AUTOMATION OF KILN BURNING ZONE

CAMERA LCU USING DCS

A PROJECT REPORT
Submitted by

MOHAMMED ARSHAD.A

(80710122026)

SURESH.V

(80710122509)

VETRIVEL.S

(80710122511)

VIKRAM.L

(80710122512)
In partial fulfillment for the award of the degree
of

BACHELOR OF ENGINEERING
in
ELECTRONICS AND INSTRUMENTATION ENGINEERING
J.J.COLLEGE OF ENGINEERING AND TECHNOLOGY
TRICHY-620009

ANNA UNIVERSITY: CHENNAI 600 025

MARCH - 2014

AUTOMATION OF KILN BURNING ZONE

CAMERA LCU USING DCS
A PROJECT REPORT
Submitted by

MOHAMMED ARSHAD.A

(80710122026)

SURESH.V

(80710122509)

VETRIVEL.S

(80710122511)

VIKRAM.L

(80710122512)
In partial fulfillment for the award of the degree
of

BACHELOR OF ENGINEERING
in
ELECTRONICS AND INSTRUMENTATION ENGINEERING
J.J.COLLEGE OF ENGINEERING AND TECHNOLOGY
TRICHY-620009

ANNA UNIVERSITY: CHENNAI 600 025

MARCH - 2014

AUTOMATION OF KILN BURNING ZONE

CAMERA LCU USING DCS
A PROJECT REPORT
Submitted by

MOHAMMED ARSHAD.A

(80710122026)

SURESH.V

(80710122509)

VETRIVEL.S

(80710122511)

VIKRAM.L

(80710122512)

In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
in
ELECTRONICS AND INSTRUMENTATION ENGINEERING
J.J.COLLEGE OF ENGINEERING AND TECHNOLOGY
TRICHY-620009

ANNA UNIVERSITY: CHENNAI 600 025

MARCH - 2014
i

ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE
Certified that this project report AUTOMATION OF KILN BURNING ZONE
CAMERA LCU USING DCS is a bonafide work of MOHAMMED
ARSHAD

.A

(80710122026)

SURESH.V

(80710122509),

VETRIVEL.S (80710122511) and VIKRAM.L (80710122512) who carried

out the project work under my supervision.

SIGNATURE

SIGNATURE

Mrs.M.Banusundareswari, M.Tech ,(Ph.D),

Mr. T Rajesh M.E.,

HEAD OF THE DEPARTMENT,

SUPERVISOR ,

Department of EIE ,

Department of EIE,

JJ College Of Engineering

JJ College of Engineering

and Technology,

and Technology,

Ammapettai, Trichy-9.

Ammapettai, Trichy-9.

ii

CERTIFICATE OF EVALUATION

S.NO

College Name

Branch

: Electronics and Instrumentation Engineering

Semester

: VIII

REG. NO

J.J. College of Engineering and Technology

NAME OF THE

TITLE OF THE

NAME OF THE

STUDENTS

PROJECT

SUPERVISIOR

AUTOMATION

01

80710122026

MOHAMMED ARSHAD.A

02

80710122509

SURESH.V

03

80710122511

VETRIVEL.S

04

80710122512

VIKRAM.L

OF KILN
BURNING ZONE

Mr. T Rajesh

CAMERA LCU
USING DCS

The report of the project work submitted by the above student in partial
fulfillment

for

the

award

BACHELOR

OF

ENGINEERING

in

ELECTRONICS AND INSTRUMENTATION ENGINEERING of Anna

University were confirmed to be report of the work done by the above students and
then evaluated.

Submitted for the Viva voce Examination held on __________________

INTERNAL EXAMINER

EXTERNAL EXAMINER
iii

ACKNOWLEDGEMENT

At the outset, we ascribe our heartfelt gratitude to the Lord

Almighty for making this project possible.
We take this opportunity to express our deepest gratitude to
our college Chairman Prof.K.Ponnusamy, M.Sc., B.L., our Advisor,
Dr.V.Shanmuganathan, B.E., M.Sc. (Engg.), Ph.D., and our Principal,
Dr.S.Sathiyamoorthy, M.E., Ph.D., for sincere endeavor in educating us in
this premier institution and for their constant encouragement during the past
four years.
We

thank

our

Head

of

the

Department

Mrs.M.Banusundareswari M.Tech., (Ph.D)., and we wish to express our

sincere gratitude to our guide Mr.T.Rajesh M.E., for his valuable
guidance and encouragement in every aspect throughout the project.
We owe particular thanks to all the staff member of the
department, without whose cooperation this venture would not have
completed. Finally with the same spirit, we are thankful to our parents for
the constant encouragement support extended by them during the course of
this project.

iv

ABSTRACT
Process automation involves using computer technology and software
engineering to help process industries as diverse as paper, mining and cement
operate more efficiently and safely. Industrial automation plays vital role since
it imparts a high degree of efficiency. In cement industries, burning of clinker is
process to define the quality of cement manufacturing, In that it is necessary to
supervise the burning process. This in turn increases the efficiency of the Fuel
consumption and Quality of cement. At present PLC based supervision is
applied in industries. To try and apply centralized control. DCS enables a faster,
reliable and higher end features.DCS is a trending technique which helps in
monitoring, controlling under a single roof. Using DCS platform, controlling
number of loop process. It enable you to manage the process as a complete
system, with control over the inter relationship of the various substation.

TABLE OF CONTENTS
CHAPTER

TITLE
ABSTRACT

LIST OF FIGURES

viii

LIST OF ABBREVIATIONS

LIST OF TABLES

xi

INTRODUCTION

1.1 Introduction to Automation

1.2 Present Model

2
3

1.2.1 How It Works

PAGE NO

1.3 disadvantages of PLC

DESCRIPTION

2.1 Block Diagram

2.2 Overview Of The Setup

10

2.3 Process Description

11

2.4 Introduction to DCS

12

2.5 Modes Of Computer Control

14

2.6 Computer Control Networks

15

2.7 Description Of DCS

20

2.8 Control Loop

21

2.9 The Basic Units Of A Digital Computer

23

2.10 Digital Control Software

27

2.11 Hybrid Controller (HC900)

28

2.12 Pneumatic Cylinders

30

2.13 Solenoid Valve

31

vi

2.14 Sensor

34

2.15 Relay Board

40

2.15.1 The Electromagnetic Relay

40

INTERFACING AND DESIGN OREINTATION

43

3.1 Communications Remote I/O Rack Port

43

3.2 User Interface Support

43

3.3 Ethernet Modbus/TCP Communications

43

3.4 Ethernet Peer To Peer Communications

44

3.5 Serial Modbus RTU Communications

44
46

3.6 Design Orientation

47

3.7 SCADA Concept

49

3.7.1 Specifications

49

3.8 Generations
4

DESIGN AND SIMULATION

51

CONCLUSION

55

REFERENCES

56

vii

LIST OF FIGURES
FIGURE NO

TITLE

PAGE NO

2.1

Block diagram

2.2

Overview

10

2.3

Computer control nodes

14

2.4

PC network

16

2.5

Elements of commercial DCS

19

2.6

Components of digital control loop

22

2.7

General purpose digital computer

23

2.8

Honeywell DCS hc900

29

2.9

Pneumatic piston

30

2.10

5/2 Double coil solenoid valve

33

2.11

Double coil solenoid valve principle

34

2.12

Working principle of inductive proximity

38

sensor
2.13

Inductive proximity sensor (PNP)

