VWTPL, JAIPUR

Chapter-1

AUTOMATION

1.1 INTRODUCTION
Automation is the use of machines, control systems and information technologies to optimize
productivity in the production of goods and delivery of services. The correct incentive for
applying automation is to increase productivity, and/or quality beyond that possible with
current human labor levels so as to realize economies of scale, and/or realize predictable
quality levels. The incorrect application of automation, which occurs most often, is an effort
to eliminate or replace human labor. Simply put, whereas correct application of automation
can net as much as 3 to 4 times original output with no increase in current human labor costs,
incorrect application of automation can only save a fraction of current labor level costs. In
the scope of industrialization, automation is a step beyondmechanization. Whereas
mechanization provides human operators with machinery to assist them with the muscular
requirements of work, automation greatly decreases the need for human sensory and mental
requirements while increasing load capacity, speed, and repeatability. Automation plays an
increasingly important role in the world economy and in daily experience.
Automation has had a notable impact in a wide range of industries
beyond manufacturing (where it began). Once-ubiquitous telephone operators have been
replaced largely by automated telephone switchboards and answering machines. Medical
processes such as primary screening inelectrocardiography or radiography and laboratory
analysis of human genes, sera, cells, and tissuesare carried out at much greater speed and
accuracy by automated systems. Automated teller machines have reduced the need for bank
visits to obtain cash and carry out transactions. In general, automation has been responsible
for the shift in the world economy from industrial jobs to service jobs in the 20th and 21st
centuries.
The term automation, inspired by the earlier word automatic (coming from automaton), was
not widely used before 1947, when General Motors established the automation department.
At that time automation technologies were electrical, mechanical, hydraulic and pneumatic.

RIET/B.TECH/EE/15EREEE010/Page | 1
 VWTPL, JAIPUR

Between 1957 and 1964 factory output nearly doubled while the number of blue collar
workers started to decline.
1.2 ADVANTAGES AND DISADVANTAGES:-
The main advantages of automation are:
 Increased throughput or productivity.
 Improved quality or increased predictability of quality.
 Improved robustness (consistency), of processes or product.

The following methods are often employed to improve productivity, quality, or robustness.
Install automation in operations to reduce cycle time.
 Install automation where a high degree of accuracy is required.
 Replacing human operators in tasks that involve hard physical or monotonous work.
 Replacing humans in tasks done in dangerous environments (i.e. fire, space,
volcanoes, nuclear facilities, underwater, etc.)
Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc.
Economy improvement: Automation may improve in economy of enterprises, society or most
of humanity. For example, when an enterprise invests in automation, technology recovers its
investment; or when a state or country increases its income due to automation
like Germany or Japan in the 20th Century.
 Reduces operation time and work handling time significantly.
 Frees up workers to take on other roles.
 Provides higher level jobs in the development, deployment, maintenance and running
of the automated processes.
The main disadvantages of automation are:
Security Threats/Vulnerability: An automated system may have a limited level of
intelligence, and is therefore more susceptible to committing errors outside of its immediate
scope of knowledge (e.g., it is typically unable to apply the rules of simple logic to general
propositions).
Unpredictable/excessive development costs: The research and development cost of
automating a process may exceed the cost saved by the automation itself.

RIET/B.TECH/EE/15EREEE010/Page | 2
 VWTPL, JAIPUR

High initial cost: The automation of a new product or plant typically requires a very large
initial investment in comparison with the unit cost of the product, although the cost of
automation may be spread among many products and over time.
In manufacturing, the purpose of automation has shifted to issues broader than productivity,
cost, and time.
1.3 RELIABILITY AND PRECISION
The old focus on using automation simply to increase productivity and reduce costs was seen
to be short-sighted, because it is also necessary to provide a skilled workforce who can make
repairs and manage the machinery. Moreover, the initial costs of automation were high and
often could not be recovered by the time entirely new manufacturing processes replaced the
old. (Japan's "robot junkyards" were once world famous in the manufacturing industry.)
Automation is now often applied primarily to increase quality in the manufacturing process,
where automation can increase quality substantially. For example, internal combustion
engine pistons used to be installed manually. This is rapidly being transitioned to automated
machine installation, because the error rate for manual installment was around 1-1.5%, but
has been reduced to 0.00001% with automation.

1.4 HEALTH AND ENVIRONMENT

The costs of automation to the environment are different depending on the technology,
product or engine automated. There are automated engines that consume more energy
resources from the Earth in comparison with previous engines and those that do the opposite
too. Hazardous operations, such as oil refining, the manufacturing of industrial chemicals,
and all forms of metal working, were always early contenders for automation.

