AUTOMATION

Bachelor of Technology Rajasthan Technical University

From

InThe Partial Fulfillment of

A Practical Training Taken At

SOFCON PVT LTD(AUTOMATION) From 13th June 2011 to 13th July 2011 Submitted By: Tapesh Kumar B. TECH. IVth year Electrical Engineering Submitted To: Prof. Gauri Shankar Sharma Head of Department Electrical Engineering

Preface: MARUDHAR ENGNEERING COLLEGE Page 1

AUTOMATION An industrial SCADA & PLCs system is used for the development of the controls of machinery. This paper describes the SCADA & PLCs systems in terms of their architecture, their interface to the process hardware, the functionality and the application development facilities they provide. Some attention is also paid to the industrial standards to which they abide their planned evolution as well as the potential benefits of their use.

Acknowledgement:
I would like to thank SOFCON INDIA PVT. LIMITED, Jaipur for providing me exposure to the whole Scada & PLCs System. Id also like to thank Mr.

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AUTOMATION Mohit and Ms Pooja, for their enduring support and guidance throughout
the training. I am very grateful to the whole Control and Instrumentation Department for their support and guidance. I am also very thankful to the workers and employees near the machineries and the library in charge for their support to my training.

Youre sincerely Ta pesh kumar B. TECH, 4 year (EEE)

th

ROLL NO. (08EMEEE054)

1.Introduction 1.1Advantages and disadvantages 2. Automation tools 3.Defination of plc 4. Features of PLCs 5. Classificationof plc 6.Difference between ALLEN BRADELYplc

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7. I/O modules 7.1 EEPROM memory module 7.2Cycle of plc 7.3 Types of I/Os 7.4 Analog Input Module 8. Block diagram of a PLC 9. Generation of input signal 9.1 Generation of Output Signal 10. PLC compared with other control systems 11. Digital and analog signals 12. Ladder logic 12.1 Generally Used Instructions & symbol For PLC Programming 13. SCADA 14.Common system components 15 Systems concepts 16Hardware solutions 17 Supervisory Station 18.Communication infrastructure and methods: 19. Trends in SCADA 20. Security issues 21 SCADA companies 22. SCADA packages 23. Licensing patterns used in the SCADA software 24. EXE files used in Touch Software 25. Types of Window use in scada 26. Alarm and Events in scada 27. Scripts in In scada 28. Communication with software 29. SCADA architectures

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30. Application Development 30.1 Development Tools 30.2Configuration 31.Evolution 32.Benefits of SCADA 33.Commnucation of plc and scada 34. Difference between PLC and SCADA 35. SCADA Softwar 35.1SCADA Example Application 36SCADA Sensors 37. Example of plc 37.1 Programming For Start/Stop of Motor by PLC 37.2 Lamp Glows when at Input Switch is Actuated 38. Human Machine Interface 39. Remote Terminal Unit (RTU) 39.1 Supervisory Station 39.2 Operational philosophy 40. Conclusion 41.References

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1. Introduction: Automation is encompassing virtually every walk of life. Automation solutions are required right from agricultural to space technology. Plant Automation is the necessity for the manufacturing industry to survive in todays globally competitive market The art of making processes or machines self-acting or self-moving. Also pertains to the technique of making a device, machine, process or procedure more fully automatic. Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Automation plays an increasingly important role in the world economy and in daily experience. 1.1 Advantages and disadvantages: The main advantages of automation are: Replacing human operators in tasks that involve hard physical or monotonous work.

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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.

The main disadvantages of automation are: Unemployment rate increasesdue to machines replacing humans and putting those humans out of their jobs. Technical Limitation: Current technology is unable to automate all the desired tasks.Security Threats/Vulnerability: An automated system may have limited level of intelligence, hence it is most likely susceptible to commit error. Unpredictable development costs: The research and development cost of automating a process may exceed the cost saved by the automationitself. High initial cost: The automation of a new product or plant requires a huge initial investment in comparison with the unit cost of the product, although the cost of automation is spread in many product batches.

2. Automation tools: a. Hardware (Plc, Slc, Dcs)

b.Software (SCADA) c.Instruments (Sensor, Rtd, Motor, Valve)

3.Defination of plc:

A Programmable Logic Controller, PLC, or

Programmable Controller is a digital computer used for automation of industrial processes, such as control of machinery on factory assembly lines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory. A PLC is an example of a real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.

