Company Profile: Iv Year 2011-12 PLC, Scada

IV YEAR 2011-12 PLC, SCADA
COMPANY PROFILE
Founded in 1997, with the vision of "Best quality high end training on
automation platforms and Components (PLCs /SCADA /DCS /Drives
/Instrumentation /Electricals /networking) to serve 2 noble purposes – Cost effective
job oriented training for needy engineering graduates and upgrading skill levels of
working professional in manufacturing industry". Prolific services enterprises and
individuals in over 20 Indian cities with its wide ranging knowledge based learning
solutions in Automation industry. Prolific strength stems from its well accepted
expertise in providing turnkey automation solutions. Brief Background of prolific is
professionally run company established by technocrats with several years of
experience in the automation industry and embedded systems. Prolific is one of the
leading turnkey automation solution provider and the largest Indian advanced training
provider in the areas of automation systems and embedded systems. Prolific has fully
equipped facilities at OVER 20 KEY LOCATIONS
IN INDIA. Prolific - India's largest automation training company In order to cater to
Indian industry's demand for skilled technical manpower in high-end technologies,
Prolific established the Training division that imparts advanced technology training,
currently, in the areas of control systems, instrumentation and embedded systems.
Prolific also provides corporate training. Prolific generic teaching methodology and
focus on practical training has helped it gain strong foothold in Indian industry.
Prolific's corporate training clients include many blue-chip companies such as

Sesa Goa, Aditya Birla Group companies, Ordinance factories, Garware Polyesters,
Indian Rayon, Indal, ITC, Reliance Industries, India Cements, Saw Pipes, IPCL,
GAIL and many more (detailed list in corporate clients).
Prolific differentiates due to
» Experienced and qualified faculty
» Proven clientele of blue chip companies
» Ability to provide training on multi brand automation systems and embedded
systems
» Ability to conduct training at client's facility
» Large investment on modern equipment
» National presence - Fully equipped labs at Mumbai, Delhi, Chennai, Pune and
Cochin
» 100% track record of providing placement to fresher prolific Technology Skill Sets
Software
ASPIC, In Touch, RS View, Intellection, AIMAX, IC-2000, Coros, Cimplicity,
DasyLab, Visual Basic,
Oracle, Power Builder, HTML, JAVA.
Controllers and Data Loggers
Moore, ABB, NuDam, Yokogava, Advantech, Bells, Aplab.
PLCs
SITE NATHDWARA Page 1
Modicum, Allen Bradley, GE Fanuc, Siemens and Mitsubishi.
Instruments
All kinds of instruments used in temperature, pressure, flow, pH, weight, speed
measurement and control
Embedded Systems
Microcontrollers, Embedded C programming
Prolific Turnkey Execution Capabilities

Prolific provides end-to-end comprehensive Total Automation Solutions through
integration of cutting edge, state-of-the art PLCs (Programmable Logic Controllers),
controllers, and distributed data Acquisition and control systems, compact PCI and PC
based open control software solutions. Prolific is among the first houses to provide
SCADA based solutions on open systems in India. In the past 6 years, Prolific has
developed foothold in diverse industry segments and with blue chip customers.
Prolific is completing projects in Nepal, Bangladesh and China.

1. INTRODUCTION
Automation is basically the delegation of human control Function to technical

equipment for
 Increasing Productivity
 Increasing Quality
 Reducing Cost
 Increasing Safety in working conditions
Simplification of engineering and precise control of manufacturing

process can result in significant cost savings. The most cost-effective way, which can
pay big dividends in the long run, is flexible automation; a planned approach towards
integrated control systems. It requires a conscious effort on the part of plant managers
to identify areas where automation can result in better deployment/utilization of
human resources and savings in man-hours, down time. Automation need not be high
ended and too sophisticated; it is the phased, step-by-step effort to automate,
employing control systems tailored to one’s specific requirements that achieves the
most attractive results. That is where Industrial electronics has been a breakthrough
in the field of automation and control techniques.
1.2-ROLE OF ELECTRONICS IN AUTOMATION