39

2.14

Electromagnetic relay

40

2.15

Relay principle

41

2.16

Relay board

41

3.1

Architecture of SCADA

48

4.1

DCS functional block 1

51

4.2

DCS functional block 2

52

viii

4.3

DCS functional block 3

53

4.4

SCADA Design

54

ix

LIST OF ABBREVATIONS

SCADA

- Supervisory Control And Data Acquisition

RTDB

- Real Time Data Base

RISC

- Reduced Instruction Set Computer

SPDT

- Single Pole Double Throw

DPDT

- Double Pole Double Throw

DCS

-Distributed Control System

CPU

- Central Processing Unit

DAS

- Data Acquisition System

HMI

- Human Machine Interface

RTU

- Remote Terminal Unit

LAN

- Local Area Network

LCU

- Local Control Unit

TCP

-Transmission Control Protocol

DIP

- Dual Inline Package

DDR

- Double Data Rate

OI

- Operator Interface

NO

- Normally Open

NC

- Normally Close

SV

- Solenoid Valve

LIST OF TABLES

Figure No

Title

Page No

Categories of process
information

26

xi

CHAPTER 1
INTRODUCTION

In cement industries, efficiency of the burning process result in higher

quality of cement. Thus it is necessary to supervise the burning process to
monitor and control it.
1.1 Introduction to automation
Industrial automation is the use of control systems such as computers
to control industrial machinery and processes. Some advantages are
repeatability, tighter quality control, waste reduction, integration with
business systems, increased productivity and reduction of labor. Some
disadvantages are high initial costs and increased dependence on
maintenance. A major benefit of industrial automation technology is the
latest field bus developments.
The most popular protocols are Device Net, Provirus and ASi and the
emerging Industrial Ethernet. Implementation of industrial automation
provides capital expenditure savings associated with cable elimination
(multiple devices share wire-pairs and communicate over the bus network)
and other savings are also available through speedier commissioning A
number of Ethernet-based industrial communication systems have been
established recently. Industrial Ethernet has the potential to replace the
traditional field bus in the long term. The issue preventing many Ethernet
field bus implementations is the availability of device power.

Many industrial measurement & control devices need to be powered

from the bus and Power-Over-Ethernet (PoE) has voltage (48V) and power
(350mA maximum per device) issues in it's current implementation.
Industrial automation and process control greatly reduces the need for
human sensory and mental requirements as well.
Most complex industrial automation processes and systems can be
automated. A major advantage of industrial automation and process control
is the increased emphasis on flexibility and convertibility in the
manufacturing process. Manufacturers are increasingly demanding the
ability to easily switch from manufacturing a wide range of products without
having to completely rebuild the production lines.
1.2 Present System
In conventional system, PLC based supervision methods are used.
Though these plc based system are capable of repeatability and reliability ,
maintenance have been an issue. To calibrate the set up , engineers have to
be present at local .these result in unwanted production cost ,wastage of time
and with result in various error.

1.2.1 How it works?

The automation of kiln burning zone camera refers to supervision of
burning process to interact camera inside the kiln. It is necessary to obtain
i.e. control the parent parameters such as
Water flow
Water temperature
Air flow
Air pressure
These parameters are used to safeguard the camera lens. These
camerass working temperature is far lower than the actual temperature of
kiln furnace. when these parameters are not under normal condition the lens
position retracts from the kiln. The parameters are controlled using PLC
based controllersThe parameters are controlled using chiller unit which
minimize the water temperature which circulates inside the camera unit.
These chiller unit acts on the principle of the heat exchanger.

1.3 Disadvantage of PLC

Enterprise integration (open connectivity.
Choose the control system that will provide you with capability to
seamlessly add enterprise solutions onto your control layer. Right now you
may not be thinking of things like, Manufacturing Execution Systems
corner.

Your vendor should be able to provide a seamless flow of process

information from the control layer to information layer. Todays information
hungry corporations need to squeeze every bit of production capacity out of
their assets and Invensys ArchestrA enabled solutions provide the consistent
flow and a lifecycle that ensures tomorrows applications will work with
todays control system.
System upgrades and expansions.
A PLC, which is a disparate set of parts from multiple vendors, will make
it difficult for your facility to expand. The local SI may be around for years
but will the hardware that they supplied today be usable in the future or will
it even talk to the system components that are supplied during your next
expansion. A single company providing all the parts from one factory with
one set of quality guidelines and with one software infrastructure like
ArchestrA will guarantee that your assets are protected.
Factory support.
Inevitably problems arise during the startup and lifecycle of the project.
Consider a PLC approach with disparate parts - I/O, controllers, HMI,
Historians, web viewers, and others. As good as your SI might be, they can
only control the system that they receive. Imagine the problems when the
parts dont talk as well as they should. You must consider where you will get
your support. It will always be a better, cleaner situation when you have one
company standing behind all the components with a standard warranty and
repair contract.
4

Also consider factory support and service agreements. A major

organization like Foxboro will always stand behind the equipment and will
work to make sure that your system is up and running as quickly as possible.
Your SI can also do this, but many times their hands will be tied by the
vendors that they use.
Life-cycle cost.
Life cycle cost takes into consideration many things such as, ease of
engineering system changes, hardware and software upgradability, interface
to 3rd party devices and applications, warranty and service support, training
and more. A product line that is managed and owned completely by one
company will provide significant advantages in each of these areas. The
ArchestrA infrastructure of a system will also ensure the ability to easily
integrate future ArchestrA enabled applications into the system. An
organization with a migration track record like Foxboro, who still allows
customers to build off their original I/A Series system from 17 years ago,
will ensure the same migration and low life cycle costs remain.
Long term installation.
This point should be considered when examining the SI you will be
dealing with. Strong SIs will be able to provide a steady stream of support
over the years, however, for the best long term strategy a well known, world
class organization with a good track record of project management,
installation and local field service support will always be a more solid

