SCADA, DCS &PLC

SCADA

A SCADA (or supervisory control and data acquisition) system. It consists of

many remote terminals units for collection of data (field),that is being connected
with master station through any communication system, having main task of
collection of accurate data and controlling of process for smooth operation.

DCS

It stands for distributed Control System, controlling is performed by embedded

system (Microcontroller based or Microprocessor based controlling unit for device
or instruments from which data is to be collect. It provides very intelligent analog
control capability. It is very sensitive for HMI (Human machine Interface) for easy
and smooth control of process.
PLC
It stands for Programmable Logic controller, having get this name from the fact
that it replace the relay logic at the initial stage then it get the capability for analog
channels also for display then it get the ability for close loop control and after some
time it has the ability for redundant operation, and also its HMI having the ability
for Indication, controlling, data logging ,Alarming and backup data facility. It is
also defined as below:
“A digitally operating electronic apparatus which uses a programmable 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 input/output, various types of machines or process.”
Difference between PLC,DCS & SCADA
Due to the advent of microprocessors both the technologies are merging..But still
there are some things which are to be checked out before selecting the one that
suits your application the best.

Now a days you cannot really tell the difference between a PLC or a DCS. Since
the PLC was integrated with Analog I/O it crosses the boundary of being just
digital and crosses to the realm of DCS in handling Analogs, Bus Systems,
Distributed I/O and etc. Also, since the DCS now handles logics of Digital I/O it
also crossed the boundary to the realm of PLC.
As you know PLC as to its name Programmable Logic Controller. Its main purpose
is to replace the relay logic controls which is "On" or "Off". And DCS "Distributed
Control Systems" its emphasis is Fast analog handling because of communications
through Bus systems, networking and etc.

Summarizing all these, PLC = DCS......BUT still there are basic differences as
below

PLC is a programmable Logic controller which is used mainly for

interlocking different equipments.PLC using for perticular mechine
or production unit.PLC is economicaly low cost.PLC'S can handle analog and
digital I/O as earliear it could handle only digital.PLC'S are automatic controllers
which is a substitute to hard wired controllers.they are extensively used for
automation.PLC is for stand alone sytem.PLC is used Commonly with On\Off
(Digital) Control and may be expanded with Analog I\O Modules for Analog
Control and used for a control task.
Programmable Logic Controller

DCS: DISTRIBUTED CONTROL SYSTEMS: THIS SYSTEM DOES WHAT A

PLC WOULD DO, BUT THE DIFFERENCE IS THAT A DCS IS USED IN
MUCH LARGER AND COMPLEX APPLICATION E.G: POWER
GENERATION,
SOME COLD ROLLING MILLS etc.

DCS is the System in which controller are distributed geographically and

integrated all the control hardwares .which is connected from the various field
devices .DCS having its own network, Controller and HMI etc….Honeywell,
Yokogawa, Invensys, ABB, Emerson are the leading .DCS Vendors.DCS is the
System in which controller are distributed geographically and integrated all the
control hardwares which is connected from the various field devices.DCS having
its own network, Controller and HMI etc…Honeywell, Yokogawa, Invensys,
ABB, Emerson are the leadingDCS Vendors

Distributed Controller System

If taken from a narrow point of view, maybe PLC and DCS are
functionally the same. However, a lot of plant technicians and engineers are not
aware of the other side of the debate, namely the engineering effort and the
commercial ramifications. Of course, for huge plants with I/O's ranging from
10,000 to 30,000 I/O points, and beyond, it is silly to even think about PLC. From
my experience, a DCS is not the same with PLC in the realm of huge systems such
as oil and gas plants, as the following list will show:
1. A PLC is cost-effective up to a certain I/O count, and so is the DCS. But the
difference is in their starting points: the PLC is cost-effective from 0 to a few
thousand I/O points; the DCS becomes cost-effective starting from a few thousand
points and beyond.

2. A PLC becomes a subsystem of the DCS in rare occasions when the situation
calls for it, i.e., purchase of huge package systems with engineering schedules
incompatible with the DCS schedule (I/O lists cannot be submitted on time before
the DCS hardware freeze date). Note that this package system is a process system
using continuous control, not discrete. Based on this, a PLC can never be larger
than a DCS in terms of I/O count.