A constant demand for better and more efficient manufacturing and
process machinery has led to the requirement for higher quality and reliability in
control techniques. With the availability of intelligent, compact solid state electronic
devices, it has been possible to provide control systems that can reduce maintenance,
down time and improve productivity to a great extend. By installing efficient and
user friendly industrial electronics systems for manufacturing machinery or
processors, one can obtain a precise, reliable and prolific means for generating quality
products.
Considering the varied demand and increasing competition, one has to
provide for flexible manufacturing process. One of the latest techniques in solid state
controls that offers flexible and efficient operation to the user is “PROGRAMMABLE
CONTROLLERS”. The basic idea behind these programmable controllers was to

provide means to eliminate high cost associated with inflexible, conventional relay
controlled systems. Programmable controllers offer a system with computer
flexibility:
1. Suited to withstand the industrial environment
2. Has simplicity of operation
3. Maintenance by plant technicians and
4. Reduce machine down time and provide expandability for future.
1.3-DEFINATION OF PLC
A Programmable controller is a solid state user programmable control

system with functions to control logic, sequencing, timing, arithmetic data
manipulation and counting capabilities. It can be viewed as an industrial computer
that has a central processor unit, memory, input output interface and a programming
device. The central processing unit provides the intelligence of the controller. It
accepts data, status information from various sensing devices like limit switches,
proximity switches, executes the user control program store in the memory and gives
appropriate output commands to devices like solenoid valves, switches etc.
Input output interface is the communication link between field devices
and the controllers; field devices are wired to the I/O interfaces. Through these
interfaces the processor can sense and measure physical quantities regarding a
machine or process, such as, proximity, position, motion, level, temperature, pressure,
etc. Based on status sensed, the CPU issues command to output devices such as
valves, motors, alarms, etc. Programmer unit provides the man machine interface. It
is used to enter the application program, which often uses a simple user-friendly logic.

1.4-BENEFITS OF PROGRAMMABLE CONTROLLERS

1. Programmable controllers are made of solid state components and hence
provide high reliability.
2. They are flexible and changes in sequence of operation can easily be
incorporated due to programmability. They may be modular in nature and
thus expandability and easy installation is possible.
3. Use of PLC results in appreciable savings in Hardware and wiring cost.
4. They are compact and occupy less space.
5. Eliminate hardware items like Timers, counters and Auxiliary relays. The
presence for timers and counters has easy accessibility.
6. PLC can control a variety of devices and eliminates the need for
customized controls.
7. Easy diagnostic facilities are provided as a part of the system. Diagnosis
of the external systems also becomes very simple. Thus easy
service/maintenance.
8. Programming devices provide operator friendly interface with the
machine. Being an outcome of the latest art of electronics technology,
Programmable controllers provide higher level of performance with
computers is possible. Useful management data can be obtained and
maintained.
9. It has total protections against obsolescence and has wide scope for up
gradation.

2.PLC ARCHITECTURE
PLCs contain three basic sections:
1. Central processing unit (CPU).
2. Memory: EPROM, RAM, and so on.
3. Input/output section for communication with peripherals (ADC, DAC).
A PLC is basically a black box with a number of inputs from, and a

number of outputs to, the outside world. It can make decisions, store data, do timing
cycles, and do simple arithmetic, convert codes, and so on. The basic difference
between this black box and a hardware logic system using IC chips or a relay
controlled system, is that specific coded messages are stored in areas called program

memory, which are PROM or ROM and RAM chips. It is, however, much easier to
change a program when a different process is required than to rewire the control
system. For example, it may take electricians a couple of weeks to require a pipe
mill, whereas a programmer will spend only a fraction of this time to reprogram a
PLC since no wires will have to be changed. In addition, various recipes can be
stored in memory and accessed when required, making the program extremely
flexible.
The system operates through interaction with the processor and program
memory. When the power to the system is turned on, the processor reads the first
instruction stored in memory and acts on this instruction. When completed, it goes
back to the memory for the next instruction, and so on until task is complete. This
operation is called the fetch-execute cycle. The processor communicates with the
outside world via input and output modules.

3. THE PARTS OF A PROGRAMMABLE CONTROLLER
Programmable logic controllers (PLC) can be considered to have two parts:
1. Input/output Section
The I/O section contains input modules and output modules. Functionally,
the input modules are equivalent to the signal converters (i.e. Analog to Digital or
high power to low power). All modern PLC input modules use optical devices to
accomplish electrically isolated coupling between the input circuit and the processor
electronics.
Each input device is wired to a particular input terminal on the I/O
section. Thus if the switch is closed, 5v dc appears on input terminal, converts this dc
voltage to a digital 1 and sends it to the processor via programmable peripheral
interface (PPI). Conversely, if the switch is open, no dc voltage appears on input
terminal. Input section will respond to this condition by sending a digital 0 to the
processor. The other input terminals behave identically.

