International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 29

ISSN 2229-5518

FLOW CALIBRATION USING PLC AND SCADA

B.Bhaskar1, P.Nagashyam2, S.Priyanka3 and P.Navya4
1 Student of B-Tech, Brindavan Institute of Technology & Science Kurnool Andhra Pradesh,
8977606051,[email protected].
2 Student of B-Tech, Brindavan Institute of Technology & Science Kurnool Andhra Pradesh, 9493210608,
[email protected].
3 Student of B-Tech, Brindavan Institute of Technology & Science Kurnool Andhra Pradesh, 7416407218,
[email protected].
4 Student of B-Tech, Brindavan Institute of Technology & Science Kurnool Andhra Pradesh, 9550123813,
[email protected].

ABSTRACT main decision making module. The system is

implemented in SCADA to create the required
This paper focuses on a new step in Human Machine Interface (HMI).
calibration of flow sensors in industries. Manual One standard sensor is placed in the

IJSER
calibration requires a lot of labour and human system along with one or more test sensors. PLC
resource. This also requires a lot of hard work system receives the input from the test sensors
and patience as the person has to note each and and standard sensors and compares the two
every value at different times by taking readings readings to determine if the test sensor is
manually. The person has to take in account the working acceptably or not.
values being given by the sensors and that of the
pump or dry block calibrator. In case the reading 1. INTRODUCTION
goes critical suitable corrections have to be I. PLC
made to save the equipment from any damage.
Managing all these equipment and taking care of A PROGRAMMABLE LOGIC
them if they are damaged is a tough task. This CONTROLLER (PLC) is an industrial
paper uses the technology to increase the computer control system that continuously
efficiency and decrease the labour required for monitors the state of input devices and
the process by introducing automated calibration makes decisions based upon a custom
of sensors. program to control the state of output
The proposed system provides calibration
devices or PLC for short, is simply a special
of Flow instruments, Data Logging and Printing
computer device used for industrial control
of Calibration reports by the help of
systems Unlike general-purpose computers,
Programmable Logic Controller (PLC) and
Supervisory Control and Data Acquisition the PLC is designed for multiple inputs and
(SCADA). The proposed model can effectively output arrangements, extended temperature
supervise flow parameters in multiple sections. ranges, immunity to electrical noise, and
The PLC controls the process of calibration by resistance to vibration and impact. Programs
taking inputs and producing outputs. A to control machine operation are typically
Proportional Integral Derivative (PID) controller stored in battery-backed or non-volatile
is provided for manually overriding the memory. A PLC is an example of a real time
automatic system. The M340 PLC is used as the

IJSER © 2016
http://www.ijser.org
 International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 30
ISSN 2229-5518

system since output results must be

produced in response to input conditions A Programmable Logic Controller is
within a bounded time, otherwise a specialized computer since it is a computer, it
unintended operation will result. has all the basic component parts that any other
computer has; a Central Processing Unit,
Almost any production line, machine Memory, Input Interfacing and Output
function, or process can be greatly enhanced Interfacing. A typical programmable controller
using this type of control system. However, block diagram is shown below
the biggest benefit in using a PLC is the
The Central Processing Unit
ability to change and replicate the operation
or process while collecting and
The central processing unit is the control
communicating vital information. portion of the PLC. It interprets the program
commands retrieved from memory and acts on
II.SCADA
those commands. In present day PLC's this unit
SCADA (supervisory control and data is a microprocessor based system. The CPU is
acquisition) is a system for remote housed in the processor module of modularized
systems.

IJSER
monitoring and control that operates with
coded signals over communication channels
Memory
(using typically one communication channel
per remote station). The control system may Memory in the system is generally of two
be combined with a data acquisition system types; ROM and RAM. The ROM memory
by adding the use of coded signals over contains the program information that allows the
communication channels to acquire CPU to interpret and act on the Ladder Logic
information about the status of the remote program stored in the RAM memory. RAM
equipment for display or for recording memory is generally kept alive with an on-board
functions.[1] It is a type ofindustrial control battery so that ladder programming is not lost
system (ICS). Industrial control systems when the system power is removed. This battery
can be a standard dry cell or rechargeable
are computer-based systems that monitor
nickel-cadmium type. Newer PLC units are now
and control industrial processes that exist in
available with Electrically Erasable
the physical world. SCADA systems
Programmable Read Only Memory (EEPROM)
historically distinguish themselves from which does not require a battery. Memory is also
other ICS systems by being large-scale housed in the processor module in modular
processes that can include multiple sites, and systems.
large distances.[2]These processes include
industrial, infrastructure, and facility-based Input Unit
processes.
Input unit can be any of several different
types depending on input signals expected as
2. BRIEF REVIEW OF PLC AND SCADA described above. The input section can accept
discrete or analog signals of various voltage and
2.1 ARCHITECTURE OF PLC current levels. Present day controllers offer