1.5AUTOMATION TOOLS

Engineers can now have numerical control over automated devices. The result has been a
rapidly expanding range of applications and human activities. Computer-aided
technologies (or Coax) now serve the basis for mathematical and organizational tools used to
create complex systems. Notable examples of Coax include Computer-aided design (CAD
software) and Computer-aided manufacturing (CAM software). The improved design,
analysis, and manufacture of products enabled by Coaxhas been beneficial for industry.
RIET/B.TECH/EE/15EREEE010/Page | 3
 VWTPL, JAIPUR

Information technology, together with industrial machinery and processes, can assist in the
design, implementation, and monitoring of control systems. One example of an industrial
control system is a programmable logic controller (PLC). PLCs are specialized hardened
computers which are frequently used to synchronize the flow of inputs from
(physical) sensors and events with the flow of outputs to actuators and events.
1.6HUMAN MACHINE INTERFACE
Human-machine interfaces (HMI) or computer human interfaces (CHI), formerly known
asman-machine interfaces, are usually employed to communicate with PLCs and other
computers. Service personnel who monitor and control through HMIs can be called by
different names. In industrial process and manufacturing environments, they are called
operators or something similar. In boiler houses and central utilities departments they are
called stationary engineers.

Different types of automation tools exist:

 ANN - Artificial neural network

 BPM - Bonita Open Solution
 DCS - Distributed Control System
 HMI - Human Machine Interface
 SCADA - Supervisory Control and Data Acquisition
 PLC - Programmable Logic Controller
 PAC - Programmable automation controller
 Instrumentation
 Motion control
 Robotics

1.7LIMITATIONS TO AUTOMATION

1. Current technology is unable to automate all the desired tasks.

2. As a process becomes increasingly automated, there is less and less labor to be saved or
quality improvement to be gained. This is an example of both diminishing returns and
the logistic function.

RIET/B.TECH/EE/15EREEE010/Page | 4
 VWTPL, JAIPUR

3. Similar to the above, as more and more processes become automated, there are fewer
remaining non-automated processes. This is an example of exhaustion of opportunities.

1.8 APPLICATION

Automated mining involves the removal of human labor from

the mining process.[7] The mining industry is currently in the transition towards automation.
Currently it can still require a large amount of human capital, particularly in the third
world where labor costs are low so there is less incentive for increasing efficiency.

1.8.1 AUTOMATED VIDEO SURVEILLANCE

The Defense Advanced Research Projects Agency (DARPA) started the research and
development of automated visual surveillance and monitoring (VSAM) program, between
1997 and 1999, and airborne video surveillance (AVS) programs, from 1998 to 2002.
Currently, there is a major effort underway in the vision community to develop a fully
automated tracking surveillance system. Automated video surveillance monitors people and
vehicles in real time within a busy environment. Existing automated surveillance systems are
based on the environment they are primarily designed to observe, i.e., indoor, outdoor or
airborne, the amount of sensors that the automated system can handle and the mobility of
sensor, i.e., stationary camera vs. mobile camera. The purpose of a surveillance system is to
record properties and trajectories of objects in a given area, generate warnings or notify
designated authority in case of occurrence of particular events.

1.8.2 AUTOMATED HIGHWAY SYSTEMS

As demands for safety and mobility have grown and technological possibilities have
multiplied, interest in automation has grown. Seeking to accelerate the development and
introduction of fully automated vehicles and highways, the Congress authorized more than
$650 million over six years for intelligent transport systems (ITS) and demonstration projects
in the 1991Intermodal Surface Transportation Efficiency Act (ISTEA). Congress legislated
in ISTEA that “the Secretary of Transportation shall develop an automated highway and
vehicle prototype from which future fully automated intelligent vehicle-highway systems can
be developed. Such development shall include research in human factors to ensure the
success of the man-machine relationship. The goal of this program is to have the first fully

RIET/B.TECH/EE/15EREEE010/Page | 5
 VWTPL, JAIPUR

automated highway roadway or an automated test track in operation by 1997. This system
shall accommodate installation of equipment in new and existing motor vehicles." [ISTEA
1991, part B, Section 6054(b)].

1.9AUTOMATED MANUFACTURING
Automated manufacturing refers to the application of automation to produce things in the
factory way. Most of the advantages of the automation technology has its influence in the
manufacture processes.

The main advantages of automated manufacturing are higher consistency and quality,
reduced lead times, simplified production, reduced handling, improved work flow, and
increased worker morale when a good implementation of the automation is made.

1.10HOME AUTOMATION
Home automation (also called domotics) designates an emerging practice of increased
automation of household appliances and features in residential dwellings, particularly
through electronic means that allow for things impracticable, overly expensive or simply not
possible in recent past decades.

1.11INDUSTRIAL AUTOMATION
Industrial automation deals with the optimization of energy-efficient drive systems by precise
measurement and control technologies. Nowadays energy efficiency in industrial processes
are becoming more and more relevant. Semiconductor companies like Infineon
Technologies are offering 8-bit microcontroller applications for example found in motor
controls, general purpose pumps, fans, and ebikes to reduce energy consumption and thus
increase efficiency. One of Infineon`s 8-bit product line found in industrial automation is
the XC800 family.

Agriculture: Now that we’re moving towards automated orange-sorting[1] and autonomous
tractors[2], the next step in automated agriculture is robotic strawberry pickers[3].