solution. Secondly, working with one organization from the first phase of the
project and through expansions will ensure a good level of continuity that
will ultimately reduce life cycle costs.
Long term installation.
This point should be considered when examining the SI you will be
dealing with. Strong SIs will be able to provide a steady stream of support
over the years, however, for the best long term strategy a well known, world
class organization with a good track record of project management,
installation and local field service support will always be a more solid
solution. Secondly, working with one organization from the first phase of the
project and through expansions will ensure a good level of continuity that
will ultimately reduce life cycle costs.
High Speed Peer to peer enabling multi master capabilities.
PLCs are not peer to peer instruments. What does this mean? The impact
is felt with engineering time and wiring costs. Take for example a Gas
header to three furnaces. Without peer to peer capabilities input/output
signals from Gas Flow, Air, Blowers and valves will have to be replicated
and mapped into each of 3 PLC slots controlling each furnace. Furthermore,
the wiring from each transmitter on the header will need to be passed
directly to each PLC. With a DCS solution, the signals from each transmitter
can be mapped directly to the first Controller then copied into the second
and third controller without the need to rebuild the strategy three times.

Additionally, since the DCS controllers are peer to peer the wiring will
be daisy chained from Controller 1 to Controller 2 to Controller 3. The
overall impact of peer to peer control is significant reduction in wiring and
significant reduction in engineering time. Single database A Single Tag
database with definitions will make it easier to manage the plant and process
control models. This point must be taken into consideration in terms of life
cycle costs and system maintenance. With a PLC a change of controller or
node number will be more difficult if the address is based on the physical
location of the tag in the system
Security
With a PLC the security strategy is not provided within a security
manager package. With typical HMIs there is no tag based alarm definition
provided and therefore every signal must be handled separately. Ultimately
this will cause problems with security levels and adminstration of the
security system.
Alarms
With a PLC there is no alarm strategy out of the box. Alarm
programming will add engineering time and complexity to the system.
Maintenance of the alarm strategy will be much complicated for plant
personnel who were not involved in the original implementation. With the
Foxboro A2 hybrid automation system, alarms are embedded by the function

blocks within the control strategy which has a default alarming strategy that
works out of the box. Alarms are organized in up to 255 areas and priorities
range from 0 to 15. Also included are acknowledgement routines and alarm
handling strategies. The alarms are created at the controller level and not the
HMI level and stored into a SQL database for archiving and troubleshooting.
A 21 CFR part 11 compliant version is available.
Advanced math functions (PID control)
PLCs were not designed to do advanced math functions or accurate
analog control. If future applications require PID functionality, expensive
add-on cards that require programming in different language and different
environments using floating point math may be needed..
Domain Expertise.
Typically, working with a large DCS manufacturer ensures that there
is a significant amount of domain expertise available within the engineering
environment. Although SIs do work in certain areas it is generally
understood that the DCS vendor has expertise in specific markets because
they are working on these projects all over the world and have centralized
areas of expertise. Open communication protocols at control level as
standard. Proprietary protocols used by many PLC vendors at the control
level will make it difficult for units to communicate with 3rd party
instruments.

CHAPTER 2
DESCRIPTION
2.1 Block Diagram

Fig 2.1 Block diagram

The DCS is a main controlling platform in this process which is used

to interface the field instruments and the controller. This block diagram
shows the interfacing of filed instruments and controllers

2.2 Overview of the process set up

Fig 2.2 Overview

The structural view of the set up shows the inner circulatory tube for
water circulation. Which is a main component for heat transfer? This
enables in healthy signal feeds on which the process is parameterized for
automation

10

2.3 Process Description

The automation of kiln burning zone camera is used to continuous
monitoring from computerized control room In industries, continuously
monitoring is necessary in maintaining and controlling of process .Set up
has
Pneumatic pistons
Relay channel
Proximity Sensors
Solenoid Valves
Camera
When the field signals are healthy, the set up starts sequence of
operation. Signal actuates the forward movement of piston. Proximity
sensor signal is used as the switch for the camera. Then the camera feed
signal is drained continuously until the camera retracts. These acts as a loop
of process of interaction and retraction of Camera unit. The field signals are
water temperature, water flow, air pressure, air flow. These parameter are
healthy the camera unit will move to kiln in case anyone parameter will
unhealthy the camera unit will be retracted the camera is used to view the
burning range in the kiln. The burning range is they more important for the
cement manufacturing.

Generally, the concept of automatic control includes accomplishing

two major operations; the transmission of signals (information flow) back
and forth and the calculation of control actions (decision making). Carrying
out these operations in real plant requires a set of hardware and
instrumentation that serve as the platform for these tasks.

11

Distributed control system (DCS) is the most modern control

platform. It stands as the infrastructure not only for all advanced control
strategies but also for the lowliest control system. The idea of control
infrastructure is old. The next section discusses how the control platform
progressed through time to follow the advancement in control algorithms
and instrumentation technologies.

2.4. Introduction To DCS

To fully appreciate and select the current status of affairs in industrial
practice it is of interest to understand the historical perspective on the
evolution of control systems implementation philosophy and hardware
elements. The evolution concerns the heart of any control system which is how
information flow and decision making advanced.

1. Pneumatic Implementation: In the early implementation of automatic

control systems, information flow was accomplished by pneumatic
transmission, and computation was done by mechanical devices using
bellows, spring etc. The pneumatic controller has high margin for safety
since they are explosion proof. However, There are two fundamental
problems associated with pneumatic implementation:

Transmission: the signals transmitted pneumatically (via air

pressure) are slow responding and susceptible to interference.

Calculation: Mechanical computation devices must be relatively

simple and tend to wear out quickly.

2. Electron analog implementation: Electrons are used as the medium of

transmission in his type of implementation mode. Computation devices are
12

still the same as before. Electrical signals to pressure signals converter (E/P
transducers) and vice verse (P/E transducers) are used to communicate
between the mechanical devices and electron flow. The primary problems
associated with electronic analog implementation are:

Transmission: analog signals are susceptible to contamination

from stray fields, and signal quality tends to degrade over long
transmission line.

Calculation: the type of computations possible with electronic

analog devices is still limited.

3.

Digital Implementation: the transmission medium is still electron,

but the signals are transmitted as binary numbers. Such digital signals
are far less sensitive to noise. The computational devices are digital
computers. Digital computers are more flexible because they are
programmable. They are more versatile because there is virtually no
limitation to the complexity of the computations it can carry out.

4.

Many field sensors naturally produce analog voltage or current

signals. For this reason transducers that convert analog signals to digital
signals (A/D) and vice verse (D/A) are used as interface between the
analog and digital elements of the modern control system. With the
development of digital implementation systems, which DCS are based
on, it is possible to implement many sophisticated control strategies on a
very fast timescale.