IJSER © 2016
http://www.ijser.org
 International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 31
ISSN 2229-5518

discrete signal inputs of both AC and DC required time for rewiring of panels and devices.
voltages from TTL to 250 VDC and from 5 to With PLC control any change in circuit design
250 VAC. Analog input units can accept input or sequence is as simple as retyping the logic.
levels such as ±10 VDC, ±5 VDC and 4-20 ma. Correcting errors in PLC is extremely short and
Current loop values. Discrete input units present cost effective.
each input to the CPU as a single 1 or 0 while • Space Efficient: Today's Programmable
analog input units contain analog to digital Logic Control memory is getting bigger and
conversion circuitry and present the input bigger this means that we can generate more and
voltage to the CPU as binary number normalized more contacts, coils, timers, sequencers,
to the maximum count available from the unit. counters and so on. We can have thousands of
The number of bits representing the input contact timers and counters in a single PLC.
voltage or current depends upon the resolution Imagine what it would be like to have so many
of the unit. This number generally contains a things in one panel.
defined number of magnitude bits and a sign bit. • Low Cost: Prices of Programmable
Register input units present the word input to the Logic Controllers vary from few hundreds to
CPU as it is received (Binary or BCD). few thousands. This is nothing compared to the
prices of the contact and coils and timers that
you would pay to match the same things. Add to

IJSER
that the installation cost, the shipping cost and so
on.
• Testing: A Programmable Logic
Control program can be tested and evaluated in a
Fig 2.1 Architecture of PLC lab. The program can be tested, validated and
Extending PLC: corrected saving very valuable time.
• Visual observation: When running a
• Every PLC controller has a limited PLC program a visual operation can be seen on
number of input/output lines. the screen. Hence troubleshooting a circuit is
• If needed this number can be increased really quick, easy and simple.
through certain additional modules by system
extension through extension lines. 2.3 SCADA AECHITECTURE
• Each module can contain extension both
of input and output lines. a) Monolithic (Uses a single PC)
• Also, extension modules can have inputs b) Distributed (Uses a LAN of
and outputs of a different nature from those on PCs with different responsibilities)
the PLC controller (ex. in case relay outputs are c) Networked (Capable of
on a controller, transistor outputs can be on an connecting multiple LANs)
extension module). d) Internet of Things (Can report
state in near real-time and use the horizontal
2.2 FEATURES OF PLC scale available in cloud environments to
implement more complex control algorithms
• Flexibility: One single Programmable than are practically feasible to implement on
Logic Controller can easily run many machines. traditional PLCs)
• Correcting Errors: In old days, with
wired relay-type panels, any program alterations 2.4 FEATURES OF SCADA

IJSER © 2016
http://www.ijser.org
 International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 32
ISSN 2229-5518

• Advance Polling Management:

Replaces expensive master PLC device to poll
remote sites. Group and schedule polling cycles
for increased efficiency
• Full Redundancy: Easily configure
automatic failover to back-up server, internet
server and I/O links.
• Historical Data Viewer: Generate
graphs or tablets of historical data that you can
annotate and export.
• Alarms: Sort or filter current,
unacknowledged and historical alarms.
• Rich Graphic Capabilities: Photo-
realistic meters, switches, animations, grouping,
colour and transparent adjustment and over
3,500 images.
• Display Creations Tools: Drag & drop

IJSER
tool set and object-oriented scripting language Fig 3.1 Block Diagram of Flow
allow simple display creation and limitless
customization. This system receives readings from
• Auto-Generated SCADA Display: VT various parts of the whole system and takes
SCADA creates a display (with I/O and alarms) logical decisions based on it. Different blocks of
for each RTU. this system and functionalities are discussed
• Security: Privilege-based user account below.
control access to pages, workstation, internet
clients, WAP client and alarm notification Power Supply
system.
• Report Generation: Create custom or The Power Supply of the PLC is an
scheduled report for the screen, printer, file, essential component to running the PLC. The
database or email, Excel or excel templates. Power supply for a Programmable Logic
• Water/Wastewater Report: Daily total Controller converts the input source power into
and derived flow, pump run-time discrepancy, voltages required for internal circuitry. In some
communication error summaries. cases, it also provides an isolated VDC supply to
• High Efficiency Tag Development: power DC input circuits, switches and other
Special analog and digital tag types features indicators. System uses a CPS 3020 block for
built-in-alarms, logging and report. supplying power to both racks and is capable of
generating 24V to 48V DC supply with the
3. PROPOSED FLOW CALIBRATION power output of 15W to 31.2W.
SYSTEM
Processor Module
3.1 BLOCK DIAGRAM
The processor, or the brain of the PLC
system, is a solid-state device designed to

