STL, ST and
so on. If operator can master only one of programming languages, he can operate PLC well.
Every who want to use PLC has a good choice. Based on engineering practice, capacity and
function can be expanded by expanding number of module, so PLC has a good flexibility.

2.3.3QUALITY OF STRONG EASY OPERATION

It is very easy to edit and modify program for PLC by computer offline or online. It is very easy
to find out where the fault lie by displaying the information of fault and function of Self
Diagnosing Function, and all these make maintenance and repair for PLC easier. It is very easy
to configure PLC because of modularization, standardization, serialization of PLC

2.3.4EASY PROGRAMMING AND MODIFICATION

Programming in PLCs is easier in terms of coding and logic designing. In comparison to
embedded system and micro-controllers it is easier to program a PLC and also modification of
logical design of PLCs is easier. Since it is very user friendly and contains various function
blocks so working with PLCs has its own advantages in various fields.

2.3.5 LONGER LIFE

PLCs are free from problem of ageing due to their rugged construction and static relays have
longer life. Since heating effect is lesser in case of PLCs the reduction in efficiency and
performance is no more a problem either.

16
2.3.6 VAST APLLICATION
Application of PLCs is vast and they can be used in and of application in various industries from
power plant to manufacturing and from controlling to security they serves many purposes in a
single build that ultimately is an advantage and saves space and complexity of system is reduced
to a large extent. All these features add up and create an ultimate system which assures a high
performance in terms of accuracy, efficiency and productivity in all the industrial and controlling
processes carried out in various fields like industries, power plants, controlling station and other
concerning areas.

2.4 ARCHITECTURE
It consists of a central processing unit (CPU) containing the system microprocessor, memory,
and input/output circuitry. The CPU controls and processes all the operations within the PLC. It
is supplied with a clock with a frequency of typically between 1 and 8 MHz’s This frequency
determines the operating speed of the PLC and provides the timing and synchronization for all
elements in the system. The information within the PLC is carried by means of digital signals.
The internal paths along which digital signals flow are called buses. In the physical sense, a bus
is just a number of conductors along which electrical signals can flow.

Fig 4(ARCITECHTURE OF PLC)

The CPU uses the data bus for sending data between the constituent elements, the address bus to
send the addresses of locations for accessing stored data and the control bus for signals relating
17
to internal control actions. The system bus is used for communications between the input/output
ports and the input/output interface.

2.4.1 CPU
The internal structure of the CPU depends on the microprocessor concerned. In general they
have: An arithmetic and logic unit (ALU) which is responsible for data manipulation and
carrying out arithmetic operations of addition and subtraction and logic operations of AND, OR,
NOT and EXCLUSIVE-OR. Memory, termed registers, located within the microprocessor and
used to store information involved in program execution. A control unit which is used to control
the timing of operations.

The CPU itself has a few different operating modes: Programming mode. Run Mode Stop Mode,
Reset Mode.

2.4.2 The buses:-

The buses are the paths used for communication within the PLC. The information is transmitted
in binary form, i.e. as a group of bits with a bit being a binary digit of 1 or 0, i.e. on/off states.
The term word is used for the group of bits constituting some information. Thus an 8-bit word
might be the binary number 00100110. Each of the bits is communicated simultaneously along
its own parallel wire. The system has four buses:

 Data Bus

 Address Bus

 Control Bus

 System Bus

2.4.3 Memory
There are several memory elements in a PLC system: System read-only-memory (ROM) to give
permanent storage Random-access memory (RAM) for the users program Random-access
memory (RAM) for data. Possibly, as a bolt-on extra module, erasable and programmable read-

18
onlymemory (EPROM) for ROMs that can be programmed and then the programmable
permanent .The programs and data in RAM can be changed by the user. All PLCs will have
some amount of RAM to store programs that have been developed by the user and program data.
However, to prevent the loss of programs when the power supply is switched off, a battery is
used in the PLC to maintain the RAM contents for a period of time. After a program has been
developed in RAM it may be loaded into an EPROM memory chip, often a bolt-on module to the
PLC, and so made permanent.

The input/output unit provides the interface between the system and the outside world, allowing
for connections to be made through input/output channels to input devices such as sensors and
output devices such as motors and solenoids. It is also through the input/output unit that
programs are entered from a program panel. Every input/output point has a unique address which
can be used by the CPU. The input/output channels provide isolation and signal conditioning
functions so that sensors and actuators can often be directly connected to them without the need
for other circuitry. Electrical isolation from the external world is usually means of isolators.