13

2.5 Modes of Computer control

Computer control is usually carried out in two modes: supervisory

control or direct digital control. Both are shown in Figure 1. Supervisory
control involves resetting the set point for a local controller according to
some computer calculation. Direct digital control, by contrast, requires that
all control actions be carried out by the digital computer. Both modes are in
wide use in industrial applications, and both allow incorporating modern
control technologies. Measurements are transmitted to computer and
control signals are sent from computer to control valves at specific time
interval known as sampling time. The latter should be chosen with care.

Fig 2.3 Computer control nodes.

14

2.6 Computer Control Networks

The computer control network performs a wide variety of tasks: data
acquisition, servicing of video display units in various laboratories and
control rooms, data logging from analytical laboratories, control of plant
processes or pilot plant, etc. The computer network can be as simple as an
array of inexpensive PC's or it could be a large commercial distributed
control system (DCS).

Small Computer Network

In small processes such as laboratory prototype or pilot plants, the
number of control loops is relatively small. An inexpensive and
straightforward way to deal with the systems is to configure a network of
personal computers for data acquisition and control. An example
configuration of a PC network control system is depicted in Figure 2. The
network consists of a main computer linked directly to the process in twoway channels. Other local computers are linked to the main computer and
are also connected to the process through one-way or two-way links. Some
of these local computers can be interconnected. Each of the local
computers has a video display and a specific function. For example, some
local computers are dedicated for data acquisition only, some for local
control only and some other for both data acquisition and local control. The
main computer could have a multiple displays.

All computers operate with a multitasking operating system. They

would be normally configured with local memory, local disk storage, and
often have shared disk storage with a server.
15

Figure 2.4 PC network

Programmable Logic Controllers

Programmable logic controller (PLC) is another type of digital
technology used in process control. It is exclusively specialized for noncontinuous systems such as batch processes or that contains equipment or
control elements that operate discontinuously. It can also be used for many
instants where interlocks are required; for example, a flow control loop
cannot be actuated unless a pump has been turned on

The PLC concept is based on designing a sequence of logical

decisions to implement the control for the above mentioned cases. Such a
system uses a special purpose computer called programmable logic
controllers because the computer is programmed to execute the desired
Boolean logic and to implement the desired sequencing. In this case, the
inputs to the computer are a set of relay contacts representing the state of
various process elements. Various operator inputs are also provided. The

16

outputs from the computer are a set of relays energized (activated) by the
computer that can turn a pump on or off, activate lights on a display panel,
operate solenoid valve, and so on.PLCs can handle thousands of digital I/O
and hundreds of analog I/O and continuous PID control. PLC has many
features besides the digital system capabilities. However, PLC lacks the
flexibility for expansion and reconfiguration. The operator interface in PLC
systems is also limited. Moreover, programming PLC by a higher-level
languages and/or capability of implementing advanced control algorithms
is also limited.

PLCs are not typical in a traditional process plant, but there some
operations, such as sequencing, and interlock operations, that can use the
powerful capabilities of a PLC. They are also quite frequently a costeffective alternative to DCSs (discussed next) where sophisticated process
control strategies are not needed. Nevertheless, PLCs and DCSs can be
combined in a hybrid system where PLC connected through link to a
controller, or connected directly to network.

Commercial Distributed Control Systems

In more complex pilot plants and full-scale plants, the control loops
are of the order of hundreds. For such large processes, the commercial
distributed control system is more appropriate. There are many vendors
who provide these DCS systems such as Baily, Foxboro, Honeywell,
Rosemont, Yokogawa, etc. In the following only an overview of the role of
DCS is outlined.Conceptually, the DCS is similar to the simple PC
network. However, there are some differences. First, the hardware and
software of the DCS is made more flexible, i.e. easy to modify and

17

configure, and to be able to handle a large number of loops. Secondly, the

modern DCS are equipped with optimization, high-performance modelbuilding and control software as options. Therefore, an imaginative
engineer who has theoretical background on modern control systems can
quickly configure the DCS network to implement high performance
controllers.

A schematic of the DCS network is shown in figure 3. Basically,

various parts of the plant processes and several parts of the DCS network
elements are connected to each others via the data highway (fieldbus).. A
large number of local data acquisition, video display and computers can be
found distributed around the plant. They all communicate to each others
through the data highway. These distributed elements may vary in their
responsibilities. For example, those closest to the process handle high raw
data traffic to the local computers while those farther away from the
process deal only with processed data but for a wider audience.

The data highway is thus the backbone for the DCS system. It
provides information to the multi-displays on various operator control
panels sends new data and retrieve historical data from archival storage,
and serves as a data link between the main control computer and other parts
of the network.On the top of the hierarchy, a supervisory (host) computer is
set. The host computer is responsible for performing many higher level
functions. These could include optimization of the process operation over
varying time horizons (days, weeks, or months), carrying out special
control.

18

Fig 2.5.The elements of a commercial distributed control system

A DCS is then a powerful tool for any large commercial plant. The
engineer or operator can immediately utilize such a system to: Access a
large amount of current information from the data highway.
See trends of past process conditions by calling
archival data storage.
Alternate quickly among standard control strategies
and readjust controller parameters in software.
A sight full engineer can use the flexibility of the
framework to implement his latest controller design
ideas on the host computer or on the main control
computer.
19

In the common DCS architecture, the microcomputer attached to the

process are known as front-end computers and are usually less
sophisticated equipment employed for low level functions. Typically such
equipment would acquire process data from the measuring devices and
convert them to standard engineering units. The results at this level are
passed upward to the larger computers that are responsible for more
complex operations..

2.7 Description of the DCS elements

The typical DCS system shown in Figure 3 can consists of one or
more of the following elements:
Local Control Unit (LCU). This is denoted as local
computer in Figure 3. This unit can handle 8 to 16
individual PID loops, with 16 to 32 analog input lines, 8 to
16 analog output signals and some a limited number of
digital inputs and outputs.
Data Acquisition Unit. This unit may contain 2 to 16 times
as many analog input/output channels as the LCU. Digital
(discrete) and analog I/O can be handled. Typically, no
control functions are available.
Batch Sequencing Unit. Typically, this unit contains a
number of external events, timing counters, arbitrary
function generators, and internal logic.
Local Display. This device usually provides analog display
stations, analog trend recorder, and sometime video display
for readout.

20

 Bulk Memory Unit. This unit is used to store and recall process
data. Usually mass storage disks or magnetic tape are used
General Purpose Computer. This unit is programmed by a
customer or third party to perform sophisticated functions such as
optimization, advance control, expert system, etc.
Central Operator Display. This unit typically will contain
one or more consoles for operator communication with the
system, and multiple video color graphics display units.
Data Highway. A serial digital data transmission link
connecting all other components in the system may consist
of coaxial cable. Most commercial DCS allow for
redundant data highway to reduce the risk of data loss.
Local area Network (LAN). Many manufacturers supply a
port device to allow connection to remote devices through
a standard local area network.