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4. Features of PLCs: The main difference from other computers is that

PLC is armored for severe condition (dust, moisture, heat, cold, etc) and has the facility for extensive input/output (I/O) arrangements. These connect the PLC to sensors and actuators. PLCs read limit switches, analog process variables (such as temperature and pressure), and the positions of complex positioning systems. Some even use machine vision. On the actuator side, PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic relays or solenoids, or analog outputs. The input/output arrangements may be built into a simple PLC, or the PLC may have external I/O modules attached to a computer network that plugs into the PLC.Many of the earliest PLCs expressed all decision making logic in simple ladder logic which appeared similar to electrical schematic diagrams. The electricians were quite able to trace out circuit problems with schematic diagrams using ladder logic. This program notation was chosen to reduce training demands for the existing technicians. Other early PLCs used a form of instruction list programming, based on a stack-based logic solver.The functionality of the PLC has evolved over the years to include sequential relay control, motion control, process control, distributed control systems and networking. The data handling, storage, processing power and communication capabilities of some modern PLCs are approximately equivalent to desktop computers

5.Classification of plc:
5.1Plc 5.2 Slc 5.3Dcs

5.1 Plc: A programmable logic controller (PLC) or programmable controller is a digital

computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output

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arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in batterybacked or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result. These PLCs were programmed in "ladder logic", which strongly resembles a schematic diagram of relay logic. This program notation was chosen to reduce training demands for the existing technicians. Other early PLCs used a form of instruction list programming, based on a stack-based logic solver.Modern PLCs can be programmed in a variety of ways, from ladder logic to more traditional programming languages such as BASIC and C. Another method is State Logic, a very high-level programming language designed to program PLCs based on state transition diagrams.

5.2 Slc: In digital circuit theory, sequential logic is a type of logic circuit
whose output depends not only on the present input but also on the history of the input. This is in contrast to combinational logic, whose output is a function of, and only of, the present input. In other words, sequential logic has state (memory) while combinational logic does not.Sequential logic is therefore used to construct some types of computer memory, other types of delay and storage elements, and finite state machines. Most practical computer circuits are a mixture of combinational and sequential logic.

5.3Dcs: A distributed control system (DCS) refers to a control system

usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring.

6.Difference between ALLEN BRADELYplc:

S n o . 1 . 2 . 3 . Properties ALLENBRAEY micrologix10 00 Compaq ALLEN BRADELY micrologix1200 ALLEN BRADELYslc

Type

Compaq+Modular PMO2 RSLINX

Modular CPO3 RSLINX

Commnucati PMO2 on Cable Commnucati RSLINX on software

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4 . 5 . 6 . 7 . 8 . Programmin g Software Timers Counters Online Modification No.of i/o RSLOGIX 40 32 NO RSLOGIX 256&more 256&more NO RSLOGIX 256 and more 256&more YES

32

100

1024

7. I/O modules: Electronic plug in units used for interfacing the i/p and

o/p device in the machine or process to be controlled. I/P module receives data from i/p devices (Pushbutton, Switches, Transmitters) and send it to processor. The O/P module receives data from processor and send it to output device (Relay, Valves). Digital/Discrete:- Sends and Receives On/Off signal Analog:- Sends and receives variable input or output signals

7.1EEPROM memory module: This module is inserted into processor system for maintaining a copy of project (PLC program). This is helpful in case of memory corruption or Extended power loss. 7.2Cycle of plc:PLCs can cycle follows following path Scan cycle of PLC :
Input Image Updation Process Logic Execution Output Updation I/P module receives data from i/p devices (Pushbutton, Switches, Transmitters) and send it to processor. The O/P module receives data from processor and send it to output device (Relay, Valves).

7.3 Types of I/Os:

Local These are the I/Os placed in the PLC main rack containing CPU. These I/Os are connected to CPU through jackplane

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Distributed These are the I/O placed at remote location from the main rack containing the CPU. These I/Os are to be connected on communication bus like control net, device net or FIP I/O

7.4Analog Input Module:

An I/O module that contains circuits that convert analog input signals to digital values that can be manipulated by the processor. The signals for pressure, flow, level, temperature transmitters are connected to this module. Typically the input signal in 4-20 mA, 0-10 V.