2. The Processor
The processor of a PLC holds and executes the user program. In order to
carry out this job, the processor must store the most up-to-date input and output
conditions.
(a) Input image table:

The input conditions are stored in the input image table, which is a
portion of the processor’s memory. That is, every single input module in the I/O
section has assigned to it a particular location within the input image table. That
particular location is dedicated solely to the task of keeping track of the latest
condition of its input terminal. As mentioned in earlier section, if the input terminal
has 5v dc power fed to it by its input device, the location within the input image table
contains a binary 1(HI); if the input terminal has no 5v dc power fed to it, the location
contains a binary 0(LO).
The processor needs to know the latest input conditions because the user
program instructions are contingent upon those conditions. In other words, an
individual instruction may have one outcome if a particular input is HI and a different
outcome if that input is LO.
(b) Output image table:

The output conditions are stored in the output image table, which is
another portion of the processor’s memory. The output image table bears the same
relation to the output interface of the I/O section that while terminals are analog
inputs. You can directly connect any analog input to the processor via these terminals.
Analog signal from these terminals is first converted to digital value via
programmable peripheral interface (PPI). The I/O section’s output modules are
functionally the same as the output amplifiers. They receive a low power digital
signal from the processor and convert it into a high power signal capable of driving an
industrial load. A modern PLC output module is optically isolated, and uses a triac,
power transistor or relay as the series connected load controlling device. Terminal 1 to
8 are these type of O/P terminals whereas terminal D/A is Analog output terminal
from processor. Each output device is wired to a particular output terminal on the I/O

interface. Thus, for example, if output module 1 receives a digital 1 by applying 5v

dc to output terminal 1, thereby illuminating LED is extinguished.
Besides 5v dc (TTL devices), I/O module are also for interfacing to other
industrial levels, including 12v dc. The input image table bears to the input modules.
That is, every single output module has assigned to it a particular memory location is
dedicated solely to the task of keeping track of the latest condition of its output
module. Of course, the output situation differs from the input situation with regard to
the direction of information flow is from the output image table to the output
modules, while in the input situation the information flow is from the input modules
to the input image table. The locations within the input and output image tables are
identified by addresses, which refers to unique address of each terminal.
(C) Central processing unit:

The subsection of the processor that actually performs the program
execution will be called the central processing unit (CPU) with reference to input and
output image table CPU executes the user program and continuously updates the
output image table.
The output image table has a dual nature; its first function is to receive
immediate information from the CPU and pass if on to the output modules of the I/O
section; but secondly, it also must be capable of passing output information
“backward” to the CPU, when the user program instruction that the CPU is working
on calls for an item of output information. The input image table does not have its
dual nature. Its single mission is to acquire information from the input modules and
pass that information “forward” to the CPU when the instruction that the CPU is
working on calls for an item of input information.
(d)User program memory:

A particular portion of the processor’s memory is used for storing the user
program instructions. We will use the name user program memory to refer to this
processor subsection.
Before a PLC can begin controlling an industrial system, a human user
must enter the coded instructions that make up the user program. This procedure
called programming the PLC.

As the user enters instructions, they are automatically stored at sequential

locations within the user program memory. This sequential placement of program
instructions is self-regulated by the PLC, with no discretion needed by the human
user.
The total number of instructions in the user program can range from a half
dozen or so, for controlling a simple machine, to several thousand, for controlling a
complex machine or process.
After the programming procedure is complete, the human user manually
switches the PLC out to PROGRAM mode into RUN mode, which causes the CPU to
start executing the program from beginning to end repeatedly.
(e)The complete scan cycle:

As long as the PLC is left in the RUN mode, the processor executes the
user program over and over again. Figure depicts the entire repetitive series of events.
Beginning at the top of the circle representing the scan cycle, the first operation is the
input scan. During the input scan, the current status of every input module is stored in
the input image table, bringing it up to date.
Following the input scan, the processor enters its user program execution
and Sometimes called “program scan”. The program executes with reference to input
and output image tables and updates output image table.
Throughout the user program execution, the processor continuously keeps
its output image table up to date, as stated earlier. However, the output modules
themselves are not kept continuously up to date. Instead, the entire output image table
is transferred to the output module during the output scan following the program
execution.
(f) Data Memory:

A PLC is a computer, after all. Therefore, it can perform arithmetic,
numeric comparisons, counting, etc. Naturally the numbers and data can change from
one scan cycle to the next. Therefore the PLC must have a section of its memory set
aside for keeping track of variable data, or numbers, that are involved with the user
program. This section of memory we will call data memory.

When the CPU is executing an instruction for which a certain data value
must be known, that data value is brought in from data memory. When the CPU
executes an instruction that provides a numerical result, that result is put out into data
memory. Thus, CPU can read from or write to the data memory. Understand that this
relationship is different from the relationship between the CPU and the user program
memory. When the user program is executing, the CPU can only reads from the user
program memory, never write to it.
(g) Operating System of PLC:

The function of the operating system is to present the user with the
equivalent of an extended machine or virtual machine that is easier to program than
the underlying hardware.
Due to this operating system, PLC is very easy to program. It can be
programmed using electrical schemes with familiar relay symbols so that a plant
electrician can easily access the PLC. Even though he does not know the assembly
language or even if he may not have any familiarity with computers and electronics,
he will be able to program the PLC.
The function of PLC Operating system is:
1. Loads the user program from programming device to program memory.
2. To read status of input devices.
3. To execute user program.
4. To form and update input image table.
5. As per the status of output image table controls the output devices.
6. To provide user-friendly functions.
This O.S. makes supervision over entire system, so O.S. programs are
said to running in supervisory mode.
When the user completely enters his program in user memory, he transfers
control from PROGRAM mode to RUN mode. In RUN mode the control of the
whole system is transferred to operating system. Now operating system takes care of
the whole system such that the whole system becomes automatic and appears as
magic to users.

4. SOFTWARE DESCRIPTION
This chapter explains how to program the PLC. It describes how to write
a program, how the program is structured and representation of the programming
language.
Writing a Program:
A control program specifies a series of operations that tell the
programmable controller how it has to control a system. For example, a control
program might be the series of operations that tell the PLC how to use open loop
control or close loop control for a specific system. We must write the program in a
specific programming language and according to some specific rules so that the
programmable controller can understand it.
Method of Representation:
The following methods of representation are possible to program

PLC.
1. Statement List (STL):
STL represents the program as a sequence of operation mnemonics. A statement has
the following format:
A I 04
Where A represents AND operation,
I represent INPUT and
04 represent ADDRESS of INPUT.
2. Control System Flowchart (CSF):
CSF represents logic operations with graphics symbols.
3. Ladder Diagram (LAD):
LAD graphically represents control functions with circuit diagram symbols.

5. APPLICATIONS OF PLC
In the present industrial world, a flexible system that can be controlled by

user at site is preferred. Systems, whose logic can be modified but still, used without
disturbing its connection to external world, is achieved by PLC. Utilizing the
industrial sensors such as limit switches, ON-OFF switches, timer contact, counter
contact etc., PLC controls the total system. The drive to the solenoid valves, motors,
indicators, enunciators, etc are controlled by the PLCs.
The above said controlling elements (normally called as inputs of PLCs)
and controlled elements (called as outputs of PLCs) exist abundantly in any industry.
These inputs, outputs, timers, counters, auxiliary contacts are integral parts of all
industries. As such, it is difficult to define where a PLC cannot be used.
Proper application of a PLC begins with conversion of information into
convenient parameters to save money, time and effort and hence easy operation in
plants and laboratories.
The areas where PLC is used maximum are as follows:
1. The batch processes in chemical, cement, food and paper industries which
are sequential in nature, requiring time of event based decisions is
controlled by PLCs.
2. In large process plants PLCs are being increasingly used for automatic
start up and shut down of critical equipment. A PLC ensures that
equipment cannot be started unless all the permissive conditions for safe
start have seen established. It also monitors the conditions necessary for
safe running of the equipment and trips the equipment whenever any
abnormality in the system is detected.
3. The PLC can be programmed to function as an energy management system
for boiler control for maximum efficiency and safety.
4. In automation of blender recliners
5. In automation of bulk material handling system at ports.
6. In automation for a ship unloaded.
7. Automation for wagon loaders.