IJSER © 2016
http://www.ijser.org
 International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 33
ISSN 2229-5518

perform a wide variety of production, machine Digital Output they are transistor, relay
tool, and process-control functions. etc... This system uses DDO3202K module for
Conventional electromechanical devices, relays the digital output module. It has 32 protected
and their associated wiring formerly performed channels. It has a 40 way connector slot for
these functions. Processors provide these same parallel ATA interface.
functions, in a wider scope and variety of control
functions, with minimal effort, making the PLC Analog Input
a much more popular choice. The processor Analog Input includes temperature
operates on DC power (± 5V), that is supplied sensors/transmitters, current sensors, voltage
by the power supply. Internal DC power is also sensors and others that can convert a physical
routed through the processor and operates a quantity to a electrical signal. These electrical
portion of the I/O and devices connected to the signals used for PLC input are typically 4-20ma
service port of the PLC. Once the ladder- or 1-5vdc. We are using an AMI0810 for this
diagram program is entered into the processor, it purpose.
remains until changed by the user with one of
the programming devices. The program is Analog Output
unaltered through power failure or power off
conditions. We are using M340 for this purpose. This module produces analog output to

IJSER
It has the capability of managing single or the modules that need a set point to start
multiple racks on which slots can be equipped continue their function properly, for example, it
with: gives the operating frequency to the pump and it
• Discrete I/O Module gives set points to the drive block calibrators.
• Analog I/O Module We are using AMO0802 module to serve this
• Application Specific Module purpose.
(counter, motion control, Ethernet
modbus communication). Relay

Digital Input A relay is an electrical switch that uses an

electromagnet to move the switch from the off to
Digital input include push-buttons, limit on position instead of a person moving the
switches, relay contacts, proximity switches, switch. It takes a relatively small amount of
photo sensors (On/Off), pressure switches and power to turn on a relay but the relay can control
more. Digital inputs devices are available in something that draws much more power. This is
both DC as well as AC and some are voltage a pass through block which take input from DO
independent such as a switch contact. This block and produces switching actions
system uses DDI3202K module for the digital accordingly. It takes digital input from DO block
input module. It has 32 isolated channels that and produces or cuts off AC supply to switch on
mean it can read that many digital at a time. It the equipment that needs to be switched
has a 40 way connector slot for parallel ATA ON/OFF respectively.
interface.
Terminal Block
Digital Output A terminal block is used to fasten or
terminate wires. It is often used to connect
wiring to a ground or electrical switches and

IJSER © 2016
http://www.ijser.org
 International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 34
ISSN 2229-5518

outlets to the mains supply. These act as safety flow meter is working correctly or not by
device for the circuits and equipment in the comparing its output with a standard flow meter.
system. Their job is to take the input from one These blocks are described below.
block and forward it to another. A simple design
has several single terminals positioned in a long Pump
strip, with an insulating frame and a clamping
part to prevent the equipment from damaging. A pump is a mechanical device that
creates suction or pressure to raise or move
MTL Converters fluids. Here we are using pump to move water
across our calibration system. We are using two
This block receives outputs of pumps, one with a pumping capacity of up to
thermocouples and converts it in accordance to 10,000 litres per hour and another with a
be read by AI block. Thermocouples generate capacity of 18,000 litres per hour.
output in terms of millivolts but AO block needs
a current signal in order to properly read it. This Control Valve
is done by MTL convertors. They convert the
voltage signal from thermocouples into current Valve is a device used to control the
signals of the range 4 to 20 milliamps which passage of fluid in one direction through a

IJSER
readable by the AO block. We are using passage or pipe. Here we are using a control
MTL5575 convertors in this project. valve that takes input from AO block and opens
to allow certain flow of water. If a high pressure
Drive is detected inside pipe then the valve has to be
opened to prevent any backwards pressure that
This is the device that is used to initialize might be dangerous for the pump. This decision
the pump by giving it initial frequency. It may is taken by the PLC system or manually by user.
be used to directly give a frequency to the pump.
Otherwise AO block communicates with the Standard Flow Transmitter (FT Ref)
pump through this block. This is the block that
receives a frequency from the AO block and This is a standard Coriolis Flow Meter
forwards it to the pump. tested and approved by National Accreditation
Board for Testing and Calibration Laboratories
Human Machine Interface (HMI) (NABL). PLC System takes its decision about
changing the set points or switching the pump
This is the interface that allows a user to ON or OFF based on the output from this meter.
keep track of the whole system by standing in
front of a screen. This interface is created using Test Flow Transmitter (FT Test)
supervisory control and data acquisition
(SCADA).This allows a user to give set points This is the flow transmitter that has to be
and pumps from one place without moving calibrated using the system. Output from this
about each and every equipment. flow meter is fed to the AI block and it is
compared to the output from FT Ref. If it
3.1.2 Flow blocks produces acceptable results then it is put to use
These blocks constitute flow calibration otherwise it is either discarded or repaired.
system. This system helps us in finding out if a Pressure Switch

IJSER © 2016
http://www.ijser.org
 International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 35
ISSN 2229-5518

A pressure switch is a form of switch that

closes an electrical contact when a certain set
pressure has been reached on its input. Here it is
used to detect the pressure in the flow
calibration system. If it rises above a certain
point, it sends a signal to DI block which
forwards it to processor module and it sends the
signal to turn off the pump.