3. In large plants the DCS is king because most owners want a single source of
hardware support and service, and this mentality naturally denies the PLC a
foothold. Package vendors are no longer required to provide PLC for their system.
Everything is connected to the DCS.

SCADA:

AS ALREADY EXPLAINED, IT NOTHING BUT A SOFTWARE USED

TO GATHER DATA FROM THE FIELDS INSTRUMENTS WITH THE HELP
OF
DCS OR PLC DEPENDING ON THE APPLICATION VIA THE SERVER
AND MAKING IT AVAILABLE IN AN ANIMATED FORM. THIS IS
USUALLY FOUND IN YOUR CONTROL ROOMS AND DEVELOPMENT
ROOM
SCADA

SCADA is the Software tool in which you can able to view/Monitor/Control your
Process Variable data and Graphical representation of your plant etc...It's an
operator front end display Example of few SCADA S/W is Wonderware, IFix, RS
View, WinCC etc
SCADA is Supervisory Control and Data Aquisition which is used to control and
Monitor small number of Equipments in a field.SCADA systems are typically used
to perform data collection and control at the supervisory level. Some systems are
called SCADA despite only performing data acquisition and not control.The
supervisory control system is a system that is placed on top of a real-time control
system to control a process that is external to the
SCADA system (i.e. a computer, by itself, is not a SCADA system even though it
controls its own power consumption and cooling). This implies that the system is
not critical to control the process in real time, as there is a separate or integrated
real-time automated control system that can respond quickly enough to compensate
for process changes within the time constants of the process

SCADA is the Software tool in which you can able to

view/Monitor/Control your Process Variable data and
Graphical representation of your plant etc...
It's an operator front end display
Example of few SCADA S/W is Wonderware, IFix, RS View,
WinCC etc
 PLC:
in manufacturing processes(for
production of things)
for simple batch control
intensive logic controls
can handle a no. of I/O s at a time
DCS:
in process control (for production of
stuff)
for complex batch control
advanced analog loop controls

downtime => lost production downtime=>lost production+damage to

usually,no need of redundancy process equipment+ may lead to
dangerous conditions
so Redundancy must

fast logic scan(=reading I/Ps executing large in size

instructions and providing O/Ps) cant be easily customized

Compact, easily customized ,for smaller for larger applications and plant-wide
applications In detail

What are you manufacturing??

PLC:for simple batch control i.e.,manufacturing a batch of goods(things)

Eg.,in bottling plants
DCS:for complex batch process i.e.,producing a product by transmission from raw
materials(producing stuff)
Eg.,in oil refining plants,in steel making
Specific to type of control
PLC: very logic control intensive.Can handle a no. of digital and analog I/O's at a
time.
DCS: Regulatory/Analog loop control.It also provides ratio/cascade/model-
predictive /feed forward control
Effect of downtime
What is downtime?

It is the time that the process takes to come to normal operation after a catastrophic
failure.
PLC: Downtime results in only lost production and does not typically damage the
process conditions or equipment.
For eg.,if there is some problem in the manufacturing process of a bottling plant,
even if the process is stopped for a while, resuming the process back to its normal
operation is simple and not time tacking. providing redundancy will be costlier
than handling the downtime expenses so generally redundancy is not provided by
this.
DCS: Downtime results not only in lost production but also leads to dangerous
conditions or damages the process line and resuming the process is expensive and
difficult too.
For eg.,In steel making process if the process stops abruptly and the pipelines with
process fluid contents may freeze and damage the pipelines this would lead to
more expenses.

Degree of customisation
PLC:It delivers a tool-kit of functions and building blocks that can be easily
customized.So it can be used for varied applications by programming it according
to the application.
DCS: Its highest priority is high reliability so standard functions are baked in to
provide a complete solution to a particular application. So it can't accept many
custom modifications.

Up-front cost
PLC: in $$.
DCS: in $$$$ ;However its superior to PLC in operation and proprietary in
general.
Size
PLC: compact
DCS: large
Replacement
PLC: replaced the conventional relays
DCS: replaced the pneumatic & single loop controllers

DCS is Distributed Control Systems which is used to control very big plants by
using simple GUI screens.PLCs are interfaced with DCS for interlocking.
SCADA (supervisory control and data acquisition) is a type of software application and
hardware control that defines the way data and real-time processing is controlled. You mostly
find SCADA in certain industries such as power plants and oil and refining businesses.
1. Q: What are some different levels of SCADA machines and systems?
A: SCADA machines have several different forms. You can have field level devices such
as sensors. You can have remote terminal units (RTUs), a main controller or “master
station,” or you can have a simple computer system interface that displays data for the
user.
2. Q: Why do companies use SCADA?
A: SCADA is a methodology that defines performance and protection of data for the
plant or communication center. It helps improve productivity for employees and helps
the economy save energy.

