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PLC based process control automation using GSM and SCADA technology
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ISSN: 0975-766X
CODEN: IJPTFI
Available Online through Research Article
www.ijptonline.com
PLC BASED PROCESS CONTROL AUTOMATION USING GSM AND SCADA
TECHNOLOGY
1
V.Amala Rani, 2 S.Aaron James, 3J.Adeline Sneha, 4 Bestley Joe S
1
Assistant Professor, Department of Electronics and Instrumentation, Sathyabama University, Chennai.
2
Assistant Professor, Department of Electronics and Instrumentation, Sathyabama University, Chennai.
3
Assistant Professor, Department of Electronics and Instrumentation, Sathyabama University, Chennai.
4
Assistant Professor, Department of Electronics and Instrumentation, Sathyabama University, Chennai.
E-mail: 1v.amalarani@gmail.com,2aaronjameszion@yahoo.com,3j.adelinesneha@gmail.com,4bestleyjoe@gmail.com
Abstract
There has been an important and necessity for safety measures which has always been stressed upon us, especially in,
Industries. Process control industries comprise numerous SPM (Specials Purpose Machines) boilers& furnaces etc.
Therefore every parameter measured and controlled in those industries are abundantly vital. If one thing went wide of
the mark certainly there would be an enormous loss in price. For that reason it’s necessary to provide a safety and
security conditions in all furnace application. This paper stress that many parameters such as pressure, humidity and
temperature are controlled using by PLC-(Programmable Logic Controller), analyzed through SCADA and additionally
the total mechanism comes to a power of machine-in-charge by the help of GSM Modem. In this way, huge losses in the
process control fields could be avoided and attaining the maximum accuracy in the process could also be maintained. As
a result of all this process, the head controller could be able to make the essential or the necessary steps to sustain the
field from any hazardous situation by receiving an message with the help of GSM.
1. Introduction
This paper involves in control and monitoring the process taking place in industries. Herein, the most significant task is
done by GSM modem. The hardware components are interconnected together and simulated through SCADA software.
In this process, certain parameters like temperature, pressure and humidity are controlled and also its effects can be seen
on SCADA software. If any of the parameters like (pressure, temperature, humidity) fall below the respective set point
of GSM modem. Based on the information, the head could consult with the supervisor for future change in the process.
This provides safety measures for the process control industries like petroleum, oil and gas etc under any hazardous
conditions. Safety is always been an important concern in any type of industries. Thus the safety sector is quite
improved by clubbing the GSM Into PLC through a communication protocol. To begin with the PLC, it is just a device
which controls the output signals based on the input signals and a ladder logic program which is being programmed.
Initially there would be a supervisor to monitor and control the entire process via his “PC” through a driver software
been linked up to a PLC and that software is called SCADA, The SCADA(supervisory control and data acquisition) is
being linked with the PLC through the driver software. This software can be installed in the supervisor’s PC and it is
used to interlink the SCADA and PLC altogether. In SCADA the entire process is being supervised and controlled
virtually by the supervisor. Then there is another important modem being connected in our process which is called GSM
2. Existing System
In the prevailing process the entire process has been controlled and monitored by the supervisor. He gets the visual
output of the entire process virtually via the software SCADA. The complete process is been also programmed via PLC
software by ladder diagram format. The whole program would be in the form of ladder diagram. In this system only the
supervisor could monitor and control the entire application..In case of any abnormality is detected the supervisor alone
could observe and control the process. The disadvantage of this method is that it needs manual amount of labor to
3. Proposed System
The virtual display of the entire process is being shown in the software of SCADA. In this, the supervisor controls and
monitors the process, if any abnormality is detected; the GSM updates the abnormality process to the head of the
supervisor. The GSM main function is to update the head of the supervisor in any abnormality condition.
The head of the supervisor turn could know the true statuses of the process.The advantage of the system are the
supervisor as well as the head of the supervisor could control the process and the whole process feedback would be
known.
Right Margin
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The inputs for the parameters are sent through the variator and this gives the value for the process. The input module
acts as an isolation barrier for having a smooth flow and not to affect the PLC devices. PLC gets the input from the input
module unit and controls the process. SCADA monitors and supervises the functions in the process. The whole process
status is send through the GSM MODEM to the head personal as a message in the form of SMS. The head personnel of
the supervisor would be able to make change if necessary by replying (command) the SMS. The GSM receives the
status from the head of the supervisor and this status is given to the PLC and in turn it controls the system. The major
materials used in the system are DELTA PLC DVP 14SS (Programmable Logic Controller), ASTRA .SCADA
(Supervisory Control and Data Acquisition), GSM SIM 300_V7.03 (Global System for Mobile Communication), SMPS
In this type of PLC there are normally 8 type of input and 8 type of output. The PLC’s output depends upon the input of
the PLC. The delta PLC (programmable logic controller’s) are also referred as programmable controller, and also in the
family of computer .The delta PLC are used in the commercial purposes and industrial application and moreover the
delta PLC act’s as a controllers in our process. They monitor the inputs and make decision with respect to the input and
control the output in order to automate machines and process. The output of the delta PLC generally depends upon the
input of the PLC. The output is activated by the decision based on the status of the system’s feed-back sensors and these
An industrial measurement and control system comprising of a central host or master terminal unit, remote terminal
units and a compilation of customary software used to observe and manage distantly located field data elements.
Modern SCADA systems demonstrate principally open-loop control characteristics and make use of long distance
communications, even though some elements of closed-loop control and short distance communications also be there
.Systems similar to SCADA systems are routinely seen in factories, treatment plants etc. They are regularly referred to
as Distributed Control Systems (DCS). They include related functions to SCADA systems, except the field data
gathering or control units are generally sited within a more confined area. Communications might be by the use of a
local area network (LAN), and normally be dependable and high rate. A DCS system generally employs important
amount of closed loop control. SCADA systems alternatively cover bigger geographic areas, and rely on a mixture of
communications systems that are normally less dependable than a LAN. Closed loop control in this situation is less
advantageous. SCADA is used to supervise and control plant or equipment. The control could be involuntary or initiated
by operator commands. The data acquisition is obtained by the RTU's scanning the field inputs connected to the RTU (it
may be also called a PLC - programmable logic controller). This is done at a fast rate. The central host would scan the
RTU's (usually at a slower rate.) The data is processed to sense alarm conditions, and if an alarm is there, it will be
First set PLC,Rs232 communication for GSM modem. And set the GSM Modem for Text mode.Initialize the GSM
This diagram shows the output page of our project by ASTRA SCADA software. At first we need to select the start
button to start the process. Next the variators can be adjusted for required status. The changes happened in the variator is
shown in the ASTRA SCADA. We can able to see the three parameters used in this project. Three parameters has three
different status conditions i.e low, normal, high. If any of the parameter is changed the status is immediately shown in
the result page. In addition to that a warning sms will also be sent to the predefined mobile number.
5. GSM Output
This report shows the complete working of PLC based process control automation using GSM and SCADA technology.
The various hardware and software used in this project is thoroughly seen along with their working principle. In this
paper we have effectively completed the GSM based process control automation using SCADA.
Thus in the end of the process the supervisor could see the visual output of the process via SCADA and he could in-turn
control the process similarly the head person of the process could get the output of the process in irregularity condition.
Thus the whole project has been executed successfully and the desired result has been obtained through the end of the
process.
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Corresponding Author:
S.Aaron James*,
Email: aaronjameszion@yahoo.com