8. For blast furnace charging controls in steel plants.

9. In automation of brick molding press in refractory.
10. In automation for galvanizing unit.
11. For chemical plants process control automation.
12. In automation of a rock phosphate drying and grinding system.
13. Modernization of boiler and turbo generator set.
14. Process visualization for mining application.
15. Criteria display system for power station.
16. As stored programmed automation unit for the operation of diesel
generator sets.
17. In Dairy automation and food processing.
18. For a highly modernized pulp paper factory.
19. In automation system for the printing industry.
20. In automation of container transfer crane.
21. In automation of High-speed elevators.
22. In plastic molding process.
23. In automation of machine tools and transfer lines.
24. In Mixing operations and automation of packaging plants.
25. In compressed air plants and gas handling plants.
26. In fuel oil processing plants and water classification plants.
27. To control the conveyor/classifying system.
Thus PLC is ideal for application where plant machine interlock
requirements are finalized at a later stage and need changes during engineering trial
runs, commissioning or normal use.
FUTURE OF PLCs
The PLC offers a compromise between advance control techniques and
present day technology. It is extremely difficult to forecast the rate and form of
progress of PLCs, but there is strong evidence that development is both rapid and
cumulative. Though a PLC is not designed to replace a computer, it is useful and cost
effective for medium sized control systems. With the capability of functioning as
local controllers in distributed control systems, PLCs will retain their application in
large process plants.

A further development of PLCs leads to the development of

programmable function controller (PFC) is compatible to PCs and directly controls
the desired functions.
In India every process industry is replacing relay control systems by PLCs
and will go for PFCs in near future. In the near future every flats and offices may
possess PFCs to control room temperature, as elevator controller, maintain water tank
levels, as small telephone exchange etc.

SCADA
SUPERVISORY CONTROL AND DATA ACQUISITION
6. INTRODUCTION
SCADA is an acronym for Supervisory Control and Data Acquisition.
SCADA systems are used to monitor and control a plant or equipment in industries
such as telecommunications, water and waste control, energy, oil and gas refining and
transportation. These systems encompass the transfer of data between a SCADA
central host computer and a number of Remote Terminal Units (RTUs) and/or
Programmable Logic Controllers (PLCs), and the central host and the operator
terminals. A SCADA system gathers information (such as where a leak on a pipeline
has occurred), transfers the information back to a central site, then alerts the home
station that a leak has occurred, carrying out necessary analysis and control, such as
determining if the leak is critical, and displaying the information in a logical and
organized fashion.
These systems can be relatively simple, such as one that monitors
environmental conditions of a small office building, or very complex, such as a
system that monitors all the activity in a nuclear power plant or the activity of a
municipal water system. Traditionally, SCADA systems have made use of the Public
Switched Network (PSN) for monitoring purposes. Today many systems are
monitored using the infrastructure of the corporate Local Area Network (LAN)/Wide
Area Network (WAN). Wireless technologies are now being widely deployed for
purposes of monitoring.
SCADA systems consist of:
1. One or more field data interface devices, usually RTUs, or PLCs, which
interface to field sensing devices and local control switchboxes and valve
actuators
2. A communications system used to transfer data between field data interface
devices and control units and the computers in the SCADA central host. The
system can be radio, telephone, cable, satellite, etc., or any combination of
these.
3. A central host computer server or servers (sometimes called a SCADA Center,
master station, or Master Terminal Unit (MTU)

4. A collection of standard and/or custom software [sometimes called Human

Machine Interface (HMI) software or Man Machine Interface (MMI)
software] systems used to provide the SCADA central host and operator
terminal application, support the communications system, and monitor and
control remotely located field data interface devices.
5. SCADA is widely used in industry for Supervisory Control and Data
Acquisition of industrial processes; SCADA systems are now also penetrating
the experimental physics laboratories for the controls of ancillary systems
such as cooling, ventilation, power distribution, etc. SCADA systems have
made substantial progress over the recent years in terms of Functionality,
scalability, performance and openness such that they are an alternative to in
house development even for very demanding and complex control systems as
those of physics experiments.
Figure: Typical SCADA System