RIET/B.TECH/EE/15EREEE010/Page | 6
 VWTPL, JAIPUR

1.12AGENT-ASSISTED AUTOMATION
Agent-assisted Automation refers to automation used by call center agents to handle
customer inquiries. There are two basic types: desktop automation and automated voice
solutions. Desktop automation refers to software programming that makes it easier for the
call center agent to work across multiple desktop tools. The automation would take the
information entered into one tool and populate it across the others so it did not have to be
entered more than once, for example. Automated voice solutions allow the agents to remain
on the line while disclosures and other important information is provided to customers in the
form of pre-recorded audio files. Specialized applications of these automated voice solutions
enable the agents to process credit cards without ever seeing or hearing the credit card
numbers or CVV codes.

The key benefit of agent-assisted automation is compliance and error-proofing. Agents are
sometimes not fully trained or they forget or ignore key steps in the process.

RIET/B.TECH/EE/15EREEE010/Page | 7
 VWTPL, JAIPUR

Chapter-2
SUPERVISORY CONTROL AND DATA ACQUISTION
INTRODUCTION
An industrial SCADA system will be used for the development of the controls of the
fourLHC experiments. This paper describes the SCADA systems in terms of
theirarchitecture, their interface to the process hardware, the functionality and theapplication
development facilities they provide.Widely used in industry for Supervisory Control and
Data Acquisition of industrialprocesses, SCADA systems are now also penetrating the
experimental physicslaboratories for the controls of ancillary systems such as cooling,
ventilation, powerdistribution, etc.

2.1 SCADA
SCADA systems have made substantial progress over the recent years in terms
offunctionality, scalability, performance and openness such that they are an alternative to
inhouse development even for very demanding and complex control systems as those
ofphysics experiments.

2.2 TYPES OF SCADA

1. D+R+N ( Development +Run + Networking)
2. R+N ( Run +Networking )

2.3 FEATURES OF SCADA

1. Dynamic process Graphic :Object interact can be assigned to graphic objects for specific
user interactions. Users can also implement custom interactions like context-dependant
menus, alarm acknowledgment or custom editing.

The E-XD++ Diagram is a top-of-the-line real-time graphics and data visualization product
with various additional packages and deployment options.

RIET/B.TECH/EE/15EREEE010/Page | 8
 VWTPL, JAIPUR

2. Alarm summery: Alarm Summary page displays a historical log of alarms that you can
use for long term analysis and troubleshooting. It displays the date and time
each alarm reached ON state and OFF state.
3. Alarm history :As alarm notification providers thinking about the future, it’s sometimes important
to reflect on the past. alarm notification systems help plant operators navigate challenges that get in
the way of communication, safety, and productivity. How we meet those needs is ever-evolving.

4. Historical time trend: The Open Trend system has the ability to trend any real-time,
calculated or application generated data value from the system database. The historical
trending supports the storage of trend data for an unlimited period of time.
5. Security (Application Security): security is :Security gives a lender or oblige a legal right
of access to the pledged asset and to take their possession and title in case of default for a
foreclosure sale. 3. Computing: The extent to which a computer system is protected from
data corruption, destruction, interception, loss, or unauthorized access.
6. Data base connectivity: Event Logs are an easy way to process on-going system
information, such as: user-logs, alerts, system warnings, changed data values, etc. As well as
storing event logs in readable text files, or routing them to printers, they can be written to
sequential tables in Microsoft Access databases.
7. Device connectivity: device connectivity is a process which is other device is contact to
other device and they can share their data
8. Scripts: scripts is a programming language which is write a program to operate any device.

2.4 MANUFACTURE OF SCADA

Mod icon (Telemecanique)Visual look
Allen Brady: RS View
Siemens: win cc
Geffen:
KPIT : ASTRA
Intuition : Aspic
Wonder ware :IN touc

RIET/B.TECH/EE/15EREEE010/Page | 9
 VWTPL, JAIPUR

Chapter-3
3. MEANING OF SCADA
SCADA stands for Supervisory Control And Data Acquisition. As the name indicates, itis
not a full control system, but rather focuses on the supervisory level. As such, it is apurely
software package that is positioned on top of hardware to which it is interfaced, ingeneral via
Programmable Logic Controllers (PLCs), or other commercial hardwaremodules.

SCADA systems are used not only in industrial processes: e.g. steel making,
powergeneration (conventional and nuclear) and distribution, chemistry, but also in
someexperimental facilities such as nuclear fusion. The size of such plants range from a
few1000 to several 10 thousands input/output (I/O) channels. However, SCADA
systemsevolve rapidly and are now penetrating the market of plants with a number of
I/Ochannels of several 100 K: we know of two cases of near to 1 M I/O channels
currentlyunder development.SCADA systems used to run on DOS, VMS and UNIX; in
recent years all SCADAvendors have moved to NT and some also to Linux.