3. Q: What voltage does an RTU operate with?

A: A remote terminal unit operates at 110V/240V.

4. Q: Why would a company want to use a PLC over an RTU?

A: A programmable logic controller (PLC) is much cheaper and more flexible with
programming. PLCs have been replacing RTUs because they are also easier to
troubleshoot and have more sophisticated controls than RTUs.

5. Q: What is an HMI?
A: An HMI (human machine interface) is the system that connects to a SCADA database
that displays data for the user. The HMI allows the operator to review diagnostic data
and trending graphs.

What is a RTU?
A remote terminal unit (RTU) is a device or system that interfaces with other equipment.
Typically, a RTU converts electrical signals from the equipment to digital values that represent
such items as the open/closed status of a switch or valve and measurement values for pressure,
flow, voltage, and current.
By converting these electrical signals and sending the digital values out to the equipment, the
RTU can initiate control sequences such as opening or closing a switch or valve, and setting the
speed of a pump.
6. Q: What is DDE?
A: DDE is the acronym for dynamic data exchange. DDE provides a communication
protocol that allows devices to send and receive communication signals. This protocol
 was developed by Microsoft, so if the shop is a Microsoft shop, you will probably need
to know some things about DDE and how devices communicate.

7. Q: What are some advantages of SCADA over other protocols?

A: SCADA allows users to create object-oriented graphs, they can offer trending graphs
to review data in real-time. SCADA also deals with big data, so you can develop a
database system that displays trends over a number of years. This allows the business
quick access to important data that can be used for future growth and enhancements.

8. Q: How does SCADA handle data?

A: SCADA systems gather data and send them to a central machine that processes the
data. The SCADA software is used to manage the data and display it to the user. SCADA
also logs information about who runs reports and the data that is used.

9. Q: How does SCADA handle issues?

A: SCADA has an alarm or alert system that interfaces with personnel to send them a
warning when a system is not working properly.

10. Q: What is the “Historian” in SCADA?

A: The historian is the name given to the software service that collects events and logs
them into the database for future use.

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What is difference between PLC and SCADA

PLC- programmabale logic controller - more like a micro
controller but program resides in PLC can b modified without
knowledge of C or assembly language. maily used for making
logical flow of a process..
whereas
scada- supervisory control and data acquisition system- this
is software that control two or more PLCs.. Donno in which
laguage this program is written but as far as instrumentation engg is concerned we need to
control PLCs
from scada.

Interview Question for Automation,DCS,PLC Engineers

1. Draw system architecture showing PLC, SCADA/MMI, networking devices communication

protocol details like IP address etc.
2. Draw detailed block diagram of any field parameter like temp, pressure reading coming to
PLC can be shown on SCADA/MMI.
3. Explain 2 wire & 4 wire wiring concept.
4. Draw block diagram of close loop control. Difference open and close.
5. Draw server client architecture with example.
6. Name different types of timers used in PLC.
7. Subroutine, instruction types,
8. Explain PID?
9. PID Cascade mode, primary secondary
10. Ramp, feed forward
11. Name communication protocols and basic parameters required to establish communication
between two nodes.
12. What is difference between signal ground and power ground?
13. Explain redundancy of controller.
14. Master slave concept in Modbus
15. Modbus addressing
16. What is CRC? Parity?
17. Thermocouple –RTD difference
18. Room temp resistance for RTD.
19. IP Address classes.
20. Scan time of PLC.
21. Why 4-20 ma not 0-20 ma?
22. Bump less transfer
Input/output
In computing, input/output or I/O (or, informally, io or IO) is the communication between an
information processing system, such as a computer, and the outside world, possibly a human or
another information processing system. Inputs are the signals or data received by the system
and outputs are the signals or data sent from it. The term can also be used as part of an action;
to "perform I/O" is to perform an input or output operation.