7. OVERVIEW OF SCADA
Types of SCADA
1. D+R+N (Development +Run + Networking)
2. R+N (Run +Networking)
3. Factory focus
Features of SCADA
1. Dynamic process Graphic
2. Alarm summery
3. Alarm history
4. Real time trend
5. Historical time trend
6. Security (Application Security)
7. Data base connectivity
8. Device connectivity
9. Scripts
10. Recipe management
Manufacture of SCADA
Modicum (Telemecanique) Visual look
Allen Bradley: RS View
Siemens: win cc
Gefanc:
KPIT: ASTRA
Intelution: Aspic
Wonderware: Intouch

8. ARCHITECTURE OF SCADA
SCADA systems have evolved in parallel with the growth and sophistication
of modern Computing technology. The following sections will provide a description
of the following three generations of SCADA systems:
• First Generation – Monolithic
• Second Generation – Distributed
• Third Generation – Networked
8.1 Monolithic SCADA Systems
When SCADA systems were first developed, the concept of computing in
general centered on “mainframe” systems. Networks were generally non-existent, and
each centralized system stood alone. As a result, SCADA systems were standalone
systems with virtually no connectivity to other systems. The Wide Area Networks
(WANs) that were implemented to communicate with remote terminal units (RTUs)
were designed with a single purpose in mind–that of communicating with RTUs in the
field and nothing else. In addition, WAN protocols in use today were largely unknown
at the time. The communication protocols in use on SCADA networks were
developed by vendors of RTU equipment and were often proprietary. In addition,
these protocols were generally very “lean”, supporting virtually no functionality
beyond that required scanning and controlling points within the remote device. Also,
it was generally not feasible to intermingle other types of data traffic with RTU
communications on the network.
Connectivity to the SCADA master station itself was very limited by the
system vendor. Connections to the master typically were done at the bus level via a
proprietary adapter or controller plugged into the Central Processing Unit (CPU)
backplane. Redundancy in these first generation systems was accomplished by the use
of two identically equipped mainframe systems, a primary and a backup, connected at
the bus level. The stand by system’s primary function was to monitor the primary and
take over in the event of a detected failure. This type of standby operation meant that
little or no processing was done on the standby system. Figure 3.1 shows a typical
first generation SCADA architecture.

Figure : First Generation SCADA Architecture
8.2: Distributed SCADA Systems

The next generation of SCADA systems took advantage of developments
and improvement in system miniaturization and Local Area Networking (LAN)
technology to distribute the processing across multiple systems. Multiple stations,
each with a specific function, were connected to a LAN and shared information with
each other in real-time. These stations were typically of the mini-computer class,
smaller and less expensive than their first generation processors. Some of these
distributed stations served as communications processors, primarily communicating
with field devices such as RTUs. Some served as operator interfaces, providing the
human-machine interface (HMI) for system operators. Still others served as
calculation processors or database servers. The distribution of individual SCADA
system functions across multiple systems provided more processing power for the
system as a whole than would have been available in a single processor.
The networks that connected these individual systems were generally
based on LAN protocols and were not capable of reaching beyond the limits of the
local environment. Some of the LAN protocols that were used were of a proprietary

nature, where the vendor created its own network protocol or version thereof rather
than pulling an existing one off the shelf. This allowed a vendor to optimize its LAN
protocol for real-time traffic, but it limited (or effectively eliminated) the connection
of network from other vendors to the SCADA LAN. Figure 11.2 depicts typical
second generation SCADA architecture. Distribution of system functionality across
network-connected systems served not only to increase processing power, but also to
improve the redundancy and reliability of the system as a whole. Rather than the
simple primary/standby failover scheme that was utilized in many first generation
systems, the distributed architecture often kept all stations on the LAN in an online
state all of the time.
For example, if an HMI station were to fail, another HMI station could be
used to operate the system, without waiting for failover from the primary system to
the secondary. The WAN used to communicate with devices in the field were largely
unchanged by the development of LAN connectivity between local stations at the
SCADA master. These external communications networks were still limited to RTU
protocols and were not available for other types of network traffic. As was the case
with the first generation of systems, the second generation of SCADA systems was
also limited to hardware, software, and peripheral devices that were provided or at
least selected by the vendor.