7.5Analog Output Module:

An I/O module that contains circuits that output an analog dc signal proportional to a digital value transferred to the module from the processor. By implication, these analog outputs are usually direct (i.e., a data table value directly controls the analog signal value).

8. Block diagram of a PLC:

I/P module receives data from i/p devices (Pushbutton, Switches, Transmitters) and send it to processor. The O/P module receives data from processor and send it to output device (Relay, Valves). Digital/Discrete:- Sends and Receives On/Off signal Analog:- Sends and receives variable input or output signals

9.Generation of Input Signal:

Inside the PLC housing, connected between each input terminal and the Common terminal, is an opto-isolator device (Light-Emitting Diode) that provides an electrically isolated "high" signal to the computer's circuitry (a photo-transistor interprets the LED's light) when there is 120 VAC power applied between the

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respective input terminal and the Common terminal. An indicating LED on the front panel of the PLC gives visual indication of an "energized" input

9.1 Generation of Output Signal: Output signals are generated by the PLC's computer circuitry activating a switching device (transistor, TRIAC, or even an electromechanical relay), connecting the "Source" terminal to any of the "Y-" labeled output terminals. The "Source" terminal, correspondingly, is usually connected to the L1 side of the 120 VAC power source. As with each input, an indicating LED on the front panel of the PLC gives visual indication of an "energized" outputIn this way, the PLC is able to interface with real-world devices such as switches and solenoids. The actual of the control system is established inside the PLC by means of a computer program. This program dictates which output gets energized under which input conditions. Although the program itself appears to be a ladder diagram, with switch and relay symbols, there are no actual switch contacts or relay coils operating inside the PLC to create the logical relationships between input and output. These are imaginary contacts and coils, if you will. The program is entered and viewed via a personal computer connected to the PLC's programming port.

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10.PLC compared with other control systems:

PLCs are well-adapted to a certain range of automation tasks. These are typically industrial processes in manufacturing where the cost of developing and maintaining the automation system is high relative to the total cost of the automation, and where changes to the system would be expected during its operational life. PLCs contain input and output devices compatible with industrial pilot devices and controls; little electrical design is required, and the design problem centers on expressing the desired sequence of operations in ladder logic (or function chart) notation. PLC applications are typically highly customized systems so the cost of a packaged PLC is low compared to the cost of a specific custom-built controller design. For high volume or very simple fixed automation tasks, different techniques are used. A microcontroller-based design would be appropriate where hundreds or thousands of units will be produced and so the development cost (design of power supplies and input/output hardware) can be spread over many sales, and where the end-user would not need to alter the control. Automotive applications are an example; millions of units are built each year, and very few end-users alter the programming of these controllers. However, some specialty vehicles such as transit busses economically use PLCs instead of custom-designed controls, because the volumes are low and the development cost would be uneconomic PLCs may include logic for single-variable feedback analog control loop, a "proportional, integral, derivative" or "PID controller." A PID loop could be used to control the temperature of a manufacturing process, for example. Historically PLCs were usually configured with only a few analog control loops; where processes required hundreds or thousands of loops, a

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distributed control system (DCS) would instead be used. However, as PLCs have become more powerful, the boundary between DCS and PLC applications has become less clear-cut.

11. Digital and analog signals:

Digital or discrete signals behave as binary switches, yielding simply an On or Off signal (1 or 0, True or False, respectively). Pushbuttons, limit switches, and photoelectric sensors are examples of devices providing a discrete signal. Discrete signals are sent using either voltage or current, where a specific range is designated as On and another as Off. For example, a PLC might use 24 V DC I/O, with values above 22 V DC representing On, values below 2VDC representing Off, and intermediate values undefined. Initially, PLCs had only discrete I/O.Analog signals are like volume controls, with a range of values between zero and full-scale. These are typically interpreted as integer values (counts) by the PLC, with various ranges of accuracy depending on the device and the number of bits available to store the data. As PLCs typically use 16-bit signed binary processors, the integer values are limited between -32,768 and +32,767. Pressure, temperature, flow, and weight are often represented by analog signals. Analog signals can use voltage or current with a magnitude proportional to the value of the process signal. For example, an analog 4-20 mA or 0 - 10 V input would be converted into an integer value of 0 - 32767.Current inputs are less sensitive to electrical noise (i.e. from welders or electric motor starts) than voltage inputs. 12. Ladder logic: Ladder logic is a method of drawing electrical logic schematics. It is now a graphical language very popular for programming Programmable Logic Controllers (PLCs). It was originally invented to describe logic made from relays. The name is based on the observation that programs in this language resemble ladders, with two vertical "rails" and a series of horizontal "rungs" between them.A program in ladder logic, also called a ladder diagram, is similar to a schematic for a set of relay circuits. An argument that aided the initial adoption of ladder logic was that a wide variety of engineers and technicians would be able to understand and use it without much additional training, because of the resemblance to familiar hardware systems. (This argument has become less relevant given that most ladder logic programmers have a software background in more conventional programming languages, and in practice implementations of ladder logic have characteristics such as sequential execution and support for control flow features that make the analogy to hardware somewhat imprecise.)Ladder logic is widely used to program PLCs, where sequential control of a process or manufacturing operation is required. Ladder logic is

