PLC-SCADA and their applications

As part of sandwich apprenticeship training 2017 at ECIL

By
V.S KARTHIK PRAPANNA
14054-IE-057
 ELECTRONICS CORPORATION OF INDIA LIMITED
• It’s a Government of India enterprise
established on 11th of april,1967 under
the department of Atomic Energy
establishment (AEE) to primarily meet
the Control & Instrumentation
requirements of India’s nuclear power
project.

vision
“To contribute to the country in
achieving self reliance in strategic
electronics”.
• To accomplish this goal i.e., to
provide diversified services to our
nation indigenously ECIL gave birth
to many departments in past few
years within it.
 Chronicles of ECIL

• First Digital Computer –’TDC 12 (Trombay Digital computer-12 bit)

• First Solid State TV
• First Control & Instrumentation of Nuclear Power Plants
• First Earth Station Antenna
• First Electronic Voting Machines
• First Solid State Cockpit Voice Recorder
 Welcome to the branch of control automation
• Control automation, as it’s name suggests control of field processes or
house hold processes automatically i.e., without any human intervention,
which is also known as a control system.
• A control system is a system, which provides the desired response by
controlling the output.

• Control system is further classified into two types:

1) Open loop control system
2)closed loop control system
 Open loop and Closed loop
• In open loop control systems, output is not fed-back to the input. So, the
control action is independent of the desired output.

• In closed loop control systems, output is fed back to the input. So, the
control action is dependent on the desired output.
 Why we need PLCs in control systems?

• Here the control system’s main goal is to minimize the necessity of

continuous human monitoring and also to increase the process precision.
In order to achieve these goals it should contain basic intelligence and all
the means to put that intelligence into use.
• We have many such intelligent electronic applications like:

Micro controller
based Adruino
boards
Computer
Relay circuits
 PROGRAMMABLE LOGIC CONTROLLER
• According to NEMA standard ICS3-1978 PLC is defined as “digitally
operating electronic apparatus which uses a programming memory
for the internal storage of instructions for implementing specific
functions such as logic, sequencing, timing, counting and arithmetic
to control through digital or analog modules, various types of
machines or process”.
 M340 a typical industrial PLC/RTU
5
2 5
1 CPS
2

2 PROCESSOR

3 NOR

4 Digital input

1 4
3 3 4
5 Analog I/O 1
 Rack Supply
BMX CPS 2000/3020
Power Bank for all the modules over rack

CPS 2000 CPS 3020

Source Supply : 230V AC Source Supply : 48 DC
For main stations For remote stations
Rating 20W Rating 32W

LED Description of the Statuses

OK LED (green) •on in normal operating mode
•off when the rack power supply output voltage is
below the threshold or when the RESET button is
pressed.
24 V LED (green) •on in normal operating mode
only on the BMX CPS •off if the 24 V sensor voltage supplied by the power
2000 supply is no longer present
 Processor

Criterion:
Processing power (number of inputs/outputs managed)
Memory capacity
Communication ports

BMX P34 2020

supports maximum number of
Discrete inputs/outputs: 1024
Analog inputs/outputs: 256
Memory size: 4096Kb
Flash Memory for storing the application program/project
 Processor: Diagnostics
Label S

Pattern Indication
RUN (green): operational state •PLC hardware and PLC program operations are normal.
on •Module is in RUN state.
•PLC is in STOP mode or a blocking error in the application has been detected.
flashing •Processor is configured but not in RUN state.

off PLC is not configured (application is absent, invalid, or incompatible).

ERR (red): detected error on Processor, system, or configuration detected error
•PLC is not configured (application is absent, invalid, or incompatible).
flashing •PLC is in STOP mode or a blocking error in the application has been detected.

off Normal (no detected errors)

ETH STS (green): Ethernet on Communication OK
communication status Invalid MAC address
2 flashes
3 flashes Link not connected
4 flashes Duplicate IP address
5 flashes Waiting for a server IP address
6 flashes Secure and safe mode (with default IP address)

7 flashes Configuration conflict between rotary switches and internal configuration

