Development of SCADA System for Real-time Control of Pressure

By P.Kavya G.Sai Kiran P.Jennyfer O.Kishore Under the guidance of: Mr. B. Param Naidu

Outline of the project:

Objective of the project

What is SCADA?
Functions of SCADA SCADA applications Programmable Logic Controller(PLC) GE fanuc micro PLC IC200UAL005 VersaPro software Creating Ladder diagrams in VersaPro LabVIEW and DSC module Conclusions

OBJECTIVE
The objective of this project work is to develop SCADA/HMI for real time monitoring and control. The plant simulation (HMI) is developed by making use of either SCADA simulation software called cimplicity of GE Fanuc or National Instrument LabVIEW software.

SCADA:

SCADA(Supervisory Control and Data Acquisition) systems are used to monitor and control a plant or equipment in industries. These systems encompass the transfer of data between a SCADA central host computer and a number of Remote Terminal Units (RTUs) and/or Programmable Logic Controllers (PLCs), and the central host and the operator terminals. SCADA systems are used to automate complex industrial processes where human control is impractical.

A SCADA system performs four functions:

1.
2. 3. 4.

Data presentation(HMI)
Networked data communication Data acquisition Control

These functions are performed by four kinds of SCADA components: 1. Sensors and control relays that directly interface with the managed system. 2. Remote telemetry units (RTUs). These are small computerized units deployed in the field at specific sites and locations. RTUs serve as local collection points for gathering reports from sensors and delivering commands to control relays. 3. SCADA master units. These are larger computer consoles that serve as the central processor for the SCADA system. They provide human interface to system. 4. The communications network that connects the SCADA master unit to the RTUs in the field.

HMI - Human Machine Interface and Data Presentation: Data Presentation is handled by a master station, also called a HMI ( Human Machine Interface). The master station's job is to monitor the system's sensors. The master station then summarizes all the information and generates logs, historical trends and any deviations from standard limits.

Human Machine Interface

Data Communication
Data Communication is the ability for the individual components of the SCADA control system to communicate with each other.

Currently SCADA data is transmitted via Ethernet and IP kept on a closed LAN/WANS.
Data Acquisition Data acquisition in the SCADA control system is gathered by sensors. Digital sensors indicate definitive states ie. on/off, pressure/no pressure. The analog sensors provide variable voltage or current signals that provide real time data.

Controls: Controls of the SCADA network's automation is completed by

monitoring feedback from the master unit with input from human
operators. Today's SCADA systems are fully capable of full automation and control of regulating complex water/wastewater utility systems.

SCADA applications: Water distribution Water treatment Waste water treatment Telecommunications Energy based industries Oil and Gas refining Fuel transportation Security applications, etc..

PLC:
Programmable logic controllers (PLC) are industrially hardened microcomputers that perform discrete or continuous control functions in a variety of processing plant and factory environment. A PLC produces on/off voltages and can actuate elements such as electric motors, solenoids (pneumatic and hydraulic valves), fans, heaters and light switches. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory.

Parts of a PLC:
A power supply that converts incoming line power to the DC voltage needed to operate the PLC A Central processing Unit ( CPU )

Input and Output circuits

Screw-down terminals for connecting wires from input and output devices to the PLC

The basic programming methods for PLC are: Logic ladder diagram Mnemonic (statement list) Function block diagram The most commonly used programming method is using Ladder diagrams

GE Fanuc Micro PLC IC200UAL005

It is called as VersaMax Microcontroller IC200UAL005-BD

Thirteen configurable 24VDC inputs can be used as positive or negative logic standard or High-speed Counter inputs.
Inputs are compatible with a wide range of input devices, such as pushbuttons, limit switches, and electronic proximity switches. The module provides +24VDC output power available for field devices. The DC output circuit (Q1) can be configured to be a standard, High Speed Counter, Pulse Train or PWM output. The nine isolated 2-amp, normally-open outputs can control many types of user-supplied load devices such as motor starters, solenoids, and indicators. The DC power supply requires more current at startup voltage (approximately 4 VDC) than at rated input voltage. A minimum of 2.0 A is required to start up the DC power supply.

PLC Specifications:
Make: GE Fanuc PLC Model: 1C200NDD101 6 digital inputs (24V DC) 4 digital outputs (24V DC) 2K words of memory, 256 words of register Powerful features like built in floating point, subroutines, etc. One RS232C communication facility for PC interface.

Three channels can be configured as follows: Pulse width modulation output or Pulse train output or High speed counter input.

VersaPro software:

VersaPro is a PLC programming software used to monitor and control the operation of input/output devices connected to PLC. It is only compatible with the GE Fanuc make PLCs. Programming is done using ladder diagrams. The versapro work space is customizable.

VersaPro Workspace

Ladder Diagrams
Logic AND
The truth table of logic AND is as follows,

Conversion to Ladder Diagram,

Logic OR
The truth table of logic OR is as follows,

Conversion to Ladder Diagram,

Logic XOR
The truth table of logic XOR is as follows

conversion to Ladder Diagram,

Practical view on workspace:

Selecting functions:

LabVIEW
(Laboratory Virtual Instrumentation Engineering Workbench)

It is a platform and development environment for a visual programming language from national instruments.

The purpose of such programming is automating the usage of processing and measuring equipment in any laboratory setup.

It is commonly used for data acquisition and instrument control. LabVIEW is preferred for most applications due to its ease of use, readability, maintainability, efficiency, simplicity, performance, development time and reliability.

DSC MODULE Data Logging And Supervisory Control

The NI LabVIEW Datalogging and Supervisory Control (DSC) Module is the ideal LabVIEW add-on for developing the HMI/SCADA or high-channel-count data-logging applications. It includes tools for logging data to a networked historical database, real-time and historical trending, managing alarms and events, networking LabVIEW Real-Time targets and OPC devices into one complete system, and adding security to user interfaces.

The LabVIEW DSC Module includes: Networked, SQL-compliant database for distributed data logging. Configuration-based alarms and events. Real-time and historical trending. Event-driven architecture with OPC client/server connectivity. Unlimited tags. User-level application security. Support for Windows XP and Windows XP Embedded.

Conclusion:
Under this project after the first presentation we have learnt about the basics of PLC and have practically implemented the basic boolean logics in PLC software using ladder diagrams and verified their operations.

Reference:
Stephan J. Sosik, SCADA systems in wastewater treatment, Process Logic paper, chapter-50. S. Mackay, E. Wright, J. Park, and D. Reynders, Practical Industrial Data Networks: Design, Installation and Troubleshooting.

G. Clarke and D. Reynders, Practical Modern SCADA Protocols: DNP3, 60870.5 and Related Systems. Bailey, D., and Wright, E. Practical SCADA for Industry. Elsevier Press, Oxford, England, 2003.
http://www.ni.com

THANK YOU