Figure: Second Generation SCADA Architecture

8.3: Networked SCADA Systems
The current generation of SCADA master station architecture is closely
related to that of the second generation, with the primary difference being that of open
system architecture rather than a vendor controlled, proprietary environment. There
are still multiple networked systems, sharing master station functions. There are still
RTUs utilizing protocols that are vendor-proprietary. The major improvement in the
third generation is that of opening the system architecture, utilizing open standards
and protocols and making it possible to distribute SCADA functionality across a
WAN and not just a LAN. Open standards eliminate a number of the limitations of
previous generations of SCADA systems. The utilization of off-the-shelf systems
makes it easier for the user to connect third party peripheral devices (such as
monitors, printers, disk drives, tape drives, etc.) to the system and/or the network. As
they have moved to “open” or “off-the-shelf” systems, SCADA vendors have
gradually gotten out of the hardware development business. These vendors have
looked to system vendors such as Compaq, Hewlett-Packard, and Sun Microsystems
for their expertise in developing the basic computer platforms and operating system

software. This allows SCADA vendors to concentrate their development in an area

where they can add specific value to the system–that of SCADA master station
software.
The major improvement in third generation SCADA systems comes from
the use of WAN protocols such as the Internet Protocol (IP) for communication
between the master station and communications equipment. This allows the portion of
the master station that is responsible for communications with the field devices to be
separated from the master station “proper” across a WAN. Vendors are now producing
RTUs that can communicate with the master station using an Ethernet connection.
Figure 11.3 represents a networked SCADA system. Another advantage brought about
by the distribution of SCADA functionality over a WAN is that of disaster
survivability. The distribution of SCADA processing across a LAN in second-
generation systems improves reliability, but in the event of a total loss of the facility
housing the SCADA master, the entire system could be lost as well. By distributing
the processing across physically separate locations, it becomes possible to build a
SCADA system that can survive a total loss of any one location. For some
organizations that see SCADA as a super-critical function, this is a real benefit.
Figure: Third Generation SCADA Architecture

Hardware Architecture
One distinguishes two basic layers in a SCADA system: the "client layer" which
caters for the man machine interaction and the "data server layer" which handles most
of the process data control activities. The data servers communicate with devices in
the field through process controllers. Process controllers, e.g. PLCs, are connected to
the data servers either directly or via networks or field buses that are proprietary (e.g.
Siemens H1), or non-proprietary (e.g. Profibus). Data servers are connected to each
other and to client stations via an Ethernet LAN. The data servers and client stations
are NT platforms but for many products the client stations may also be W95
machines.
Software Architecture
The products are multi-tasking and are based upon a real-time database (RTDB)
located in one or more servers. Servers are responsible for data acquisition and
handling (e.g. polling controllers, alarm checking, calculations, logging and
archiving) on a set of parameters, typically those they are connected to.

9. FUNCTIONALITY OF SCADA
9.1 Access Control
Users are allocated to groups, which have defined read/write access
privileges to the process parameters in the system and often also to specific product
functionality.
9.2 Trending
The products all provide trending facilities and one can summaries the common
Capabilities 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
same chart
 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.
9.3 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 developed by creating derived parameters on which status or limit
checking is then performed. The alarms are logically handled centrally, i.e., the
information only exists in one place and all users see the same status (e.g., the
acknowledgement), and multiple alarm priority levels (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 filtering on group or acknowledgement of all alarms in a group).
Furthermore, it is possible to suppress alarms either individually or as a complete
group..
9.4 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 archiving is long-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 period or number of points is reached the data is overwritten. Logging of
data can be performed at a set frequency, or only initiated if the value changes or
when a specific predefined event occurs. Logged data can be transferred to an archive
once the log is full. The logged data is time-stamped and can be filtered when viewed
by a user. The logging of user actions is in general performed together with either a
user ID or station ID. There is often also a VCR facility to play back archived data.
9.5 Report Generation
One can produce reports using SQL type queries to the archive, RTDB or
logs. Although it 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.
9.6 Automation
The majority of the products allow actions to be automatically triggered
by events. A scripting language provided by the SCADA products allows these actions
to be defined.
In general, one can load a particular display, send an Email, run a user
defined application or script and write to the RTDB. The concept of recipes is
supported, whereby a particular system configuration can be saved to a file and then
re-loaded at a later date. Sequencing is also supported whereby, as the name indicates,
it is possible to execute a more complex sequence of actions on one or more devices.
LAKE FILTER

