Advantages of Automation:
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Disadvantages of Automation:
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2 Programmable Logic Controller
A programmable logic controller, PLC is a digital computer used for
automation of typically industrial electromechanical processes, such as control
of machinery on factory assembly lines etc. It is a solid state user
programmable control system with functions to control logic, sequencing,
timing, arithmetic data manipulation and counting capabilities. It can be
viewed as an industrial computer that has a central processor unit, memory,
input output interface and a programming device. The central processing unit
provides the intelligence of the controller. It accepts data, status information
from various sensing devices like limit switches, proximity switches, executes
the user control program stored in the memory and gives appropriate output
commands to devices such as solenoid valves, switches etc.
A constant demand for better and more efficient manufacturing and
process machinery has led to the requirement for higher quality and reliability
in control techniques. With the availability of intelligent, compact solid state
electronic devices, it has been possible to provide control systems that can
reduce maintenance, down time and improve productivity to a great extend.
One of the latest techniques in solid state controls that offers flexible and
efficient operation to the user is programmable controllers.
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2.2 History of PLCS
1. The first PLCS were designed and developed by Modicon as a relay re-
placer for GM and Landis.
2. The primary reason for designing such a device was eliminating the
large cost involved in replacing the complicated relay based machine
control systems for major U.S. car manufacturers.
3. These controllers eliminated the need of rewiring and adding additional
hardware for every new configuration of logic.
4. The first PLC, model 084, was invented by Dick Morley in 1969.
5. The first commercial successful PLC, the 184, was introduced in 1973
and was designed by Michel Greenberg.
3. Timers - These come in many varieties and increments. The most com-mon
type is an on-delay type. Others include off-delay and both retentive and non-
retentive types. Increments vary from 1 millisecond to 1 second.
Output Relays (coils) - These are connected to the outside world. They physically
exist and send on/off signals to solenoids, lights, etc. They can be transistors, relays
depending upon the model chosen.
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5. Data Storage - Typically there are registers assigned to simply store
data. They are usually used as temporary storage for math or data
manipulation. They can also typically be used to store data when power
is removed from the PLC. Upon power-up they will still have the same
contents as before power was removed
1. Input Scan: Detects the state of all input devices that are connected to
the PLC.
2. Program Scan: Executes the user created program logic.
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SCAN TIME: Time taken by PLC to execute these three steps (Checking
Input status, Executing Program, Updating Output Status) is denoted by its
scan time.
1. If Input1 is ON (or true) - power (logic) completes the circuit from the
left rail to the right rail - and Output1 turns ON (or true).
2. If Input1 is OFF (or false) - then the circuit is not completed and logic
does not flow to the right - and Output 1 is OFF (or false).
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This can be used to represent any input to the control logic such as a switch or
sensor, a contact from an output, or an internal output. When solved the
referenced input is examined for a true (logical 1) condition. If it is true, the
contact will close and allow logic to flow from left to right. If the status is
FALSE (logical 0), the contact is open and logic will NOT flow from left to
right.
Output energize
This can be used to represent any discrete output from the control logic.
When ”solved” if the logic to the left of the coil is TRUE, the referenced
output is TRUE (logical 1).
Examine if open
When solved the referenced input is examined for an OFF condition. If the
status is OFF (logical 0) power (logic) will flow from left to right. If the status
is ON, power will not flow.
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3 SCADA
3.1 Introduction
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
hard-ware to which it is interfaced, in general via PLC. SCADA systems are
now also penetrating the experimental physics laboratories for the controls of
ancillary systems such as cooling, ventilation, power distribution, etc. More
recently they were also applied for the controls of smaller size particle
detectors such as the L3 moon detector and the NA48 experiment, to name
just two examples at CERN.
SCADA systems have made substantial progress over the recent years in
terms of functionality, scalability, performance and openness such that they
are an alternative to in house development even for very demanding and
complex control systems as those of physics experiments.
The process can be industrial, infrastructure or facility based as described
below:
3.2 WONDERWARE-INTOUCH
InTouch is worlds leading supervisory control and data acquisition software.
The InTouch software package consist of Tags (Memory + I/O). The package
is available in 64, 256, 1000 and 64,000 Tags with the three options:
3. Factory focus
With DRN package one can develop as well as run the application but in case
of RN one cannot develop/modify the application. The application can be
developed by using DRN package and can be installed on RN package.
2. Siemens: win cc
3. Wonderware : Intouch
2. Alarm summary
3. Alarm history
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4. Real time trend
8. Device connectivity
9. Scripts
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3.4.2 Real-time and Historical Trends
2. Typically the trends plots the value with reference to the time.
3. Real-time data will plot the real-time value fixed period of time while
historical data stored value which can be viewed on demand.