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useful for simple but critical control systems, or for reworking old hardwired relay circuits. As programmable logic controllers became more sophisticated it has also been used in very complex automation systems.Ladder logic can be thought of as a rule-based language, rather than a procedural language. A "rung" in the ladder represents a rule. When implemented with relays and other electromechanical devices, the various rules "execute" simultaneously and immediately. When implemented in a programmable logic controller, the rules are typically executed sequentially by software, in a loop. By executing the loop fast enough, typically many times per second, the effect of simultaneous and immediate execution is obtained. In this way it is similar to other rule-based languages, like spreadsheets or SQL. However, proper use of programmable controllers requires understanding the limitations of the execution order of rungs.

--( )-- a regular coil, true when its rung is true --(\)-- a "not" coil, false when its rung is true --[ ]-- A regular contact, true when its coil is true (normally false) --[\]-- A "not" contact, false when its coil is true (normally true)

12.1Generally

Used Programming:
Input Instruction

Instructions

&

symbol

For

PLC

--[ ]-- This Instruction is Called IXC or Examine If Closed If a NO switch is actuated then only this instruction will be true. If a NC switch is actuated then this instruction will not be true and hence output will not be generated. --[\]-- This Instruction is Called IXO or Examine If Open If a NC switch is actuated then only this instruction will be true. If a NC switch is actuated then this instruction will not be true and hence output will not be generated.

Output Instruction

--( )-- This Instruction Shows the States of Output. If any instruction either XIO or XIC is true then output will be high. Due to high output a 24 volt signal is generated from PLC processor.

Rung

Rung is a simple line on which instruction are placed and logics are created E.g.; ---------------------------------------------

13.SCADA: SCADA stands for Supervisory Control and Data Acquisition. As

the name indicates, it is not a full control system, but rather focuses on the supervisory level. As such, it is a purely software package that is positioned

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on top of hardware to which it is interfaced, in general via Programmable Logic Controllers (PLCs), or other commercial hardware modules. SCADA systems are used not only in industrial processes: e.g. steel making, power generation (conventional and nuclear) and distribution, chemistry, but also in some experimental facilities such as nuclear fusion. The size of such plants range from a few 1000 to several 10 thousands input/output (I/O) channels. However, SCADA systems evolve rapidly and are now penetrating the market of plants with a number of I/O channels of several 100 K: we know of two cases of near to 1 M I/O channels currently under development. SCADA systems used to run on DOS, VMS and UNIX; in recent years all SCADA vendors have moved to NT and some also to Linux.

14.Common system components:

A SCADA System usually consists of the following subsystems: A Human-Machine Interface or HMI is the apparatus which presents process data to a human operator, and through this, the human operator monitors and controls the process. A supervisory (computer) system, gathering (acquiring) data on the process and sending commands (control) to the process. Remote Terminal Units (RTUs) connecting to sensors in the process, converting sensor signals to digital data and sending digital data to the supervisory system. Programmable Logic Controller (PLCs) used as field devices because they are more economical, versatile, flexible, and configurable than special-purpose RTUs.Communication infrastructure connecting the supervisory system to the Remote Terminal Units

15 Systems concepts:
The term SCADA usually refers to centralized systems which monitor and control entire sites, or complexes of systems spread out over large areas (anything between an industrial plant and a country). Most control actions are performed automatically by remote terminal units ("RTUs") or by programmable logic controllers ("PLCs"). Host control functions are usually restricted to basic overriding or supervisory level intervention. For example, a PLC may control the flow of cooling water through part of an industrial process, but the SCADA system may allow operators to change the

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set points for the flow,and enable alarm conditions, such as loss of flow and high temperature, to be displayed and recorded. The feedback control loop passes through the RTU or PLC, while the SCADA system monitors the overall performance of the loop.