2.8 The control loop

The control loop remains the same as the conventional feedback
control loop, but with the addition of some digital components. Figure 4
shows a typical single direct digital control-loop. Digital computer is used
to take care of all control calculations. Since the computer is a digital
(binary) machine and the information coming out of the process in an
analog for, they had to be digitized before entering the computer. Similarly
the commands issued by the computer are in binary, they should be
converted to analog (continuous) signals before implemented on the final
control element. This is the philosophy behind installing the A/D and D/A

21

converter on the control loop. Signal conditioning is used to remove noise

and smooth transmitted data. Amplifier can also be used to scale the
transmitted data if the signals gain is small Signal generators (transducer)
are used to convert the process measurements into analog signals. The most
common analog signals used are 0-5 Volts and 4 -20mA. Some of the
process variables are represented in millivolts such as those form
thermocouples, strain gauges, pH meters, etc. Multiplexers are often used
to switch selectively a number of analog signals.All instrumentation
hardware (1-9) is designed, selected, installed and maintained by an
instrumentation engineer. The latter can either purchased from a
commercial vendor or developed in-house by a process/control engineer
(See section 7.3) . The terminal is the main operator interface with the
control system. The operator can use the terminal to monitor the control
performance, adjust the set points and tune the controller parameters

Fig 2.6 Component of a digital control loop

22

2.9 The basic units of a digital computer

The digital computer used in DCS systems is a regular
microcomputer with the simplified components shown in Figure 5. It
includes the arithmetic unit, which carry out arithmetic and logic
commands. The control unit is the part of the computer responsible for
reading program statements from memory, interpreting them, and causing
the appropriate action to take place. The memory unit is used for storing
data and programs. Typical computers have Random-Access-Memory
(RAM) and Read-Only-Memory (ROM). The final unit is the input/output
interface.
The I/O interface is necessary for the computer to communicate with
the external world. This interface is the most important in the control
implementation. The process information is fed to the computer through the
I/O interface and the commands made by the computer are sent to the final
control element through the I/O interface

Fig 2.7 A general purpose digital computer

23

In control application, the design of the I/O devices and interface is

an important part of the overall digital control philosophy. The following
subsections discuss some of these issues.

Information presentation and accuracy.

The modern digital computer is a binary machine. This means that
internal data and arithmetic and logic must be represented in binary format.
Therefore all process information flowing into and out of the computer
must also be converted to that form. Traditionally, the computer memory
location is made up of a collection of bits called a word (register). A typical
computer word consists of 16 bits (new computers carry 32-bits word).
Consider, for example, the following machine number:

In this case, analog process information should be first changed to

voltage or current as mentioned earlier. Then it is converted to digital form
by an electronic device called analog to digital converter (A/D). Similarly,
digital information is converted to analog form (Voltage or current) by a
digital to analog converter (D/A). The accuracy (resolution) of such
digitization process depends on the number of bits used to for
representation. The degree of resolution is given by:
Resolution = [full scale range] 2m11

where m is the number of bits in the representation. Obviously, higher

resolution can be obtained at higher number of bits. For example, consider
a sensor sends an analog signal between 0 and 1 volt and assume only a
three- bit computer word is available.

24

Assume now a 4-bit word is available for the same analog signal.
Then the full range will be divided over 15 points, i.e. sixteen equally
spaced values between 0 and 1 can be recognized, and the error in
resolution will be in the order of 1/30. Most current control-oriented ADC
and DAC utilize a 10 to 12 bit representation (resolution better than 0.1%).
Since most micro- and minicomputers utilize at least a 16-bit word, the
value of an analog variable can be stored in one memory word. New
computers are capable of using 32-bit word. Therefore, new generation of
ADC and DAC with higher resolution (up to 16 to 20 bit) are emerging.

Process interface
A typical plant with large number of variables contains abundance of
process information (data). Therefore, process information can be classified
under several classes (groups). Then a specialized device can be used to
transfer all information of a specific class into and out of the computer.
This way designing different I/O interface for each I/O device to be
connected to the computer is avoided.
The digital input/output signals can be easily handled because the
match the computer representation format. The digital interface can be
designed to have multiple registers, each with the same number of bits as
the basic computer word. In this way a full word of 16-bit can represent 16
separate process binary variables and can be transmitted to the computer at
one time and stored. Each bit will determine the state of a specific process
input lie. For example, a state of 1 means the input is on and 0 means off or
vice verse.

25

Table : Categories of process information

Type

Example

1. Digital

Relay
Switch
Solenoid valve
Motor drive

2. Generalized digital

Laboratory instrument output

Alphanumerical displays

3. Pulse or pulse train

Turbine flow meter

Stepping motor
Thermocouple or strain gauge

4. Analog

(millivolt)
Process instrumentation (4 20 mA)
Other sensors (0 -5 Volt)

Hence, a 16-bit register can be used as interface device to transmit 4

digits of result because four-bits are necessary to represent one digit (0-9)
of binary coded decimal.
In the input pulse information case, a single register (interface
device) is designed for each input line. The register ordinarily consists of
pulse counter. The accumulated pulses over a specified length of time are
transferred to the computer in binary or BCD count. The output pulse
interface consists of a device to generate a continuous train of pulses
followed by a gate. The gate is turned on and off by the computer. The
analog input information must be digitized by ADC before fed to the
computer. Since the process has a large number of analog sensing devices,
a multiplexer is used to switch selectively among various analog signals.
26

The main purpose of a multiplexer is to avoid the necessity of using a single

ADC for each input line. The DAC devise performs the reverse operation. Each
analog output line from the computer has its own dedicated DAC. The DAC is
designed such that it holds (freeze) a previous output signal until another command
is issued by the computer.

Timing
The control computer must be able to keep track of time (real time) in order
to be able to initiate data acquisition operations and calculate control outputs or to
initiate supervisory optimization on a desired schedule. Hence, all control
computers will contain at least one hardware timing device. The so-called real-time
clock represents one technique. This device is nothing more than a pulse generator
that interrupts the computer on a periodic basis and identifies itself as interrupting
device.

Operator interface.
The operator interface is generally a terminal upon which the operator can
communicate with the system. Such terminals usually permit displaying graphical
information. Often these display consoles are color terminals for better visibility
and recognition of key variables. For example, the operator can type in requests for
information or displaying trends, changing controller parameters or set points,
adding new control loop, and so on.