4.5 PLC OPERATION

The PLC operates internally in a way very similar to computers. The inputs are continuously
monitored and copied from the I/O module into RAM memory which is divided into the input
and output sections. The CPU steps through the control program in another section of the
memory and fetches the input variables from the input RAM. Depending on the program and the
state of inputs, the output RAM is filled with the control variables which are then copied into the
I/O module where they control the processes.

4.6 PLC PROGRAMMING

One of the main advantages of the PLC controller is that it is a programmable device, which
makes it possible, unlike in the relay logic, to easily design and modify the control program or
process without any changes in the wiring (no hardware modifications). To make the
programming of the PLC systems easy and efficient, industry standards defining the

19
programming approach and the programming languages used were adopted. This reduces the
need for personel training by making a set of languages standard for all PLC Knowing the PLC
programming languages and programming standards is thus one of the most important
considerations for anyone involved in the PLC area.

4.7 PLC LANGUAGE

The function of all programming languages is to allow the user to communicate with the
programmable controller (PC) via a programming device. They all convey to the system, by
means of instructions, a basic control plan. Ladder diagrams, function blocks, and the sequential
function chart are the most common types of languages encountered in programmable controller
system design. Ladder diagrams form the basic PC languages, while function blocks and the
sequential function charting are categorized as high-level languages. The basic programmable
controller languages consist of a set of instructions that will perform the most common type of
control functions like relay replacement, timing, counting, sequencing, and logic. However, the
instruction set may be varied from one controller to another, because it depends on controller
model, specification and requirements. It may be extended or enhanced to perform other basic
operations.

Here are some typical combinations of the languages:

1. Ladder diagrams only.

2. Ladder diagrams and function blocks.

3. Ladder and sequential function chart.

4. Ladder, function blocks, sequential function chart.

4.8 LADDER LANGUAGE

The ladder diagram language is a symbolic instruction set that is used to create a programmable
controller program. Before the extension of the ladder language, the standard ladder instruction
set was limited to performing only relay equivalent functions, using the basic relay-type contact
and coil symbols similar to those shown in figure 1. A necessary for greater flexibility, coupled

20
with developments in technology, it is now extended to six sub-instruction setsand they are
relay-type, timer/counter, data manipulation, arithmetic, data transfer, and program control.
Desired control logic can be obtained by formatting the ladder instruction symbols and store into
memory. Example of ladder logic program:

Example-1

------[ ]--------------[ ]----------------O---

Key Switch 1 Key Switch 2 Door Motor

This circuit shows two key switches that security guards might use to activate an electric motor

on a bank vault door. When the normally open contacts of both switches close, electricity is able

to flow to the motor which opens the door. This is a logical AND.

Example-2

Often we have a little green "start" button to turn on a motor, and we want to turn it off with a

big red "Stop" button.

--+----[ ]--+----[\]----( )---

| start | stop run

||

+----[ ]--+

run

-------[ ]--------------( )---

run motor.

21
 2.9 WORKING OF PLC :-
The operation of a programmable controller is relatively simple. The input/output (I/O) system is
physically connected to the field devices that are encountered in them machine or that are used in
the control of a process. These field devices may be discrete or analog input/output devices, such
as limit switches, pressure transducers, push buttons, motor starters, solenoids, etc. The I/O
interfaces provide the connection between the CPU and the information providers (inputs) and
controllable devices (outputs).During its operation, the CPU completes three processes: It reads,
or accepts, the input data from the field devices via the input interfaces. processor of the PLC to
evaluate all the rungs and update the I/O image table with the status of outputs. This scan time
may be a few milliseconds for a small program or on a fast processor, but older PLCs running
very large programs could take much longer (say, up to 100 ms) to execute the program. If the
scan time were too long, the response of the PLC to process conditions would be too slow to be
useful. As PLCs became more advanced, methods were developed to change the sequence of
ladder execution, and subroutines were implemented. This simplified programming.