Data acquisition begins at the RTU or PLC level and includes meter readings and equipment status reports that are communicated to SCADA as required. Data is then compiled and formatted in such a way that a control room operator using the HMI can make supervisory decisions to adjust or override normal RTU (PLC) controls. Data may also be fed to a Historian, often built on a commodity Database Management System, to allow trending and other analytical auditing. SCADA systems typically implement a distributed database, commonly referred to as a tag database, which contains data elements called tags or points. A point represents a single input or output value monitored or controlled by the system. Points can be either "hard" or "soft". A hard point represents an actual input or output within the system, while a soft point results from logic and math operations applied to other points. (Most implementations conceptually remove the distinction by making every

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property a "soft" point expression, which may, in the simplest case, equal a single hard point.) Points are normally stored as value-timestamp pairs: a value, and the timestamp when it was recorded or calculated. A series of value-timestamp pairs gives the history of that point. It's also common to store additional metadata with tags, such as the path to a field device or PLC register, design time comments, and alarm information.

16.Hardware solutions:
SCADA solutions often have Distributed Control System (DCS) components. Use of "smart" RTUs or PLCs, which are capable of autonomously executing simple logic processes without involving the master computer, is increasing. A functional block programming language, IEC 61131-3 (Ladder Logic), is frequently used to create programs which run on these RTUs and PLCs. Unlike a procedural language such as the C programming language or FORTRAN, IEC 61131-3 has minimal training requirements by virtue of resembling historic physical control arrays. This allows SCADA system engineers to perform both the design and implementation of a program to be executed on an RTU or PLC. A Programmable automation controller (PAC) is a compact controller that combines the features and capabilities of a PC-based control system with that of a typical PLC. PACs are deployed in SCADA systems to provide RTU and PLC functions. In many electrical substation SCADA applications, "distributed RTUs" use information processors or station computers to communicate with protective relays, PACS, and other devices for I/O, and communicate with the SCADA master in lieu of a traditional RTU. Since about 1998, virtually all major PLC manufacturers have offered integrated HMI/SCADA systems, many of them using open and nonproprietary communications protocols. Numerous specialized third-party HMI/SCADA packages, offering built-in compatibility with most major PLCs, have also entered the market, allowing mechanical engineers, electrical engineers and technicians to configure HMIs themselves, without the need for a custom-made program written by a software developer.

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AUTOMATION 17.Supervisory Station:

The term "Supervisory Station" refers to the servers and software responsible for communicating with the field equipment (RTUs, PLCs, etc), and then to the HMI software running on workstations in the control room, or elsewhere. In smaller SCADA systems, the master station may be composed of a single PC. In larger SCADA systems, the master station may include multiple servers, distributed software applications, and disaster recovery sites. To increase the integrity of the system the multiple servers will often be configured in a dual-redundant or hot-standby formation providing continuous control and monitoring in the event of a server failure. Initially, more "open" platforms such as Linux were not as widely used due to the highly dynamic development environment and because a SCADA customer that was able to afford the field hardware and devices to be controlled could usually also purchase UNIX or OpenVMS licenses. Today, all major operating systems are used for both master station servers and HMI workstations.

18. Communication infrastructure and methods:

SCADA systems have traditionally used combinations of radio and direct serial or modem connections to meet communication requirements, although Ethernet and IP over SONET / SDH is also frequently used at large sites such as railways and power stations. The remote management or monitoring function of a SCADA system is often referred to as telemetry. This has also come under threat with some customers wanting SCADA data to travel over their pre-established corporate networks or to share the network with other applications. The legacy of the early low-bandwidth protocols remains, though. SCADA protocols are designed to be very compact and many are designed to send information to the master station only when the master station polls the RTU. Typical legacy SCADA protocols include Modbus RTU, RP-570, Profibus and Conitel. These communication protocols are all SCADA-vendor specific but are widely adopted and used. Standard protocols are IEC 60870-5-101 or 104, IEC 61850 and DNP3. These communication protocols are standardized and recognized by all major