RESERVIOR MANAGEMENT
PROJECT







CONCLUSION
Thus it can be concluded using cost benefit analysis and some technical aspects being
included in the report that through total automation solution, synthetic chemical plant
following gain points can be achieved:
 Enhanced control over plant operation
 Better usage of utilities like boiler etc.
 Higher productivity
 Improved skill of workmen
 Better monitoring leading to reduced maintenance
 Greater safety of plant and personal

REFERENCES
(1) PROGRAMMABLE LOGIC CONTROLLERS, OPERATION,

INTERFACING AND PROGRAMMING.
 JOB DEN OTTER.
(2) IBM PC AND CLONES

 GOVINDRAJALU.
(3) MICROPROCESSORS AND INTERFACING PROGRAMMING AND

HARDWARE.
 DOUGLAS HALL.
(4) THE 8051 MICROCONTROLLER ARCHITECTURE, PROGRAMMING

AND APPLICATIONS.
 KENNETH AYALA.
(5) MICROPROCESSOR ARCHITECTURE, PROGRAMMING AND

APPLICATIONS.
 RAMESH GAONKAR.
(6) MICROPROCESSORS AND MICROCOMPUTERS.

 B. RAM.
(7) PROGRAMMING IN ANSI C.

 E. BALAGURUSAMY.
(8) SIEMENS SIMATIC S5 PROGRAMMABLE CONTROLLER.

 SYSTEM MANUAL.
(9) DIGITAL ELECTRONICS.

 WIILIAM GOTHMAN.
(10) INTEGRATED CIRCUITS.

 K R BOTKAR.
(11) DATA SHEETS FROMNATIONAL SEMICONDUCTOR CORPORATION,

INTEL, PHILLIPS, FAIRCHILD SEMICONDUCTOR
CORPORATION, MOTOROLA CORPORATION.
(12) MAGAZINES – ELECTRONICS FOR YOU (EFY).
(13) OLD PROJECT REPORTS AND SEMINARS ON PLCS.


Company Profile: Iv Year 2011-12 PLC, Scada

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IV YEAR 2011-12 PLC, SCADA

Prolific's corporate training clients include many blue-chip companies such as

Modicum, Allen Bradley, GE Fanuc, Siemens and Mitsubishi.

Prolific Turnkey Execution Capabilities

Prolific is completing projects in Nepal, Bangladesh and China.

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Automation is basically the delegation of human control Function to technical

Simplification of engineering and precise control of manufacturing

1.2-ROLE OF ELECTRONICS IN AUTOMATION

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1. Suited to withstand the industrial environment

2. Has simplicity of operation

3. Maintenance by plant technicians and

4. Reduce machine down time and provide expandability for future.

A Programmable controller is a solid state user programmable control

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1.4-BENEFITS OF PROGRAMMABLE CONTROLLERS

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PLCs contain three basic sections:

1. Central processing unit (CPU).

2. Memory: EPROM, RAM, and so on.

3. Input/output section for communication with peripherals (ADC, DAC).

A PLC is basically a black box with a number of inputs from, and a

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3. THE PARTS OF A PROGRAMMABLE CONTROLLER

Programmable logic controllers (PLC) can be considered to have two parts:

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(a) Input image table:

(b) Output image table:

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interface. Thus, for example, if output module 1 receives a digital 1 by applying 5v

(C) Central processing unit:

(d)User program memory:

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As the user enters instructions, they are automatically stored at sequential

(e)The complete scan cycle:

(f) Data Memory:

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(g) Operating System of PLC:

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The following methods of representation are possible to program

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In the present industrial world, a flexible system that can be controlled by

The areas where PLC is used maximum are as follows:

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8. For blast furnace charging controls in steel plants.

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A further development of PLCs leads to the development of

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4. A collection of standard and/or custom software [sometimes called Human

Figure: Typical SCADA System

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Figure : First Generation SCADA Architecture

8.2: Distributed SCADA Systems

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Figure: Second Generation SCADA Architecture

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software. This allows SCADA vendors to concentrate their development in an area