CARDERR (red): memory card •Memory card is missing.
detected error on •Memory card not usable (bad format, unrecognized type).
•Memory card content is inconsistent with internal RAM application.
•Memory card is valid and recognized.
off •Application on card is consistent with the internal RAM application.
I/O (red): input/output status •Error detected on a configured module or CPU channel
on •Configuration mismatch with the application (module missing...)
off Normal (no detected errors)
SER COM (yellow): serial data status flashing Data exchange (send/receive) on the serial connection in progress

off No data exchange on the serial connection

 Digital input
General Field Loop/Wiring Diagram:

24V

P S CI
R E R
O 24V
10 N C
C SI U
E N IT
S G
S
O
R MODULE

PANEL
 Digital input
BMXDDI3202 :

positive logic (or sink) module

32 input
=1 IF Voltagechannels ≥ 11 V
=0 IF Voltage < 5 V
 Digital Output
General Field Loop/Wiring Diagram:

GND

T
O
P
R FI
O E
C 10 24V L
E D
Relay
S Pre-actuator
S
O
R
MODULE

PANEL
 Digital output
BMXDDO1602 :

Positive logic (or source) module

16 output channels
Current/channel 0.625 A
Current/module 10 A
 Analog Input
General Field Loop/Wiring Diagram:

24V Field
Instrument

P A
R D
O 0 C 0V 4mA
2
C
0 to 16000 1V 5
4mA to 20mA
E C 0
to Ω
S K
S T 5V
O Count=160* (Current-4)
R MODULE Current=(0.001* Count)+4

PANEL
 Analog Output

Field
GND Instrument

0 to 16000
4mA to 20mA

PANEL
 Analog Output

BMX AMO 0802 :

8 channels
current ranges for each output: 0..20 mA & 4..20 mA
 NOR
BMX NOR 0200 :
The BMX NOR 0200 H module supports these functions and
protocols:
RTU protocols:
Built-in RTU protocols for serial or Ethernet communications
IEC 60870-5-101 (master or slave)
IEC 60870-5-104 (client or server)
DNP3 serial (master or slave)
DNP3 IP (client or server)
Modbus TCP (client or server)
Main RTU Protocol Features:
Time synchronization through protocol facility or NTP
Events management with time stamping - Sequence of Events (SOE)
Events queue stored in RAM memory (up to 100,000 events for all
clients)
Events data backfill to SCADA application via protocol facility
Unsolicited messaging data exchanges
Protocol setup via Web page
 NOM

BMX NOM 0200 :

2-way asynchronous serial line
Modbus Serial (master or slave)
Channels of the BMX NOM 0200 module include:
Two isolated RS485 Physical Interfaces,
One non-isolated RS232 Physical Interface,
Modbus Serial (ASCII and RTU) and Character Mode communication
types
 NOC
BMX NOC 0401:
Interface between a M340 RTU and other Ethernet network devices
by means of either the EtherNet/IP
or the Modbus TCP communication protocol
Provided in main stations as interface to Main Station PLCs

An important point that has to be noted is that all the

m340 series processors can only handle upto 3 TCP/IP ports
including its own TCP/IP port .That means in case of processors like
BMX P34 2020 where the processor itself has an inbuilt TCP/IP port
that station can have two more ports that’s all not more than that.
 Ladder diagram and its implementation

Push button
ON
OFF

%I0 %I 0.2.1 %Q 0.2.3

(button) (Pre-act)
_ + FUSE
01
Pre-act
%Q2
+ _
FUSE

DDM(16 channel-I/O module) LADDER PROGRAM

NOTE: In this case Topological addressing has been used to address the ‘NO’ contact
 SCADA
• SCADA(Supervisory Control And Data Acquisition) is a category of
software application program for process control, the gathering of data
in real time from remote locations in order to control equipment and
conditions.
• SCADA systems include hardware and software components. The
hardware gathers and feeds data into a computer that has SCADA
software installed . The computer then processes this data and presents it
in a timely manner.
• SCADA also records and logs all events into a file stored on a hard disk or
sends them to a printer.
• SCADA applications warn when conditions become hazardous by
sounding alarms.
Typical SCADA architecture
Solid State Cockpit Voice Recorder
Deep space network antenna (32m)
Nuclear plant control room
APSARA
TDC-12