Interface

An I/O interface is required whenever the I/O device is driven by the processor. The interface
must have necessary logic to interpret the device address generated by the processor.
Handshaking should be implemented by the interface using appropriate commands (like BUSY,
READY, and WAIT), and the processor can communicate with an I/O device through the
interface. If different data formats are being exchanged, the interface must be able to convert
serial data to parallel form and vice versa

Channel I/O
Channel I/O requires the use of instructions that are specifically designed to perform I/O
operations. The I/O instructions address the channel or the channel and device; the channel
asynchronously accesses all other required addressing and control information. This is similar to
DMA, Direct memory access (DMA) is a feature of computer systems that allows certain
hardware subsystems to access main system (RAM) memory independently of the central
processing unit (CPU). but more flexible.

I/O throttling
input/output throttling, a technique used to more efficiently handle memory processing. During
low-memory conditions, a system will slow down the processing of I/O memory requests,
typically processing one sequence at a time in the order the request was received. I/O throttling
slows down a system but typically will prevent the system from crashing.

Analog vs. Digital

We live in an analog world. There are an infinite amount of colors to paint an object (even if the
difference is indiscernible to our eye), there are an infinite number of tones we can hear, and
there are an infinite number of smells we can smell. The common theme among all of these
analog signals is their infinite possibilities.

Digital signals and objects deal in the realm of the discrete or finite, meaning there is a limited
set of values they can be. That could mean just two total possible values, 255, 4,294,967,296, or
anything as long as it’s not ∞ (infinity).

Analog Signals
Define: Signals

The signals we’re talking about are time-varying “quantities” which convey some sort of
information. In electrical engineering the quantity that’s time-varying is usually voltage (if not
that, then usually current). So when we talk about signals, just think of them as a voltage that’s
changing over time.Signals are passed between devices in order to send and receive information.

Analog Signal Graphs

Because a signal varies over time, where time is plotted on the horizontal, x-axis, and voltage on
the vertical, y-axis. Easiest way to identify if it’s analog or digital; a time-versus-voltage graph of
an analog signal should be smooth and continuous.

While these signals may be limited to a range of maximum and minimum values, there are still
an infinite number of possible values within that range. For example, the analog voltage coming
out of your wall socket might be clamped between -120V and +120V, but, as you increase the
resolution more and more, you discover an infinite number of values that the signal can actually
be (like 64.4V, 64.42V, 64.424V, and infinite, increasingly precise values).

Example Analog Signals

Video and audio transmissions are often transferred or recorded using analog signals. The
composite video coming out of an old RCA jack, for example, is a coded analog signal usually
ranging between 0 and 1.073V. Tiny changes in the signal have a huge effect on the color or
location of the video.An analog signal representing one line of composite video data.Pure audio
signals are also analog. The signal that comes out of a microphone is full of analog frequencies
and harmonics, which combine to make beautiful music.

Digital Signals

Digital signals must have a finite set of possible values. The number of values in the set can be
anywhere between two and a-very-large-number-that’s-not-infinity. Most commonly digital
signals will be one of two values – like either 0V or 5V. Timing graphs of these signals look like
square waves.

Or a digital signal might be a discrete representation of an analog waveform. Viewed from afar,
the wave function below may seem smooth and analog, but when you look closely there are tiny
discrete steps as the signal tries to approximate values:

That’s the big difference between analog and digital waves. Analog waves are smooth and
continuous, digital waves are stepping, square, and discrete.

Example Digital Signals

Not all audio and video signals are analog..

Most communication between integrated circuits is digital. Interfaces like serial, I2C, and SPI all
transmit data via a coded sequence of square waves.Serial peripheral interface (SPI) uses many
digital signals to transmit data between devices.

Analog and Digital Circuits

Analog Electronics

Most of the fundamental electronic components – resistors, capacitors, inductors, diodes,

transistors, and operational amplifiers – are all inherently analog. Circuits built with a
combination of solely these components are usually analog.

Analog circuits are usually complex combinations of op amps, resistors, caps, and other
foundational electronic components. This is an example of a class B analog audio amplifier.

Analog circuits are usually much more susceptible to noise (small, undesired variations in
voltage). Small changes in the voltage level of an analog signal may produce significant errors
when being processed.