2.10 Digital control software

To make the best use of a DCS system, an advance control strategy or
supervisory optimization can be incorporated in the main host computer. In the
past, computer control projects are written in assembly language, an extremely
27

tedious procedure. Nowadays most user software is written in higher-level

languages such as BASIC, FORTRAN, C etc. In many cases, the user is able to
utilize the template routines supplied by the vendor, and is required only to
duplicate these routines and interconnect them to fit his own application purposes.
Another way is to write his own complete control program and implement it.

Other software in the form of control-oriented programming languages is

supplied by the vendor of process control computers. A simpler approach for the
user is to utilize vendor-supplied firmware or software to avoid writing programs.
Currently, most DCS manufacturers develop their own advance control and
optimization software, which can included in the package as options. Similarly,
many control algorithm developers; (DMC, ASPEN, etc) design a special interface
to allow incorporating their own control programs into most of the commercial
DCS network.

2.11 HYBRID CONTROLLER (HC900)

The Honeywell HC900 Hybrid Controller is an advanced loop and logic
controller offering a modular design sized to satisfy the control and data
acquisition needs of a wide range of process equipment. When combined with the
optional, performance rich 1042 or 559 Operator Interfaces that fully integrate the

controller database, configuration and setup time is minimized. This powerful

combination together with Honeywell's performance proven control technology
provides users an ideal solution for process control.

28

2.11.1SPECIFICATION

Name

:- HC900 C30

Make

:- HoneyWell

Communication Protocol

:- Ethernet/RS 232

Analog input

:- 8 Channel universal type .

Analog output

:- 8 Channel (4-20mA).

Digital input

:- 16 Channel source.

Digital output

:- 16 Channel sink.

Supply

:- 24 VDC

Fig 2.8 Honeywell DCS HC900

29

2.12PNEUMATIC CYLINDERS
2.12.1 SPECIFICATION

Make

:- JANATICS

Type

:- Cylinder , Non- Magnetic.

Bore

:- 20mm.

Stroke

:- 125mm.

Pneumatic cylinders (sometimes known as air cylinders) are mechanical

devices which use the power of compressed gas to produce a force in a
reciprocating linear motion.

Fig 2.9Pneumatic Piston

30

Like hydraulic cylinders, something forces a piston to move in the desired

direction. The piston is a disc or cylinder, and the piston rod transfers the force it
develops to the object to be moved. Engineers sometimes prefer to use pneumatics
because they are quieter, cleaner, and do not require large amounts of space for
fluid storage.Because the operating fluid is a gas, leakage from a pneumatic
cylinder will not drip out and contaminate the surroundings, making pneumatics
more desirable where cleanliness is a requirement. For example, in the mechanical
puppets of the Disney Tiki Room, pneumatics are used to prevent fluid from
dripping onto people below the puppets.

2.13 SOLENIOD VALVES

A Valve is a device that regulates the flow of a air by opening, closing or
partially obstructing various passageways. Valves are technically pipefitting, but
are usually discussed as a separate category. In an open valve, fluid flows in a
direction from higher pressure to lower pressure.

OPERATING VALVES
Valves may be operated manually, either by a hand wheel, level or pedal.
Valves may also be automatic, driven by changes in pressure, temperature or flow.
These changes may act upon a diaphragm or a piston which in turn activates the
valve.
More complex control systems using valves requiring automatic control
based on an external input require an actuator. An actuator will stroke the valves
depending on its input and set-up, allowing the valve to be positioned accurately,

31

TYPES
Valves are quite diverse and may be classified into a number of basic types.
Valves may also be classified by how they are actuated:

Hydraulic

Pneumatic

Manual

Solenoid

Motor

PNEUMATIC VALVES
These valves are usually used in mild force operation to stand up to 10 to 15
bar pressure. Some special valves control the direction of the flow of air/gas and
act as a control unit for a system.

CONTROL VALVES
Directional control valves route the air to the desired actuator. They usually
consist of a spool inside a cast iron or steel housing. The spool slides to different
position in the housing, intersecting grooves and channels route the air based on
the spools positions. The spool has a central positions maintained with springs, in
this position the supply air is blocked, or returned to tank. Sliding the spool to one
side routes the pneumatic air to an actuator and provides a return path from the
actuator to tank. When the spool is moved to the opposite direction the supply and
return paths are switched.

32

Pressure relief valves are used in several places in pneumatic machinery; on

the return circuit to maintain a small amount of pressure for breaks, pilot lines, etc..
On pneumatic cylinders to prevent overloading and pneumatic line/seal . On the
pneumatic reservoir, to maintain small positive pressure, thereby excluding
moisture.

DOUBLE ACTING SOLENOID VALVE

The valve could be either hydraulic or pneumatic. There are two solenoid
used in this valve. When either solenoid is actuated, the valve is opened for one
directions air. With both solenoids off, the pistons is in the centre position there is
no air. When cylinders go to the centre or opposite position, there must be a way
for the fluid back of the position to drain out.

fig 2.10 5/2 Double coil solenoid valve

33

Fig 2.11 5/2 Double Coil Solenoid Valve Principle

2.13.1 Specification

Make

: JANATICS

Type Of Valve

: 5/2 Double Coil Valve

Operation Mode

: NC Mode

Inlet Port

:1

Outlet Port

:2

Exhaust Port

:2

2.14 Sensor
A sensor is a converter that measures a physical quantity and converts it into
a signal which can be read by an observer or by an instrument. Sensors are used in
everyday objects such as touch-sensitive elevator buttons and lamps which dim or
brighten by touching the base. There are also innumerable applications for sensors
of which most people are never aware.

34

Applications include cars, machines, aerospace, medicine, manufacturing

and robotics. A sensor is a device, which responds to an input quantity by
generating a functionally related output usually in the form of an electrical or
optical signal. A sensor's sensitivity indicates how much the sensor's output
changes when the measured quantity changes.

Is sensitive to the measured property only

Is insensitive to any other property likely to be encountered in its

application

Does not influence the measured property

Chemical Sensor
A chemical sensor is a self-contained analytical device that can provide
information about the chemical composition of its environment, that is, a liquid or
gas phase. The information is provided in the form of a measurable
physical signal that is correlated with the concentration of a certain chemical
species (termed as analytic). Two main steps are involved in the functioning of a
chemical sensor, namely, recognition and transduction. In the recognition step,
analytic molecules interact selectively with receptor molecules or sites include in
the structure of the recognition element of the sensor.

Biosensor
In Biomedicine And Biotechnology, Sensors Which Detect Analytes Thanks
To A Biological Component, Such As Cells, Protein, Nucleic Acid Or Biomimetic
Polymers, Are Called Biosensors.