3.1 ARCHITECTURE

3.1.1 HARDWARE ARCHITECTURE

One distinguishes two basic layers in a SCADA system: the "client layer" which catersfor the
man machine interaction and the "data server layer" which handles most of theprocess data
control activities. The data servers communicate with devices in the fieldthrough process
controllers. Process controllers, e.g. PLCs, are connected to the dataservers either directly or
via networks or fieldbuses that are proprietary (e.g. SiemensH1), or non-proprietary (e.g.
Profit bus). Data servers are connected to each other and toclient stations via an Ethernet
LAN. The data servers and client stations are NT platformsbut for many products the client
stations may also be W95 machines. Fig.3.1. shows typicalhardware architecture.

RIET/B.TECH/EE/15EREEE010/Page | 10
 VWTPL, JAIPUR

Figure 3.1:- Typical Hardware Architecture

However, it is possible to have dedicated servers for particular tasks, e.g. historian,data
logger, alarm handler. Fig. 3.1 shows a SCADA architecture that is generic for theproducts
that were evaluated.

3.2 COMMUNICATIONS

3.2.1 INTERNAL COMMUNICATION

Server-client and server-server
server communication is in general on a publish
publish-subsc
subscribe andevent-
driven basis and uses a TCP/IP protocol, i.e., a client application subscribes to parameter
which is owned by a particular server application and only changes to that parameter are then
communicated to the client application.

RIET/B.TECH/EE/15EREEE010/Page
RIET/B.TECH/EE/15EREEE | 11
 VWTPL, JAIPUR

3.2.2 ACCESS TO DEVICES

The data servers poll the controllers at a user defined polling rate. The polling rate maybe
different for different parameters. The controllers pass the requested parameters to thedata
servers. Time stamping of the process parameters is typically performed in thecontrollers and
this time-stamp is taken over by the data server. If the controller andcommunication protocol
used support unsolicited data transfer then the products willsupport this too.
The products provide communication drivers for most of the common PLCs and widelyused
field-buses, e.g., Modbus. Of the three fieldbuses that are recommended at CERN,both Profit
bus and Worldflip are supported but CANbus often not [3]. Some of the driversare based on
third party products (e.g., Applica cards) and therefore have additionalcost associated with
them. A single data server can support multiple communicationsprotocols: it can generally
support as many such protocols as it has slots for interfacecards.
The effort required to develop new drivers is typically in the range of 2-6 weeksdepending on
the complexity and similarity with existing drivers, and a driverdevelopment toolkit is
provided for this.

3.3 INTERFACING

3.3.1 APPLICATION INTERFACES / OPENNESS

The provision of OPC client functionality for SCADA to access devices in an open
andstandard manner is developing. There still seems to be a lack of devices/controllers,which
provide OPC server software, but this improves rapidly as most of the producers
ofcontrollers are actively involved in the development of this standardThe products
alsoprovide
• An Open Data Base Connectivity (ODBC) interface to the data in the archive/logs,
but not to the configuration database,
• An ASCII import/export facility for configuration data,
• A library of apis supporting C, C++, and Visual Basic (VB) to access data in the
RTDB, logs and archive. The API often does not provide access to the product's
internal features such as alarm handling, reporting, trending, etc.
RIET/B.TECH/EE/15EREEE010/Page | 12
 VWTPL, JAIPUR

The PC products provide support for the Microsoft standards such as Dynamic
DataExchange (DDE) which allows e.g. to visualize data dynamically in an
EXCELspreadsheet, Dynamic Link Library (DLL) and Object Linking and Embedding
(OLE).
3.3.2 DATABASE
The configuration data are stored in a database that is logically centralized but
physicallydistributed and that is generally of a proprietary format.System (RDBMS) at a
slower rate either directly or via an ODBC interface
3.4 FUNCTIONALITY

3.4.1 ACCESS CONTROL

Users are allocated to groups, which have defined read/write access privileges to theprocess
parameters in the system and often also to specific product functionality.
3.4.2 MMI
The products support multiple screens, which can contain combinations of synopticdiagrams
and text.They also support the concept of a "generic" graphical object with links to
processvariables. These objects can be "dragged and dropped" from a library and included
into asynoptic diagram.
Most of the SCADA products that were evaluated decompose the process in
"atomic"parameters (e.g. a power supply current, its maximum value, its on/off status, etc.)
towhich a Tag-name is associated. The Tag-names used to link graphical objects to
devicescan be edited as required. The products include a library of standard graphical
symbols, many of which would however not be applicable to the type of applications
encounteredin the experimental physics community.Standard windows editing facilities are
provided: zooming, re-sizing, scrolling... On-lineconfiguration and customization of the MMI
is possible for users with the appropriate privileges. Links can be created between display
pages to navigate from one view toanother.