3.2 IMPLEMENTATION OF FLOW Fig 3.2.1(b) SCADA Equipments

CALIBRATION SYSTEM

Implementation of flow calibration using 3.2.2 PROGRAMMING:

PLC AND SCADA involves
According to the international standard for
3.2.1 Software Description programmable controller programming
languages, following is a list of programming

IJSER
Unity Pro - IEC Programming Software for languages specified:
Modicon PACs
a) Ladder diagram (LD)
A unique software platform to increase b) Sequential Function Charts (SFC)
design productivity and performance of your c) Function Block Diagram (FBD)
Modicon M340, M580, Momentum, Premium, d) Structured Text (ST)
Quantum and Quantum Safety applications e) Instruction List (IL)

Ladder Diagram:

Ladder logic is the main programming

method used for PLC's. Ladder logic has been
developed to mimic relay logic. The decision to
use the relay logic diagrams was a strategic one.
By selecting ladder logic as the main
programming method, the amount of retraining
needed for engineers and trades people was
greatly reduced
Fig 3.2.1(a) UNITY PRO PLC Bus
Sequential Function Charts (SFC)
SCADA – Vijeo CITECT
SFCs have been developed to
Vijeo Citect is a stand-alone control accommodate the programming of more
station to redundant supervisor, a solution exists advanced systems. These are similar to
perfectly suited to your specific needs. flowcharts, but much more powerful. This
method is much different from flowcharts

IJSER © 2016
http://www.ijser.org
 International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 36
ISSN 2229-5518

because it does not have to follow a single path

through the flowchart.

Function Block Diagram (FBD)

FBD is another graphical programming

language. The main concept is the data flow that
starts from inputs and passes in block(s) and
generates the output.
Fig 3.2.2 Ladder Logic
Structured Text (ST)
4. RESULT
Programming has been developed as a
more modern programming language. It is quite The Coriolis Sensor is used as
similar to languages such as BASIC and Pascal.
Standard flow sensor. The flow sensor
Structured Text (ST) is a high level textual
language that is a Pascal like language. It is very values which are sensed by both field and

IJSER
flexible and intuitive for writing control standard sensor is displayed on the HMI.
algorithms. This saves the user from the trouble of
manually observing and operating the
Ladder logic
instruments. Calibration of multiple flow
Ladder logic is widely used to program sensors can be done simultaneously, and the
PLCs, where sequential control of a process or report is generated at the HMI by user and
manufacturing operation is required. Ladder
stored.
logic is useful for simple but critical control
systems or for reworking old hardwired relay
circuits. The language itself can be seen as a set
of connections between logical checkers
(contacts) and actuators (coils). If a path can be
traced between the left side of the rung and the
output, through asserted (true or "closed")
contacts, the rung is true and the output coil
storage bit is asserted (1) or true. If no path can
be traced, then the output is false (0) and the
"coil" by analogy to electro-mechanical relays is
considered "de-energized".

4. SCADA Result

IJSER © 2016
http://www.ijser.org
 International Journal of Scientific & Engineering Research, Volume 7, Issue 3, March-2016 37
ISSN 2229-5518

[3]OFFICE OF THE MANAGER

5. CONCLUSION
NATIONAL COMMUNICATIONS
SYSTEMctober 2004. "Supervisory
This report summarizes all the work
Control and Data Acquisition
we have done on our paper i.e. on
(SCADA)Systems" (PDF).NATIONAL
“AUTOMATIC FLOW CONTROL
COMMUNICATIONS SYSTEM
AND CALIBRATION USING PLC AND
SCADA”. [4]www.scheinderelectric.com
It further describes the detailed
structure of a PLC, other hardware units and
also software used in this paper.

6. FUTURE SCOPE

PLCs are used widely in industries

IJSER
now a days to control many parameters like
flow rate, temperature, pressure etc.. PLCs
can also be used to mix chemicals in the
required quantity automatically. It can also
be implemented in educational institutions
or domestic applications for filling of water
in different blocks from single place through
SCADA.

7. REFERENCE

[1] Boyer, Stuart A. (2010). SCADA

Supervisory Control and Data
Acquisition. USA: ISA - International
Society of Automation.
p. 179. ISBN 978-1-936007-09-7.

[2]Jump up^ "Introduction to Industrial

Control Networks" (PDF). IEEE
Communications Surveys and Tutorials.
2012.

IJSER © 2016
http://www.ijser.org