4. Depending upon the storing capacity of the hard-disk on can specify the
no of days the data can be stored .
5. Some SCADA software show real-time and historical trends in single
graphics while few others use separate tools.
3.4.3 Alarms
1. Every plant need proper monitoring and control of the process parame-
ters.
2. Alarms represent warnings of process conditions that could cause prob-
lems, and require an operator response.
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3. Generally alarms are implemented by using the lamps or hooters in field
but in SCADA it can be represented using animation.
4. In many SCADA software, four type of alarm limits are used ie HI,
HIHI, LOW, LOW LOW.
1. In many case we use the same plant for manufacturing different prod-
uct range. for example an oil blending plant can manufacture power oil,
transformer oil, automobile oil.
2. The recipe management is facility is used to maintain various recipes of
different products and implement it on the process.
3. The recipe can be stored in a single server and it can be fetched by any
client server from any area to run the process.
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Figure 11: Schematic of Recipe management
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3.4.5 Security
1. Every SCADA Software has various levels of security for securing the
application by avoiding unauthorized access.
2. Depending upon the access level given the operator / engineers is
allowed to do the task. In the most of the case, operators are allowed
only to operate the plant while maintenance engineers can do the
application modifications.
3. The security can be given for individuals as well as for groups.
3.4.8 Scripts
1. Script is a way of writing logic in SCADA software, every SCADA
soft-ware has its own instruction and way of writing program.
2. Use scripts, one can develop complex applications. You can create your
own functions to suit the requirement. execution.
3. Various types of scripts make project execution simpler for
programmer.
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2. Water and sewage: State and municipal water utilities use SCADA to
monitor and regulate water flow, reservoir levels, pipe pressure and
other factors. Industrial Processes such as Manufacturing.
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4 Project Using PLC: Glowing of four LED using
START, STOP and SELECTOR Switches
As specified in the objective there are four conditions under which LEDs
of different colors will glow. Once the STOP button is button is pressed the
process will stop. This whole idea is implemented in the ladder logic.
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4.4 Programming:
1. Figure with explanation
Rung 0000:
(a) The input XIC I:0/1 (START switch) is connected with XIC
C5:0/DN, XIO I:0/2 (STOP switch), XIO C5:1/DN, XIO
C5:2/DN,XIO C5:3/DN and the binary output B3:0/0.
(b) Except C5:0/DN all the DN bits are XIO because the condition 1 is
checked where except C5:0/DN none of the DN bits should be
high.
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Figure 17: B3:0/0 is high and Red LED glows
(a) B3:0/0 is connected as input to the output O:0/0. The output O:0/0
indicates the red LED.
(b) As soon as the B3:0/0 goes HIGH the output O:0/0 is energized.
Hence the output red LED glows.
3. Figure with explanation
Rung 0003:
(a) The input XIC I:0/1 (START switch) is connected with XIC
C5:0/DN, XIO I:0/2 (STOP switch), XIC C5:1/DN, XIO
C5:2/DN,XIO C5:3/DN and the binary output B3:0/0.
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Figure 18: B3:0/1 is high and Green LED glows
(b) Except C5:0/DN and C5:1/DN all the DN bits are XIO because
here condition 2 is checked where except C5:0/DN and C5:1/DN
none of the DN bits should be high.
(c) The output B3:0/1 is connected as input parallel to I:0/1 to make a
holding circuit, so that even if the START button is released
B3:0/1 remains high.
(d) When the SELECTOR switch is pressed twice, the accumulator
value of all the counters becomes 2. The C5:0/DN and C5:1/DN
becomes HIGH.
(e) When the START switch is pressed then all the inputs in the rung
0003 are HIGH, therefore, the output B3:0/1 will be energized i.e.
it goes HIGH.
(f) Since, XIC C5:1/DN is now HIGH , therefore, XIO C5:1/DN in
rung 0001 goes LOW, therefore, B3:0/0 goes LOW and hence the
red LED stops glowing.
Rung 0004:
(a) B3:0/1 is connected as input to the output O:0/1. The output O:0/1
indicates the green LED.
(b) As soon as the B3:0/1goes HIGH the output O:0/1 is energized.
Hence the output green LED glows.
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4. Figure with explanation
Rung 0005:
(a) The input XIC I:0/1 (START switch) is connected with XIC
C5:0/DN, XIO I:0/2 (STOP switch), XIC C5:1/DN, XIC
C5:2/DN,XIO C5:3/DN and the binary output B3:0/2.