RIET/B.TECH/EE/15EREEE010/Page | 13
 VWTPL, JAIPUR

3.4.3 TRENDING
The products all provide trending facilities and one can summarize the commoncapabilities
as follows:
• the parameters to be trended in a specific chart can be predefined or defined online
• a chart may contain more than 8 trended parameters or pens and an unlimited
• number of charts can be displayed (restricted only by the readability)
• real-time and historical trending are possible, although generally not in the samechart
• historical trending is possible for any archived parameter
• zooming and scrolling functions are provided
• parameter values at the cursor position can be displayed
• The trending feature is either provided as a separate module or as a graphical object
• (ActiveX), which can then be embedded into a synoptic display. XY and other
statistical
• analysis plots are generally not provided.
3.4.4 ALARM HANDLING
Alarm handling is based on limit and status checking and performed in the data servers.More
complicated expressions (using arithmetic or logical expressions) can be developedby
creating derived parameters on which status or limit checking is then performed. Thealarms
are logically handled centrally, i.e., the information only exists in one place andall users see
the same status (e.g., the acknowledgement), and multiple alarm prioritylevels (in general
many more than 3 such levels) are supported.
It is generally possible to group alarms and to handle these as an entity (typically filteringon
group or acknowledgement of all alarms in a group). Furthermore, it is possible tosuppress
alarms either individually or as a complete group. The filtering of alarms seenon the alarm
page or when viewing the alarm log is also possible at least on priority, timeand group.
However, relationships between alarms cannot generally be defined in astraightforward
manner. E-mails can be generated or predefined actions automaticallyexecuted in response to
alarm conditions
3.4.5 LOGGING/ARCHIVING
The terms logging and archiving are often used to describe the same facility.
However,logging can be thought of as medium-term storage of data on disk, whereas
RIET/B.TECH/EE/15EREEE010/Page | 14
 VWTPL, JAIPUR

archiving islong-term storage of data either on disk or on another permanent storage

medium.Logging is typically performed on a cyclic basis, i.e., once a certain file size, time
periodor number of points is reached the data is overwritten. Logging of data can be
performedat a set frequency, or only initiated if the value changes or when a specific
predefinedevent occurs. Logged data can be transferred to an archive once the log is full.
Thelogged data is time-stamped and can be filtered when viewed by a user. The logging
ofuser actions is in general performed together with either a user ID or station ID. There
isoften also a VCR facility to play back archived data.

3.4.6 REPORT GENERATION

One can produce reports using SQL type queries to the archive, RTDB or logs. Althoughit is
sometimes possible to embed EXCEL charts in the report, a "cut and paste"capability is in
general not provided. Facilities exist to be able to automatically generate,print and archive
reports.

3.5 APPLICATION DEVELOPMENT

3.5.1 CONFIGURATION
The development of the applications is typically done in two stages. First the
processparameters and associated information (e.g. relating to alarm conditions) are
definedthrough some sort of parameter definition template and then the graphics,
includingtrending and alarm displays are developed, and linked where appropriate to the
processparameters. The products also provide an ASCII Export/Import facility for
theconfiguration data (parameter definitions), which enables large numbers of parameters
tobe configured in a more efficient manner using an external editor such as Excel and
thenimporting the data into the configuration database.
However, many of the PC tools now have a Windows Explorer type development studio.The
developer then works with a number of folders, which each contains a differentaspect of the
configuration, including the graphics.The facilities provided by the products for configuring
very large numbers of parametersare not very strong. However, this has not really been an
issue so far for most of theproducts to-date, as large applications are typically about 50K I/O
RIET/B.TECH/EE/15EREEE010/Page | 15
 VWTPL, JAIPUR

points and databasepopulation from within an ASCII editor such as Excel is still a workable
option.On-line modifications to the configuration database and the graphics is generally
possiblewith the appropriate level of privileges.

3.5.2 DEVELOPMENT TOOLS

The following development tools are provided as standard:
• A graphics editor, with standard drawing facilities including freehand, lines, squares
circles, etc. It is possible to import pictures in many formats as well as using predefined
symbols including e.g. Trending charts, etc. A library of generic symbols is provided that
can be linked dynamically to variables and animated as they change. It is also possible to
create links between views so as to ease navigation at run-time.
• A data base configuration tool (usually through parameter templates). It is in general
possible to export data in ascii files so as to be edited through an ascii editor or excel.
• A scripting language
• An application program interface (api) supporting c, c++, vb a driver development toolkit
to develop drivers for hardware that is not supported by the scada product.
3.5.3 OBJECT HANDLING
The products in general have the concept of graphical object classes, which
supportinheritance. In addition, some of the products have the concept of an object within
theconfiguration database. In general the products do not handle objects, but rather handle
individual parameters, e.g., alarms are defined for parameters, logging is performed
onparameters, and control actions are performed on parameters. The support of objects
istherefore fairly superficial.
3.6 EVOLUTION
SCADA vendors release one major version and one to two additional minor versionsonce per
year. These products evolve thus very rapidly so as to take advantage of newmarket
opportunities, to meet new requirements of their customers and to take advantageof new
technologies.
As was already mentioned, most of the SCADA products that were evaluated decomposethe
process in "atomic" parameters to which a Tag-name is associated. This is impracticalin the
case of very large processes when very large sets of Tags need to be configured. Asthe
RIET/B.TECH/EE/15EREEE010/Page | 16
 VWTPL, JAIPUR

industrial applications are increasing in size, new SCADA versions are now beingdesigned to
handle devices and even entire systems as full entities (classes) thatencapsulate all their
specific attributes and functionality. In addition, they will alsosupport multi-team
development.