35

Nanosensor
Nanosensors are any biological, chemical, or surgical sensory points used to
convey information about nanoparticles to the macroscopic world. Their use
mainly includes various medicinal purposes and as gateways to building other
nanoproducts, such as computer chips that work at the nanoscale and nanorobots.
Presently, there are several ways proposed to make nanosensors, including topdown lithography, bottom-up assembly, and molecular self-assembly
Limit Switch
A limit switch is a switch operated by the motion of a machine part or
presence of an object. They are used for control of a machine, as safety interlocks,
or to count objects passing a point.[1] A limit switch is an electromechanical device
that consists of an actuator mechanically linked to a set of contacts. When an
object comes into contact with the actuator, the device operates the contacts to
make or break an electrical connection. Limit switches are used in a variety of
applications and environments because of their ruggedness, ease of installation,
and reliability of operation. They can determine the presence or absence, passing,
positioning, and end of travel of an object. They were first used to define the limit
of travel of an object; hence the name Limit Switch.
A limit switch with a roller-lever operator; this is installed on a gate on a
canal lock, and indicates the position of a gate to a control system.Standardized
limit switches are industrial control components manufactured with a variety of

36

operator types, including lever, roller plunger, and whisker type. Limit switches
may be directly mechanically operated by the motion of the operating lever. A reed
switch may be used to indicate proximity of a magnet mounted on some moving
part. Proximity switches operate by the disturbance of an electromagnetic field, by
capacitance, or by sensing a magnetic field.
Rarely, a final operating device such as a lamp or solenoid valve will be
directly controlled by the contacts of an industrial limit switch, but more typically
the limit switch will be wired through a control relay, a motor contactor control
circuit, or as an input to a programmable logic controller.
Miniature snap-action switch may be used for example as components of
such devices as photocopiers or computer printers, to ensure internal components
are in the correct position for operation and to prevent operation when access doors
are opened. A set of adjustable limit switches are installed on a garage door opener
to shut off the motor when the door has reached the fully raised or fully lowered
position

Proximity Sensors
A proximity switch is also like a limit switch, but it is not mechanical. It
could be either magnetic or infrared etc. A proximity sensor is a sensor able to
detect the pressure of presence of nearby objects without any physical contact. A
proximity sensor often emits an electromagnetic radiation and looks for changes in
the field or return signal. The object being sensed is often referred to as the
proximity sensors target.

37

Types
A electrical capacitance proximity sensor converts a variation in
electrostatics capacitance between an detecting electrode and ground electrode
caused by approaching the nearby object into the variation in an oscillation
frequency, transforms or laniaries the oscillation frequency into a direct current
voltage and compares the direct current voltage with predetermined threshold
value to detect the nearby object. The maximum distance that this sensor can detect
is defined nominal range.Different proximity sensor targets demand different
sensors. A capacitive or photoelectric sensor might be suitable for a plastic target.
Proximity sensor are used in various facts of manufacturing for detecting the
approach of metal objects. Depending on the principle of operation, each type of
sensor will have different performance level for different types of objects.

Inductive Proximity Sensor

Fig 2.12 Working principle of Inductive Proximity sensor

38

Fig 2.13 Inductive type Proximity Sensor (PNP)

2.14.1 Specification

Make

: Magnum

Type

: Inductive Type (PNP)

Operation mode

: No Mode

Sensing distance

: 8mm

Diameter

: 8mm

Supply voltage

: 24vdc

An inductive proximity sensor requires a metal target. Inductive proximity

sensors have a lossy resonant circuit at the input side whose loss resistance can be

39

change by the proximity of an electrically conductive medium. Proximity sensors

often are employed in manufacturing industries in which the sensors are exposed
to harsh environmental conditions. Inductive proximity sensors are used in
automation engineering to defined operating states in automating plants,
production systems and process engineering plants.

2.15 Relay Board

2.15.1 The Electromagnetic Relay
The electromagnetic relay consists of a multi-turn coil, wound on an iron
core, to form an electromagnet. When the coil is energized by passing current
through it, the core becomes temporarily magnetized. The magnetized core attracts
the iron armature. The armature is pivoted which causes it to operate one or more
sets of contacts. When the coil is de-energized the armature and contacts are
released.

Fig 2.14 Electromagnetic Relay

The coil can be energized from a low power source such as a transistor while
the contacts can switch high powers such as the mains supply. The relay can also

40

be situated remotely from the control source. Relays can generate a very
high voltage across the coil when switched off. This can damage other components
in the circuit. To prevent this diode is connected across the coil. The cathode of the
diode is connected to the most positive end of the coil.

Fig 2.15 Relay Principle

The spring sets can be a mixture of NO ,NC and CO. Look at the page on
switches to see how they can be used in circuits. Various coil operating voltages
(ac and dc) are available. The actual contact points on the spring sets are available
for high current and low current operation. The REED RELAY has a much faster
operation than the relays described above.

Fig 2.16 Relay Board

41

2.15.2 Specification

Relay Board-Make

: ConnectWell

Relay-Make

: OMRON

Coil

: 24VDC 500mA

Contact

: 2 change over

Terminals

: 2 common
2 normally close
2 normally open

Relays are usually SPDT or DPDT but they can have many more sets of
switch contacts, for example relays with 4 sets of changeover contacts are readily
available.

42

CHAPTER 3
INTERFACING AND DESIGN ORENTIATION
3.1 Communications Remote I/O Rack Port (C50, C70, C75)
An Ethernet port is dedicated to supporting remote I/O racks. This
10/100Base-T Connection on the C50 and C70 CPU supports a single direct
connected remote rack or up to 4 remote racks when connected through an external
Ethernet switch. The C75 CPU supports a single direct connected rack orup to 5
remote racks using external switches.

3.2 User Interface Support

The 900 Control Station interface may be connected via Ethernet or serial
communications. Up to three interfaces may be connected to a controller for
distances up to 328 feet (100Meters) via Ethernet or 2000 feet (609 meters)
between the controller and operator interface. 3rd party user Interface support is
provided through an isolated RS485 port connection using Modbus/RTU protocol,
or Ethernet with Modbus/TCP protocol.

3.3 Ethernet Modbus/TCP Communications

HC900 controllers communicate with their host PC interfaces over an
Ethernet 10/100Base-T communication network using the Modbus/TCP protocol,
an open protocol interface available for most popular HMI software packages. The
controllers Ethernet ports are MDIX and configured to auto negotiate and will
default to half duplex if host fails to negotiate. The C30 supports up to 5 host

43

connections while the C50/C70/C75 support up to 10 concurrent host connections

over an Ethernet network for control supervision and data acquisition.
The Designer software can also address any of the controllers concurrently
over Ethernet for configuration monitoring, diagnostic interrogation, upload/
download, or on-line configuration changes. As a result, a HC900 network of
controllers and operator interfaces can be partitioned into process segments to
assure proper control performance. Each of these process segments, in turn, can be
accessed via common HMI software within the plant environment using an
Ethernet LAN.