Digital Electronics

Digital circuits operate using digital, discrete signals. These circuits are usually made of a
combination of transistors and logic gates and, at higher levels, microcontrollers or other
computing chips. Most processors, whether they’re big beefy processors in your computer, or
tiny little microcontrollers, operate in the digital realm.Digital circuits make use of components
like logic gates, or more complicated digital ICs (usually represented by rectangles with labeled
pins extending from them).

Digital circuits usually use a binary scheme for digital signaling. These systems assign two
different voltages as two different logic levels – a high voltage (usually 5V, 3.3V, or 1.8V)
represents one value and a low voltage (usually 0V) represents the other.

Analog and Digital Combined

It’s not rare to see a mixture of analog and digital components in a circuit. (analog-to-digital
converters, pulse-width modulation, and digital-to-analog converters. An analog-to-digital
converter (ADC) allows a microcontroller to connect to an analog sensor (like photocells or
temperature sensors), to read in an analog voltage. The less common digital-to-analog converter
allows a microcontroller to produce analog voltages, which is handy when it needs to make
sound.
What is a Logic Level?

describes any specific, discrete state that a signal can have. In digital electronics, we generally
restrict our study to two logic states - Binary 1 and Binary 0., a logic level is a specific voltage or
a state in which a signal can exist. We often refer to the two states in a digital circuit to be ON or
OFF. Represented in binary, an ON translates to a binary 1, and an OFF translates to a binary 0.
In Arduino, we call these signals HIGH or LOW, respectively.

Logic 0 or Logic 1

Digital electronics rely on binary logic to store, process, and transmit data or information. Binary
Logic refers to one of two states – ON or OFF. This is commonly translated as a binary 1 or
binary 0. A binary 1 is also referred to as a HIGH signal and a binary 0 is referred to as a LOW
signal.

The strength of a signal is typically described by its voltage level. How is a logic 0 (LOW) or a
logic 1 (HIGH) defined? Manufacturers of chips generally define these in their spec sheets. The
most common standard is TTL or Transistor-Transistor Logic.

Transistors

A transistor is a semiconductor device used to amplify and switch electronic signals

and electrical power. It is composed of semiconductor material with at least three
terminals for connection to an external circuit.In small, discrete quantities, transistors can be
used to create simple electronic switches, digital logic, and signal amplifying circuits.

Serial Communication

Introduction

Embedded electronics is all about interlinking circuits (processors or other

integrated circuits) to create a symbiotic system. In order for those individual
circuits to swap their information, they must share a common communication
protocol. Hundreds of communication protocols have been defined to achieve
this data exchange, and, in general, each can be separated into one of two
Parallel vs. Serial
Diodes

The key function of an ideal diode is to control the direction of current-flow. Current passing
through a diode can only go in one direction, called the forward direction. Current trying to flow
the reverse direction is blocked. They’re like the one-way valve of electronics.

Current-Voltage Relationship

The most important diode characteristic is its current-voltage (i-v) relationship. This defines what
the current running through a component is, given what voltage is measured across it. Resistors,
for example, have a simple, linear i-v relationship…Ohm’s Law. The i-v curve of a diode,
though, is entirely non-linear. It looks something like this:

The current-voltage relationship of a diode. In order to exaggerate a few important points on the
plot, the scales in both the positive and negative halves are not equal.

Depending on the voltage applied across it, a diode will operate in one of three regions:

1. Forward bias: When the voltage across the diode is positive the diode is “on” and
current can run through. The voltage should be greater than the forward voltage (VF) in
order for the current to be anything significant.
2. Reverse bias: This is the “off” mode of the diode, where the voltage is less than VF but
greater than -VBR. In this mode current flow is (mostly) blocked, and the diode is off. A
very small amount of current (on the order of nA) – called reverse saturation current – is
able to flow in reverse through the diode.
3. Breakdown: When the voltage applied across the diode is very large and negative, lots of
current will be able to flow in the reverse direction, from cathode to anode.
 Voltage Dividers
A voltage divider is a simple circuit which turns a large voltage into a smaller one. Using just two
series resistors and an input voltage, we can create an output voltage that is a fraction of the input.
Voltage dividers are one of the most fundamental circuits in electronics

Resistors

Resistors are electronic components which have a specific, never-changing electrical resistance.
The resistor’s resistance limits the flow of electrons through a circuit.

They are passive components, meaning they only consume power (and can’t generate it).