3.7 ENGINEERING
Whilst one should rightly anticipate significant development and maintenance savings
byadopting a SCADA product for the implementation of a control system, it does not meana
"no effort" operation. The need for proper engineering can not be sufficientlyemphasized to
reduce development effort and to reach a system that complies with therequirements, that is
economical in development and maintenance and that is reliable androbust. Examples of
engineering activities specific to the use of a SCADA system are thedefinition of:
A library of objects (PLC, device, subsystem) complete with standard objectbehavior (script,
sequences, ...), graphical interface and associated scripts foranimation,templates for different
types of "panels", e.g. Alarms,instructions on how to control e.g.
A mechanism to prevent conflicting control(if not provided with the SCADA),alarm levels,
behavior to be adopted in case of specific alarms.

3.8 POTENTIAL BENEFITS OF SCADA

The benefits one can expect from adopting a SCADA system for the control ofexperimental
physics facilities can be summarized as follows:

• A rich functionality and extensive development facilities. The amount of effort

invested in SCADA product amounts to 50 to 100 p-years!
• The amount of specific development that needs to be performed by the end-user is
limited, especially with suitable engineering.
• Reliability and robustness. These systems are used for mission critical industrial
processes where reliability and performance are paramount. In addition, specific
development is performed within a well-established framework that enhances
reliability and robustness.
• Technical support and maintenance by the vendor.
RIET/B.TECH/EE/15EREEE010/Page | 17
 VWTPL, JAIPUR

For large collaborations, as for the CERN LHC experiments, using a SCADA system fortheir
controls ensures a common framework not only for the development of the
specificapplications but also for operating the detectors. Operators experience the same "look
andfeel" whatever part of the experiment they control. However, this aspect also depends to
asignificant extent on proper engineering.

RIET/B.TECH/EE/15EREEE010/Page | 18
 VWTPL, JAIPUR

Chapter-4
PROGRAMMABLE LOGIC CONTROLLER
(PLC)
4.1 INTRODUCTION
Control engineering has evolved over time. In the past humans were the mainmethod for
controlling a system. More recently electricity has been used for control andearly electrical
control was based on relays. These relays allow power to be switched onand off without a
mechanical switch. It is common to use relays to make simple logicalcontrol decisions. The
development of low cost computer has brought the most recent revolution,the Programmable
Logic Controller (PLC). The advent of the PLC began in the1970s, and has become the most
common choice for manufacturing controls.
PLCs have been gaining popularity on the factory floor and will probably remainpredominant
for some time to come. Most of this is because of the advantages they offer.
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.

4.1.1 LADDER LOGIC

Ladder logic is the main programming method used for PLCs. As mentionedbefore, ladder
logic has been developed to mimic relay logic. The decision to use the
relayTopics:Objectives:
• Know general PLC issues
• To be able to write simple ladder logic programs
• Understand the operation of a PLC
• PLC History
• Ladder Logic and Relays
• PLC Programming
• PLC Operation
RIET/B.TECH/EE/15EREEE010/Page | 19
 VWTPL, JAIPUR

Modern control systems still include relays, but these are rarely used for logic. Arelay is a
simple device that uses a magnetic field to control a switch. When a voltage is applied to the
input coil, the resulting current creates a magneticfield. The magnetic field pulls a metal
switch (or reed) towards it and the contacts touch,closing the switch. The contact that closes
when the coil is energized is called normallyopen. The normally closed contacts touch when
the input coil is not energized. Relays arenormally drawn in schematic form using a circle to
represent the input coil. The outputcontacts are shown with two parallel lines. Normally open
contacts are shown as twolines, and will be open (non-conducting) when the input is not
energized. Normally closedcontacts are shown with two lines with a diagonal line through
them. When the input coilis not energized the normally closed contacts will be closed
(conducting).

Relays are used to let one power source close a switch for another (often high current) power
source, while keeping them isolated. An example of a relay in a simple control application is
shown in Figure 4. In this system the first relay on the left is used as normally closed, and
will allow current to flow until a voltage is applied to the input A. The second relay is
normally open and will not allow current to flow until a voltage is applied to the input B. If
current is flowing through the first two relays then current will flow through the coil in the
third relay, and close the switch for output C. This circuit would normally be drawn in the
ladder logic form

RIET/B.TECH/EE/15EREEE010/Page | 20
 VWTPL, JAIPUR

Figure 4.1:- A Simple Relay Controller

The example in Figure 4.1 does not show the entire control system, but only the logic. When
we consider a PLC there are inputs, out
outputs, and the logic. Figure 4.2 shows a more complete
representation of the PLC. Here there are two inputs from push buttons.

We can imagine the inputs as activating 24V DC relay coils in the PLC. This in turn drives
an output relay that switches 115V AC, that will turn on a light. Note, in actual PLCs inputs
are never relays, but outputs are often relays. The ladder logic in the PLC is actually a
computer program that the user can enter and change. Notice that both of the input push
buttons are normally open, but the ladder logic inside the PLC has one normally open
contact, and one normally closed contact. Do not think that the ladder logic in the PLC needs
to match the inputs or outputs. Many beginners will get caught trying to make the ladder
logic match the input types.

