Programmable Logic Controllers,

Industrial Field Buses and SCADA

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Significance of topic…
 Programmable Logic Controllers, Industrial
buses and SCADA are key areas for
Automation solutions.
 Solutions for factory automation, process
automation, safety applications, and the
entire range of drive technology are
available with PLC, SCADA and buses.

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…Significance of topic
 The current trend is Totally Integrated
Automation

 Totally Integrated Automation allows a perfect

interplay of all integrated automation components

 This presentation will focus on practical aspects of

PLCs, SCADA and Industrial buses

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Programmable Logic Controllers
 A Programmable Logic Controller [1] is a micro-
controller based device which is specifically designed to
operate in the industrial environment that can be rather
harsh.

 A PLC package is capable of monitoring status of inputs

connected with it to take decisions according to the
control program, and manipulates its outputs to achieve
Automation.

 Basically it is an alternate solution to the previously

under taken Wired Logic Control (WLC) technology
but it can accommodate more advanced options.

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Basic PLC operation…

INPUT CPU
OUTPUT
MODULE CENTRAL MODULE
PROCESSING
UNIT

Programming Operator
Device Interface

Basic PLC Operation

…Basic PLC operation
 Output modules convert control instructions from
the CPU into a digital or analog signal that can be
used to control various field devices (actuators).
 A programming device is used to input the desired
instructions.
 These instructions determine what the PLC will do
for a specific input.
 An operator interface device allows process
information to be displayed and new control
parameters to be entered.

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PLC Operation Example

Pushbuttons (sensors), in this simple example,

connected to PLC inputs, can be used to start and
stop a motor connected to a PLC through a motor
starter (actuator).

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Traditional Control versus
Programmable Control

Figure 1.5: Comparison between the traditional and Programmable

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Control System [3]
Solutions Communities
Solutions Communities are:

•Automotive •Metals
•Cement •Mining
•Chemical •Oil & Gas
•Food & Beverage •Pharmaceutical
•Glass •Production Machines
•Machine Tools •Pulp & Paper
•Marine •Semiconductor
•MES
Advantages of PLCs…
 The same (WLC) and even additional complicated tasks can be
done with a PLC.
 Wiring to connect field devices and contacts of
relays/contactors is made in the control program saved in the
memory of PLC.
 Transforming the functions and rectifying errors are much
easier to work out.
 It is more simple and easy to develop and modify a control
program in a PLC than making a circuit by wiring then re-
wiring it for modifications.
 Another significant advantage is smaller physical size as
compared to hard-wire based solutions.
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…Advantages of PLCs
 Speed of operation is quite fast so it is much more
easy and fast to cater modifications.
 PLCs are incorporated with diagnostics and priority
functions
 Diagnostics are accessible from a central location
 Applications can be instantaneously recognized
and documented
 Applications can be reproduced faster and relatively
lower cost than WLC based systems.

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PLC Programming Packages
 A PLC program may contain at least one or more user
written instructions which are used to accomplish a
task. Developing a PLC program is equivalent to
build a set of instructions to obtain desired sequence
of operation.
 There are several programming packages available
including:
1. Ladder logic
2. Statement list and
3. Function block diagrams
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Industrial Field Buses
Some widely used Field bus standards are:

 CAN (The Controller Area Network)

 DeviceNet
 Foundation Field Bus
 ModBus
 Profibus (Profibus PA, Profibus DP)

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ModBus…
 MODBUS Protocol is a messaging arrangement developed
by Modicon in 1979.
 It is used to set up master-slave/client-server communication
between intelligent field devices.
 It is a by default standard which is purely open and the
mainly used network protocol used for industrial
manufacturing.
 MODBUS devices communicate using a master-slave
method in which only master can initiate queries.
 Standard MODBUS networks utilize one of two types of
transmission modes:
ASCII Mode and RTU Mode.
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…ModBus Query

Station Number
Function Code
Data Bytes Station Number
Query-Response (Flexible) Function
Data Code
Bytes
Cycle (Flexible)
Error Check

Error Check

Respon
se

 MODBUS includes communication of intelligent devices with sensors and

instruments.
 It also offers monitoring of field devices using PCs and HMIs.
 MODBUS also served as an ideal protocol for RTU applications where
wireless communication is required

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Profibus Family…
PROFIBUS-DP (Distributed Processing)
Designed for communication between programmable logic controllers and
decentralized I/O, basically under the control of a single master
Replaces parallel signal transmission with 24 V or 0 to 20 mA by “ intelligent
DIN rail”

PROFIBUS-PA (Process Automation)

Permits data communication and power over the bus using 2-wire
Connects sensors and actors on one common bus line even in intrinsically-safe
areas (chemical industry)
Physical Layer according to international standard IEC 61158-2.
PROFIBUS-FMS (Field Messaging Specification)

General-purpose for peer-to-peer communication at the cell level.