Fig:5 (SCAN CYCLE)

22
2.10 Ladder Logic and Programming PLCs
A PLC has many “input” terminals, through which it interprets “high” and “low” logical states
from sensors and switches. It also has many output terminals, through which it outputs “high”
and “low” signals to power lights, solenoids, contactors, small motors, and other devices lending
themselves to on/off control. In an effort to make PLCs easy to program, their programming
language was designed to resemble ladder logic diagrams. Thus, an industrial electrician or
electrical engineer accustomed to reading ladder logic schematics would feel comfortable
programming a PLC to perform the same control functions. PLCs are industrial computers, and
as such their input and output signals are typically 120 volts AC, just like the electromechanical
control relays they were designed to replace. Although some PLCs have the ability to input and
output low-level DC voltage signals of the magnitude used in logic gate circuits, this is the
exception and not the rule. The following illustration shows a simple PLC, as it might appear
from a front view. Two screw terminals provide connection to 120 volts AC for powering the
PLC’s internal circuitry, labeled L1 and L2. Six screw terminals on the left-hand side provide
connection to input devices, each terminal representing a different input “channel” with its own
“X” label. The lower-left screw terminal is a “Common” connection, which is generally
connected to L2 (neutral) of the 120 VAC power source. An indicating LED on the front panel of

Fig:6 (input energized)

23
By this plc gives indication that input has energized and able to interface with
other devices such as switches ,sensors and push buttons which helps in operation
further moniter via scada software in site

Fig :7( HOW TO PROGRAM )

When the pushbutton switch is unactuated (unpressed), no power is sent to the X1 input of the
PLC. Following the program, which shows a normally-open X1 contact in series with a Y1 coil,
no “power” will be sent to the Y1 coil. Thus, the PLC’s Y1 output remains de-energized, and the
indicator lamp connected to it remains dark. If the pushbutton switch is pressed, however, power
will be sent to the PLC’s X1 input. Any and all X1 contacts appearing in the program will
assume the actuated (non-normal) state, as though they were relay contacts actuated by the
energizing of a relay coil named “X1”. In this case, energizing the X1 input will cause the
normally-open X1 contact will “close,” sending “power” to the Y1 coil.

24
 CHAPTER 3.

SCADA
(SUPERVISORY CONTROL AND DATA ACQUISITION)

3.1 WHAT IS SCADA?

SCADA is an acronym for Supervisory Control and Data Acquisition, which is a system for
gathering and analyzing real-time data. Such systems were first used in the 1960s. the SCADA
industry was essentially born out of a need for a user-friendly front-end to a control system
containing PLCs(programmable logic controllers). SCADA networks enable remote monitoring
and control of an amazing variety of industrial devices, such as water and gas pumps, track
switches, and traffic signals .One of the key processes of SCADA is the ability to monitor an
entire system in real time. This is facilitated by the data acquisitions including meter reading and
checking statuses of sensors that are communicated at standard intervals depending on the
system.

(Fig.: 8 Control panel of SCADA)

25
3.2 FIELDS WHERE SCADA CAN BE USED
SCADA can be used to manage many kinds of equipment. Typically, SCADA systems are used
to automate complex industrial process where human control is impractical. Around the world,
SCADA system control are used in the following industries:
3.2.1 Manufacturing: SCADA systems manage parts inventories for JIT manufacturing.

3.2.2 Buildings, facilities and environments: facility managers use SCADA to control
HVAC.

3.2.3 Electrical power generation, transmission and distribution: electric utilities are
SCADA systems to detect current flow and line voltage, to monitor the operation of circuit
breakers.

3.2.4 Water and sewage: state and municipal water utilities use SCADA to monitor and
regulate water flow, reservoir levels, and pipe pressure.

3.2.5 Mass transit: transit authorities use SCADA to regulate electricity to subways, trams
And trolley buses; to automate traffic signals for rail systems.

3.2.6 Traffic signals:

SCADA regulates traffic lights, controls traffic flow and detects out of-order signals.

3.3 HOW DOES SCADA WORK?

A SCADA network consists of one of more Master Terminal Units (MTUs), which are utilized
by operators to monitor and control a large number of Remote Terminal Units (RTUs). The
MTU is often a computing platform, like a PC, which runs SCADA software. The RTUs are
generally small dedicated devices that are hardened for outdoor use and industrial environments.
Fig.: 3.2 Working of SCADA
As we saw earlier, there are several parts of a working SCADA system A SCADA system
usually includes signal hardware , controllers, networks, user interface(HMI), communications
equipment and software.