3.4 Ethernet Peer to Peer Communications

Peer data communications between one HC900 controller and up to 32 other
HC900 controllers is supported over Ethernet via UDP protocol for process
interlocks or data sharing. Both digital and analog data exchange are supported
using peer data exchange function blocks, up to 2240 parameters between peer
controllers. No specialized software is required. Peer data can be given signal tag
references for use in a control or data acquisition strategy. Peer to peer data
interchange does not consume one of the host connection.

3.5 Serial Modbus RTU Communications

Serial Modbus RTU communications is available on the isolated RS485 (2
wire) ports of the HC900 Controller CPU assembly in a Master or Slave mode. The
protocol of these ports is user selectable between ELN protocol for use with HC
Designer software or Serial Modbus to interface with other compatible devices
.

44

Modbus RTU Slave- Isolated RS485 ports may be configured for

simultaneous operation as a Modbus slave port to allow each to communicate with
a single Modbus master.
The Modbus protocol supports read and write access to a default address
map of certain function blocks and parameters. In configurations 4.0 and later, a
map of customized addresses, blocks and parameters can be created either by
editing the default map or from scratch. In the default map (fixed), a 4000 register
array is available to allow the user to specify the address locations of specific
controller data to optimize controller communications.

The data in the array may also be accessed in user specified formats (data
types) such as analog data in Float 32, unsigned 16, signed 16, unsigned 32, signed
32, and digital data in signed 16 or unsigned 16. The data type selections in the
4000 register array provide compatibility with devices such as 3rd party touch
panels. In the custom map, all data formats are adjustable. Modbus RTU MasterEither of the ports may be configured as a Modbus RTU master, one per controller.
Up to 32 devices may be multi-dropped on the isolated RS485 port.

Function blocks are available in the HC900 controller to allow the user to
specify read and write operations to up to 32 external Modbus compatible slave
devices and up to 1024 data points. Modbus TCP Initiator The Ethernet ports may
be configured as a Modbus TCP initiator. Function blocks are available in the
HC900 controller to allow the user to specify read and write operations to
compatible slave devices for up to 1024 data points

45

3.6 Design Orientation

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 or other
commercial hardware modules.

SCADA systems are used not only in most industrial processes: e.g. steel
making, power generation (conventional and nuclear) and distribution, chemistry,
but also in some experimental facilities such as nuclear fusion. SCADA systems
used to run on DCS, VMS and UNIX.

SCADA systems are widely used in industry for Supervisory Control and
Data Acquisition of industrial processes. 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.
Scalability is understood as the possibility to extend the SCADA based control
system by adding more process variables, more specialized servers (e.g. for alarm
handling) or more clients. The products achieve scalability by having multiple data
servers connected to multiple controllers. Each data server has its own
configuration database and RTDB and is responsible for the handling of a subset of
the process variables (acquisition, alarm handling, archiving).

46

3.7 SCADA Concepts

The term SCADA usually refers to centralized systems which monitor and
control entire sites, or complexes of systems spread out over large areas(anything
from an industrial plant to a nation). Host control functions are usually restricted to
basic overriding or supervisory level intervention.
For example, a DCS may control the flow of cooling water through part of
an industrial process, but the SCADA system may allow operators to change the
set points for the flow, and enable alarm conditions, such as loss of flow and high
temperature, to be displayed and recorded. The feedback control loop passes
through the RTU or DCS, while the SCADA system monitors the overall
performance of the loop.
SCADA systems typically implement a distributed database, commonly
referred to as a tag database, which contains data elements called tags or points. A
point represents a single input or output value monitored or controlled by the
system. Points can be either hard or soft. A hard point represents an actual
input or output within the system, while a soft points results from logic and math
operations applied to other points SCADA systems are significantly important
systems used in national infrastructures such as electric grids, water supplies and
pipelines. However, SCADA systems have many security vulnerabilities.

3.7.1 Human Machine Interface

A 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. HMI is usually linked to the SCADA systems databases and software

47

programs, to provide trending, diagnostic data, and management information such

as scheduled maintenance procedures, logistic information, detailed schematics for
a particular sensor the field, or as complex as a multi-projector display representing
the position of all of the elevators in a skyscraper or all of the trains on a railway.or
machine, and expert-system troubleshooting guides.The HMI package for the
SCADA system typically includes a drawing program that the operators or system
maintenance personnel use to change the waythese points are represented in the
interface. These representations can be as simple as an on-screen traffic light,
which represents the state of an actual traffic light in

SCADA Architecture

Fig 3.1 Architecture of SCADA

48

3.7..1 Specifications

Software

: Wonderware InTouch Ver. 10.0

Manufacturer

: Invensys

Programming Language : Graphical Representation

Communication Protocol : RS 232 comm.
I/O Server

: MODBus I/O Server

3.8 Generation
First Generation: Monolithic
In the first generation, computing was done by mainframe computers.
Networks 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 the 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 the primary mainframe system. Some first generation SCADA systems
were developed as turn key operations that ran on minicomputers like the PDP11 series. These systems were read only in the sense that they could display
information from the existing analog based control systems to individual operator
workstations but they usually didnt attempt to send control signals to remote

49

stations due to analog based telemetry issues and control center management
concerns with allowing direct control from computer workstations. They would
also perform alarming and logging functions and calculate hourly and daily system
commodity accounting function

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 knew enough to determine how secure
a SCADA installation was. Since both parties had vested interests in keeping
security issues quiet, the security of a SCADA installation was often badly over
estimated, if it was considered at all.

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 attack. On the other hand, the usage of standard protocols and
security techniques means that standard security improvements are applicable to
the SCADA systems, assuming they receive timely maintenance and updated.

50

CHAPTER 4
DESIGN AND SIMULATION

Fig 4.1 DCS -functional block diagram 1

51

Fig 4.2 DCS -functional block diagram 2

52

Fig 4.3 DCS -functional block diagram 3

53

Fig 4.4 SCADA design

54

CHAPTER 5
CONCLUSION

The automation of monitoring enables in continuous monitoring of flied

operations reduces response time drastically. This process also increases the
quality of output with minimal of cost. Automation ensures the reliability & life
time of the instruments. This continuous monitoring system can be implanted in
various industrial environments where the continuous monitoring is necessary but
it is hard. The automation also results in increase in productivity and net profit of
the process.

Future Enhancement
Artificial intelligence can be used so that the controller will control the
combustion process with the help of flied signals. Usage of artificial intelligence
are under development stage which will result minimal of human intervene with
high output efficiency of the process.

55

REFERENCE

1) Wireless Ad-Hoc Networks For Industrial Automation: Current Trends And

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