Can be used for extensive and complex communication tasks.
Academic approach (layer 7 services based on MMS, ISO 9506).
Disappearing
…Profibus Family
FMS DP PA

Profibus FMS DP-profiles PA-profiles

device
Stack profiles

DP basic functions
Fieldbus
Messaging
Specification
Upper layers

Link IEC interface

Phy RS 485 Fibre optics IEC 61158-2

ProfiNet…
 PROFINET is the open Industrial Ethernet standard
 This standard is specified in IEC 61158 [18] and IEC 61784
[19] compatible with Ethernet (IEEE802.3)
 It allows existing fieldbus systems such as PROFIBUS PA,
PROFIBUS DP, AS-Interface, INTERBUS, and DeviceNet
to be included without modifying existing field devices.
 This characteristic insures that the investments of plant
operators, machine and plant manufacturers, and device
manufacturers are all protected.

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…ProfiNet
The PROFINET model is based on a modular concept
which permits the user to select the required
functionality.

 PROFINET CBA is appropriate for component based

machine-to-machine communication using TCP/IP and also
for real time communication in modular plant manufacturing.

 PROFINET I/O illustrates an I/O data view on distributed

I/O. PROFINET I/O features Real Time (RT) communication
and Isochronous Time real-time (IRT) communication with
the distributed Input/Output.

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Integration of ProfiNet with Profibus
 PROFINET specifies a model to integrate existing
PROFIBUS with other fieldbus systems for instance
INTERBUS and DeviceNet.

Figure 4.3 Fieldbus systems can be easily integrated in

PROFINET

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Advantages of ProfiNet
 Bring plant online faster
 Easily integrate machines
 Real-time production management
 Remote access
 Accurate motion control
 Faster troubleshooting
 Predictive maintenance
 Wireless connectivity
 Connect legacy buses
 Provision of plant safety
 Reduction in energy consumption

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 SCADA
 SCADA is a short form for Supervisory Control and Data
Acquisition.

 SCADA systems are utilized to monitor and control a plant

or equipment in industries

 Major application areas include energy, oil and gas refining,

telecommunications, water and waste control, and
transportation.

 These systems include the transfer of data between a

SCADA Master Terminal Unit (MTU) and a number of
Remote Terminal Units (RTUs) and/or Programmable Logic
Controllers (PLCs), and the MTU to the operator
workstation.
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 Components of SCADA…
SCADA systems consist of:
 One or more field data interface devices which are usually
termed as RTUs, or PLCs
 A communications system (means of telemetry) utilized to
transmit data between field data interface devices and control
units and the computers in the MTU of SCADA.
 A central host computer server or collection of servers,
sometimes called a SCADA Center, master station, or Master
Terminal Unit (MTU)
 A collection of standard and/or custom software, sometimes
called Human Machine Interface (HMI) software

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…Components of SCADA

Figure 5.1 Typical SCADA System 24

SCADA Architectures

 SCADA systems have evolved in parallel with the

development and sophisticated intelligence of modern
computing technology.
 Three Generations of SCADA include:
1. First Generation – Monolithic
2. Second Generation – Distributed
3. Third Generation – Networked

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SCADA Applications…

Public or Private Infrastructure:

 Water treatment and distribution
 Waste water collection and treatment
 Electrical power transmission and
distribution
 Oil and gas pipeline monitoring and
control

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…SCADA Applications

Industrial Processes (continuous, batch, or

repetitive):
 Remote monitoring and control of oil and gas
production, pumping, and storage at refineries from
both offshore platforms and onshore wells
 Electrical power distribution from nuclear, gas-fired,
coal, or renewable resources

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SCADA Examples…

Energy and Network Management System using SCADA [28]

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SCADA Examples…

Water Management system using SCADA

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…SCADA Examples

Automated Meter Reading using SCADA (Source: CIMCON

Software)

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