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3.4 WHY SCADA?

SCADA systems are an extremely advantageous way to run and monitor processes. They are
great for small applications, such as climate control, but they can be effectively used in large
applications such as monitoring and controlling a nuclear power plant or mass transit system.
SCADA can come in open and non-proprietary protocols. Smaller systems are extremely
affordable and can either be purchased as a complete system or can be mixed and matched with
specific components. Large systems can also be created with SCADA system software can also
be easily configured for almost any application, removing the need for custom software
development. SCADA is acronym that denotes Supervisory Control and Data Acquisition.
SCADA is a control system with applications in managing large-scale, automated industries
operations. Factories and plants, water supply systems, nuclear and conventional power
generator systems etc are a few examples. The SCADA systems, nuclear and conventional power
generator etc.

3.5 ARCHITECTURE OF SCADA

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 ( Fig.: 9 Architecture of SCADA)

3.5.1 First generation: “Monolithic”-in the first generation, computing was done by
mainframe computers. Networking did not exist at the time SCADA was developed. Thus
SCADA systems were independent systems with no connectivity to other systems. Wide Area
Networks were later designed by RTU vendors to communicate with the RTU. The
communication protocols used were often proprietary at that time. The first-generation SCADA
system was redundant since a back-up mainframe system was connected at the bus level and was
used in the event of failure of primary mainframe system.

3.5.2 Second generation: “Distributed”-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. The network protocols used were still mostly proprietary,
which led to significant security problems for any SCADA system that received attention from a
hacker.

3.5.3 Third generation: “Networked”- Due to the usage of standard protocols and the fact that
many networked SCADA systems are accessible from the internet; the systems are potentially
vulnerable to remote cyber-attacks. On the other hand, the usage of standard protocols and
security techniques means that standard security improvements are applicable to the SCADA
systems, assuming timely maintenance and updates

3.6 COMPONENTS OF SCADA-

3.6.1 A human- machine interface or HMI –

HMI is the apparatus which presents process data to human-machine interface or HMI is the
apparatus which presents process data to a human operator, and through which the human
operator controls the process. An HMI is usually linked to the SCADA system’s databases and
software programs, to provide trending, diagnostic data, and management .information such as
scheduled maintenance procedures, logistics information, detailed schematics for a particular
sensor or machine and expert-system troubleshooting guides. The HMI system usually presents
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the information to the operating graphically, in the form of a mimic diagram. This means that the
operator can see a schematic representation of the plant being controlled.

3.6.2 System concepts-

A supervisory (computer) system, gathering (acquiring) data on the process and sending
commands (control) to the process. The term SCADA usually refers to centralized systems
which monitor and control entire sites, or complexes of systems spread out over large areas.
Most control actions are performed automatically by RTUs or by PLCs. Host control functions
are usually restricted to basic overriding or supervisory level intervention.

3.6.3 Remote terminal units (RTUs) –

RTU used to connecting sensors in the process, converting sensor signals to digital data and
sending digital data to the supervisory system. The RTU connects to physical equipment.

3.6.4 Programmable logic controller (PLCs) –

PLC is a solid state device or mini industrial computer that performs discrete or sequential logics
in a factory environment. It was originally developed to replace mechanical relay, timers, and
counters. PLCs are successfully used to execute complicated control operations. Its purpose to
monitor crucial parameters & adjust process operation accordingly. It is a digital computer used
for automation of electromechanical processes, such as control of machinery on factory assembly
lines, amusement rides, or light fixtures. PLCs are used in many industries and machines.

3.6.5 Supervisory station- communication infrastructure connects the supervisory system to

the remote terminal units. The term supervisory station refers to the servers and software
responsible for communicating with the field equipment (RTUS, PLCs, etc.), and then to the
HMI software running on workshops in the control room, or elsewhere. In smaller SCADA
systems, the master station may be composed of a single PC. In larger SCADA systems, the
master station may include multiple servers the multiple servers will often be configured in a
dual-redundant or hot-standby formation providing continuous control and monitoring in the
event of a server failure.