RIET/B.TECH/EE/15EREEE010/Page
RIET/B.TECH/EE/15EREEE | 21
 VWTPL, JAIPUR

Figure 4.2:-A PLC Illustrated With Relays

Many relays also have multiple outputs (throws) and this allows an output relay to also be an
input simultaneously. The circuit shown in Figure 4.2 is an example of this, it is called a seal
in circuit. In this circuit the current can flow through either branch of the circuit, through the
contacts labeled A or B. The input B will only be on when the output B is on. If B is off, and
A is energized, then B will turn on. If B turns on then the input B will turn on, and keep
output B on even if input A goes off. After B is turned on the output B will not turn off.

RIET/B.TECH/EE/15EREEE010/Page | 22
 VWTPL, JAIPUR

4.2 PROGRAMMING
The first PLCs were programmed with a technique that was based on relay logic wiring
schematics. This eliminated the need to teach the electricians, technicians and engineers how
to program a computer - but, this method has stuck and it is the most common technique for
programming PLCs today. An example of ladder logic can be seen in Figure 4.3. To interpret
this diagram imagine that the power is on the vertical line on the left hand side, we call this
the hot rail. On the right hand side is the neutral rail. In the figure there are two rungs, and on
each rung there are combinations of inputs (two vertical lines) and outputs (circles). If the
inputs are opened or closed in the right combination the power can flow from the hot rail,
through the inputs, to power the outputs, and finally to the neutral rail. An input can come
from a sensor, switch, or any other type of sensor. An output will be some device outside the
PLC that is switched on or off, such as lights or motors. In the top rung the contacts are
normally open and normally closed.Which means if input A is on and input B is off, then
power will flow through the output and activate it. Any other combination of input values
will result in the output X being off.

Figure 4.3:- A Simple Ladder Logic Diagram

RIET/B.TECH/EE/15EREEE010/Page | 23
 VWTPL, JAIPUR

The second rung of Figure 4.4 is more complex, there are actually multiple combinationsof
inputs that will result in the output Y turning on. On the left most part of therung, power
could flow through the top if C is off and D is on. Power could also (andsimultaneously) flow
through the bottom if both E and F are true. This would get powerhalf way across the rung,
and then if G or H is true the power will be delivered to output Y.In later chapters we will
examine how to interpret and construct these diagrams.There are other methods for
programming PLCs. One of the earliest techniquesinvolved mnemonic instructions. These
instructions can be derived directly from the ladderlogic diagrams and entered into the PLC
through a simple programming terminal.

Anexample of mnemonics is shown in Figure 4.4. In this example the instructions are
readone line at a time from top to bottom. The first line 00000 has the instruction LDN
(inputload and not) for input 00001. This will examine the input to the PLC and if it is off it
willremember a 1 (or true), if it is on it will remember a 0 (or false). The next line uses an
LD(input load) statement to look at the input. If the input is off it remembers a 0, if the
inputis on it remembers a 1 (note: this is the reverse of the LD). The AND statement recalls
thelast two numbers remembered and if the are both true the result is a 1, otherwise the
resultis a 0. This result now replaces the two numbers that were recalled, and there is only
onenumber remembered. The process is repeated for lines 00003 and 00004, but when
theseare done there are now three numbers remembered. The oldest number is from the
AND,the newer numbers are from the two LD instructions. The AND in line 00005 combines
theresults from the last LD instructions and now there are two numbers remembered. The
ORinstruction takes the two numbers now remaining and if either one is a 1 the result is a
1,otherwise the result is a 0. This result replaces the two numbers, and there is now a single
number there. The last instruction is the ST (store output) that will look at the last value
stored and if it is 1, the output will be turned on, if it is 0 the output will be turned off.

RIET/B.TECH/EE/15EREEE010/Page | 24
 VWTPL, JAIPUR

Figure 4.4:- An Example of a Mnemonic Program and Equivalent Ladder Logic

The ladder
adder logic program in Figure4.4
Figure4.4, is equivalent to the mnemonic program.Even if you
have programmed a PLC with ladder logic, it will be converted to mnemonicform before
being used by the PLC. In the past mnemonic programming was the mostcommon, but now it
is uncommon for users to even see mnemonic programs.
Sequential Function Charts (SFCs) have been developed to accommodate the programmingof
more advanced systems. These are similar to flowcharts, but much morepowerful.
morepowerful The
example seen in Figure 8 is doing two different things. To read tthe
he chart,start at the top
where is says start.. Below this there is the double horizontal line that saysfollow both paths.
As a result the PLC will start to follow the branch on the left and righthand sides separately
and simultaneously. On the left there aare two functions the first oneis the power up function.
This function will run until it decides it is done, and the powerdown function will come after.
On the right hand side is the flash function, this will rununtil
until it is done. These functions look
unexplained, but each function, such as power upwill
will be a small ladder logic program. This

RIET/B.TECH/EE/15EREEE010/Page
RIET/B.TECH/EE/15EREEE | 25
 VWTPL, JAIPUR

method is much different from flowchartsbecause it does not have to follow a single path
through the flowchart.