(b) Except C5:3/DN all the DN bits are XIC because here condition 3
is checked where C5:0/DN ,C5:1/DN and C5:2/DN bits should be
high.
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Rung 0006:
(a) B3:0/2 is connected as input to the output O:0/2. The output O:0/2
indicates the yellow LED.
(b) As soon as the B3:0/2goes HIGH the output O:0/2 is energized.
Hence the output yellow LED glows.
Rung 0007:
(a) The input XIC I:0/1 (START switch) is connected with XIC
C5:0/DN, XIO I:0/2 (STOP switch), XIC C5:1/DN, XIC
C5:2/DN,XIC C5:3/DN and the binary output B3:0/2.
(b) All the DN bits are XIC because here condition 4 is checked where
all DN bits should be high.
(c) The output B3:0/3 is connected as input parallel to I:0/1 to make a
holding circuit, so that even if the START button is released
B3:0/3 remains high.
(d) When the SELECTOR switch is pressed four times, the accumula-
tor value of all the counters becomes 4. The C5:0/DN, C5:1/DN,
C5:2/DN and C5:3/DN becomes HIGH.
(e) When the START switch is pressed then all the inputs in the rung
0007 are HIGH, therefore, the output B3:0/3 will be energized i.e.
it goes HIGH.
(f) Since, XIC C5:3/DN is now HIGH, therefore, XIO C5:3/DN in
rung 0001, 0003 and 0005 goes LOW, therefore, the red, green and
yel-low LED stops glowing.
5. Figure with explanation
Rung 0008:
(a) B3:0/3 is connected as input to the output O:0/3. The output O:0/3
indicates the blue LED.
(b) As soon as the B3:0/3goes HIGH the output O:0/3 is energized.
Hence the output blue LED glows.
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Figure 20: Counters get Reset
4.5 Results
All the conditions mentioned in the objective are obtained
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5 Project Using SCADA: Sewage Water Treatment
1. Application Manager,
2. Window Maker
3. Window Viewer
5.4 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 re-
place, 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 ”Break
Cell” 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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Figure 21: Schematic of Object Properties
10. For our project we require tanks, pipes, valves, agitators etc. these
objects are picked up the symbol factory and other objects like
screening filter etc. are built by us using the basic shapes and some like
the oxygen bubbles and the sediments are picked by performing ”break
symbol” operation on various objects of general manufacturing option
(e.g. coal mining).
11. Next we place the objects as per the setup required for water treatment
and modify the objects property. For example, when water is to be
transferred from one tank to the other the source tank must be full
initially and the liquid level of the source tank should decrease steadily
and water level in the destination tank should increase steadily in the
destination tank.
12. For this we double click on the tank, select “vertical” under ”fill”
option. We give the tag name A and then specify the values of
maximum and minimum fill percentages along with the values of the
’A’.
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Figure 22: Window in development mode in Window maker
15. We see that we need to use duplicate of the tanks and rotators in case of
sedimentation and oxidation tank because a tank once filled cannot be
emptied and a rotator once rotated cannot be stopped. Hence their
duplicates are used keeping in mind their visibility.
16. Visibility is a property which is required when we want to use the same
properties of an object for more than once with different values of tag
name. In Intouch this is not allowed, therefore we make duplicate of the
object, then modify their properties and apply the visibility property.
24. Now, we test our project in window viewer. For this we click on ”Run-
time!” icon at the top right corner of the tool bar.
25. This option takes us to the run- time environment. As soon as Window
Viewer is started we see that it follows the instructions of ”On Show”
until the switch is turned on. As soon as the switch is turned on, it
follows the instructions of ”While Showing”.
27. We can change our script and properties of the various objects used in
Window Viewer but test its execution in Window Maker. The functions
of both are different.
28. The following snapshot shows the execution of the program:
(b) Oxygenation and chlorination of water in the chlorine tank after its
sedimentation
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Figure 25: Oxygenation and chlorination of water
(c) Chlorinated water is being passed through a filter and stored in an-
other tank for usage.
29. This process continues to execute repeatedly until the STOP switch is
turned on.
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5.5 Results
The design of ”Sewage Water Treatment System” is successfully
implemented in Intouch SCADA.
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6 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
the same “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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References
[1] Richard A. Cox, ”Technicians Guide to Programmable Controllers” , 4th
edition, Vikash Publishing House, New Delhi.
[2] J. R. Hackworth, F.D. Hackworth, ”Programmable Logic Controllers
Programming Methods and Applications” Pearson Education, New Delhi
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