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3.7 APPLICATIONS OF SCADA-
Unlike in plant process control systems, SCADA systems typically include a remote
telecommunication link. Real-time measurements and controls at remote stations are transferred
to a CPU through the communication link. Large systems can monitor and control 10-2000
remote sites, with each site containing as many as 2000 I/O points. By small industrial
companies the technology was deemed unobtainable because of high association with those
systems could not be fully used because of their massive I/O capacities. Application size can be
20k I/O to 450k I/O under development. A typical SCADA application requires several low cost
distributed RTUs. Controlled by a central station/master. Applications in plant process control
system.

3.7.1 Building maintenance –

It provides a quick and easy method for creating graphical views of your building monitoring
and control systems. Use a common Web-enabled user interface to integrate facility functions
such as HVAC, lighting, energy, security, fire and elevator giving maintenance personnel and
other35operators an easy way to display, monitor and control critical key operating parameters in
multiple facilities from a single location

.3.7.2 Energy –
The energy industry is one of today’s most dynamic business environment with decisions being
driven by increased regulation, growing demand and escalating costs. Used in electrical utility
control centers to present a graphical view of the power system and the capability to analyze
past and current events as well as to predict potential future issues

.3.7.3 Manufacturing–
It makes easy to monitor and control multiple shop floor processes from a single location and
have immediate visibility to data trends, making it easy to anticipate potential problems. The
manufacturing assembly, engine testing, robotic welding, paint shop and material handling can
benefit.
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3.7.4 Water & Waste Water–
The following water and waste water includes that can be benefit from SCADA solutions
sanitation systems, water utilities municipalities, distribution, filtration, desalination, remediation,
etc. It provides water and wastewater processing organizations with powerful real-time data
visualization tools to display, monitor and control all areas of the process.

3.7.5 Healthcare–
The following health care industry segments that can benefit: hospitals and other health care
facilities, drug and pharmaceutical, water purification systems, packaging, medical equipment
manufacturing, etc. offers a data visualization solutions that saves time and efficiently supports
the overall management of today’s health care and pharmaceutical industry.

3.7.6 Petrochemical– The oil, gas and petrochemical companies need to be able to easily
manage their daily operations while adhering to regulatory requirements. It enables monitoring
and control of data as well heads, pumping stations and cooling towers, etc. – between
geographically isolated locations from a single location. The following oil, gas & petrochemical
industries that can benefits .

3.7.7 Digital Signage solutions–

It is the perfect solution for digital signage application in areas such as corporate
communications, education, tourism, retail ,financial services, restaurant, conferences, etc. It is a
powerful software design solution for your digital signage display needs. Using status,
companies can display meaningful real-time information such as sales or manufacturing figures
or, using the built-in Scheduler, cycle a series of messages generated by the designer for
corporate visitors, internal or other employee messages

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3.8 ADVANTAGES OF SCADA-

The computer can record and store a very large amount of data. The data can be displayed in any
way the user requires Thousands of sensors over a wide area can be connected to the system The
operator can incorporate real data simulations into the system Many types of data can be
collected from the RTUs The data can be viewed from anywhere not just on site

3.9 DISADVANTAGES OF SCADA-

The system is more complicated than the sensor to panel type. Different operating skills are
required, such as system analysis and programmer. With thousands of sensors there is still a lot
of wire to deal with. The operator can see only as far as the PLC. monitor. Control remote sites
via web browser and security concern.

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 CHAPTER 4

Project Using SCADA:

5.1 Sewage Water Treatment

Design Sewage Water Treatment System in Wonderware Intouch SCADA.

5.1.2 Software Used:

Wonderware Intouch version 9.0Wonderware is a brand of industrial software sold by Schneider
Electric.Wonderware was part of Invensys PLC, and Invensys PLC was acquired in January
2014 by Schneider Electric. Wonderware software is used in diverse industries, including:
Facilities Management, Food and Beverage, Mining and Metals, Power, Oil and Gas, and Water
and Waste water. Wonderware Intouch Software is an open and extensible Supervisory HMI and
SCADA solution that enables the rapid creation of standardized, reusable visualization
applications and deployment across an entire enterprise. InTouch SCADA consists of three
major programs:

1. Application Manager,
2. Window Maker
3. Window Viewer

5.1.3 Working of Project:

The project is made in Window Maker and executed in Window Viewer. In

window viewer, the project would run as:
When the START switch is turned on, water from the storage tank flows to the sedimentation
tank after passing through the screening filter. As soon as the sedimentation tank is filled the
rotator inside the tank is turned on so As to deposit the sediments at the bottom of the tank. Next,
clean water from the sedimentation tank is transferred to the chlorine tank where the water is
chlorinated to kill the germs and make it fit for drinking. Next, the water is oxygenated by
passing the water from the chlorine tank is filtered and stored in another tank for usage.