4.3 PLC Connections

When a process is controlled by a PLC it uses inputs from sensors to make decisions and
update outputs to drive actuators, as shown in Fi
Figure 4.5.. The process is a real process that
will change over time. Actuators will drive the system to new state
statess (or modes of operation).
This means that the controller is limited by the sensors available, if an input is not available,
the controller will have no way to detect a condition.

Figure 4.5
4.5:- The Separation of Controller and Process

The control loop iss a continuous cycle of the PLC reading inputs, solving the ladderlogic, and
then changing the outputs. Like any computer this does not happen
happeninstantly.
stantly. Figure 4.6
shows the basic operation cycle of a PLC. When power is turned oninitially the PLC does a
quick sanity check to ensure that the hardware is working properly.

If there is a problem the PLC will halt and indicate there is an error. For example, ifthe PLC
backup battery is low and power was lost, the memory will be corrupt and thiswill result in a
fault. If the PLC passes the sanity check it will then scan (read) all theinputs. After the inputs
values are stored in memory the ladder logic will be scanned(solved) using the stored values
RIET/B.TECH/EE/15EREEE010/Page
RIET/B.TECH/EE/15EREEE | 26
 VWTPL, JAIPUR

- not the current values. This is done to prevent logicproblems when inputs change during the
ladder logic scan. When the ladder logic scan iscomplete the outputs will be scanned (the
output values will be changed). After this thesystem goes back to do a sanity check, and the
loop continues indefinitely. Unlike normalc
normalcomputers,
omputers, the entire program will be run every
scan. Typical times for each of the stagesis in the order of milliseconds.

Figure 4.6:- The Scan Cycle of a PLC

4.4 Ladder Logic Inputs

PLC inputs are easily represented in ladder logic. In Figure 4.7 there
re are three types of inputs
shown. The first two are normally open and normally closed inputs, discussed previously.
The IIT (Immediate InpuT) function allows inputs to be read after the input scan, while the
ladder logic is being scanned. This allows lad
ladder
der logic to examine input values more often
than once every cycle.

RIET/B.TECH/EE/15EREEE010/Page
RIET/B.TECH/EE/15EREEE | 27
 VWTPL, JAIPUR

Figure 4.7:- Ladder Logic Inputs

4.5 Ladder Logic Outputs

In ladder logic there are multiple types of outputs, but these are not consistently available on
all PLCs. Some of the outputs will be externally connected to devices outside the PLC, but it
is also possible to use internal memory locations in the PLC. Six types of outputs are shown
in Figure 4.8.. The first is a normal output, when energized the output will turn on, and
energize an output. The circle with a diagonal line through is a normally on output.When
energized the output will turn off. This type of ooutput
utput is not available on all PLC types.When
initially energized the OSR (One Shot Relay) instruction will turn on for one scan, but then
be off for all scans after, until it is turned off. The L (latch) and U (unlatch) instructions can
be used to lock outputs
puts on. When an L output is energized the output will turn on
indefinitely, even when the output coil is DE energized.. The output can only be turned off
using a U output. The last instruction is the IOT (Immediate Output)) that will allow outputs
to be updated
ated without having to wait for the ladder logic scan to be completed.

RIET/B.TECH/EE/15EREEE010/Page
RIET/B.TECH/EE/15EREEE | 28
 VWTPL, JAIPUR

Figure 4.8:- Ladder Logic Outputs

RIET/B.TECH/EE/15EREEE010/Page
RIET/B.TECH/EE/15EREEE | 29
 VWTPL, JAIPUR

Chapter-5
CONCLUSION

 Automation is the use of machines, control systems and information technologies to

optimize productivity in the production of goods and delivery services.
 The correct incentive for applying automation is to increase productivity, and/or quality
beyond that possible with current human labor levels so as to realize economies of scale,
and/or realize predictable quality levels.
 The incorrect application of automation, which occurs most often, is an effort to
eliminate or replace human labor
 As we all know that the branch instrumentation plays a very important role in the
management of automation in any industry or process plant. Each and every process
requires the need of certain specific instruments for their controlling.
 When the word automation comes into play, instrumentation automatically involves in it.
Without the help of instrumentation it is not possible to apply automation in any industry.
 A feedback system is applied in the industry, i.e. a set point is given and the input is
feedback according to the current output and the set point applied.
 When PLC i.e. programmable logic control type automation is applied in any industry, it
requires the continuous reading of these parameters.

RIET/B.TECH/EE/15EREEE010/Page | 30
 VWTPL, JAIPUR

REFERENCES

 http://www.google.co.in/#hl=en&sclient=psy- bih=667
 http://www.google.co.incement+wikipedia&oq=instruments+of++SCADA+wikipedi
a&gs
 http://www.google.co.in/automation==241
 http://www.google.co.in/PLC==441

RIET/B.TECH/EE/15EREEE010/Page | 31