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5.1.4 Programming:

1. In the Intouch Application Manager, we select file → New → Create new

Application. This creates a new Intouch application.

2. When we double click on this application, it opens Intouch Window maker.

3. In Window maker we select File → New Window. A dialog box appears

asking for name, window type, window color and other properties.

4. We name the window as ”sewage water treatment”, window type as replace,

frame style as single and click on OK. A window appears as per defined by
us.

5. Next we click on the wizard icon. The Wizard Selection window appears in
which there are various options of the graphical objects.

6. We select fixture switches from the Switches option of the Wizard selection
window. The rest all other graphical objects will be picked from the Symbol
factory option.

7. In the Wizard Selection window, we select symbol factory option and then
Double click it. This opens the symbol factory window.

8. In the symbol factory window there are various categories of the graphical
Objects like Tanks, agitator wheels etc. We select the different objects as
per our requirement.

9. For all the objects taken from the symbol factory, we perform ”BreakCell”
operation so that we are able to change their properties as per our
requirement Following is the figure showing the list of the properties
available for each object from Symbol Factory:

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 Fig10 (schematic of object properties)

10. For our project we require tanks ,valves , pipes, indicators that we all get
from symbol factory that is shown above.

11. Next we put all the objects in water treatment according to the setup and
modify their object properties. Now for example to fill tank we require
another tank so the first tank which is fill already will fill another tank
through from pipe. Now the first tank will decrease steadily .

12.For that double click on tank then select vertical property under fill
option ,now give the tag name and also specify max and min percentage
values.
13.Similarly all object properties are assign in same way.

14.Script for water treatment is given below.

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 FIG 11( SCRIPT FOR PLANT )

15. Finished window is shown below:

FIG12 ( WINDOWS WONDERWARE )

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 16.The following shows the operation of plant:

(A) Transfer of sewage water from storage tank and sedimentation tank
(B) Oxidization and chloronization process takes place in tank.

Fig 13(sedimantaion of water)

5.1.5 Results
The design of ”Sewage Water Treatment System” is successfully implemented in Intouch
SCADA.

5.1.6 Future Scope

1. This project can be implemented practically when SCADA is connected with PLC. More
enhanced features can be added up to it. For e.g. Reverse Osmosis purification system can be
added.

2. The project based on sewage can be extended to water purification systems, oil refinery
systems in industries.

3. The project can also be extended to packaged drinking water industries where water is first
purified, then filled into bottles, capped, labelled and then sold in bottles.

5.2 Automatic lift control-

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In this I design a model of lift control in which I shows how a lift works. In this
model we use PLC, relays, dc gear motor, sensors & switches. All plays very important
role. We upload a program in PLC which is formed in ladder logic.

Fig14: program for automatic lift control

Switches are used to calling or going the lift upward or downward and sensors are used to sense the
present position of lift. Dc gear motor used to rotate the pulley in which lift is fixed.

6.3 Automatic bottle filing plant

In this project we design a program for a bottle filing plant. In which we used a counter belt, motor, valve,
sensors & internal timer of PLC. Sensors used as switch which sense the position of bottle it used
where bottle have to be stopped. Timer is used to count the time for which valve is open to fill
the bottle.

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Fig15: Automatic bottle filing plant

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 CHAPTER 5

CONCLUSION

With the speed of changing technology today it is easy to lose sight or knowledge of the basic
theory or operation of programmable logic. Most people simply use the hardware to produce the
results they desire. Hopefully, this report has given the reader a deeper insight into the inner
workings of programmable logic and its role in mechanical operations. The idea of
programmable logic is very simple to understand, but it is the complex programs that run in the
ladder diagrams that make them difficult for the common user to fully understand. Hopefully
this has alleviated some of that confusion. SCADA is used for the constructive working, using a
SCADA system for control ensures a common framework not only for the development of the
specific applications but also for operating the detectors. Operators experience thesame ”look
and feel” whatever part of the experiment they control. However, this aspect also depends to a
significant extent on proper engineering.

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