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SCADA vendors. Many of these protocols now contain extensions to operate over TCP/IP. It is good security engineering practice to avoid connecting SCADA systems to the Internet so the attack surface is reduced. RTUs and other automatic controller devices were being developed before the advent of industry wide standards for interoperability. The result is that developers and their management created a multitude of control protocols. Among the larger vendors, there was also the incentive to create their own protocol to "lock in" their customer base. A list of automation protocols is being compiled here. Recently, OLE for Process Control (OPC) has become a widely accepted solution for intercommunicating different hardware and software, allowing communication even between devices originally not intended to be part of an industrial network.

19. Trends in SCADA:

There is a trend for plc and HMI/SCADA software to be more "mix-andmatch". In the mid 1990s, the typical DAQ I/O manufacturer supplied equipment that communicated using proprietary protocols over a suitabledistance carrier like RS-485. End users who invested in a particular vendor's hardware solution often found themselves restricted to a limited choice of equipment when requirements changed (e.g. system expansions or performance improvement). To mitigate such problems, open communication protocols such as IEC870-5-101/104, DNP3 serial, and DNP3 LAN/WAN became increasingly popular among SCADA equipment manufacturers and solution providers alike. Open architecture SCADA systems enabled users to mix-and-match products from different vendors to develop solutions that were better than those that could be achieved when restricted to a single vendor's product offering. Towards the late 1990s, the shift towards open communications continued with individual I/O manufacturers as well, who adopted open message structures such as Modbus RTU and Modbus ASCII (originally both developed by Modicon) over RS-485. By 2000, most I/O makers offered completely open interfacing such as Modbus TCP over Ethernet and IP.

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The North American Electric Reliability Corporation (NERC) has specified that electrical system data should be time-tagged to the nearest millisecond. Electrical system SCADA systems provide this Sequence of events recorder function, using Radio clocks to synchronize the RTU or distributed RTU clocks. SCADA systems are coming in line with standard networking technologies. Ethernet and TCP/IP based protocols are replacing the older proprietary standards. Although certain characteristics of frame-based network communication technology (determinism, synchronization, protocol selection, environment suitability) have restricted the adoption of Ethernet in a few specialized applications, the vast majority of markets have accepted Ethernet networks for HMI/SCADA. With the emergence of software as a service in the broader software industry, a few vendors have begun offering application specific SCADA systems hosted on remote platforms over the Internet. This removes the need to install and commission systems at the end-user's facility and takes advantage of security features already available in Internet technology, VPNs and SSL. Some concerns include security, Internet connection reliability, and latency. SCADA systems are becoming increasingly ubiquitous. Thin clients, web portals, and web based products are gaining popularity with most major vendors. The increased convenience of end users viewing their processes remotely introduces security considerations. While these considerations are already considered solved in other sectors of internet services, not all entities responsible for deploying SCADA systems have understood the changes in accessibility and threat scope implicit in connecting a system to the internet.

20. Security issues:

The move from proprietary technologies to more standardized and open solutions together with the increased number of connections between SCADA systems and office networks and the Internet has made them more

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vulnerable to attacks - see references. Consequently, the security of SCADAbased systems has come into question as they are increasingly seen as extremely vulnerable to cyber warfare/cyber terrorism attacks. In particular, security researchers are concerned about: the lack of concern about security and authentication in the design, deployment and operation of existing SCADA networks the mistaken belief that SCADA systems have the benefit of security through obscurity through the use of specialized protocols and proprietary interfaces the mistaken belief that SCADA networks are secure because they are purportedly physically secured the mistaken belief that SCADA networks are secure because they are supposedly disconnected from the Internet SCADA systems are used to control and monitor physical processes, examples of which are transmission of electricity, transportation of gas and oil in pipelines, water distribution, traffic lights, and other systems used as the basis of modern society. The security of these SCADA systems is important because compromise or destruction of these systems would impact multiple areas of society far removed from the original compromise. For example, a blackout caused by a compromised electrical SCADA system would cause financial losses to all the customers that received electricity from that source. How security will affect legacy SCADA and new deployments remains to be seen. There are two distinct threats to a modern SCADA system. First is the threat of unauthorized access to the control software, whether it be human access or changes induced intentionally or accidentally by virus infections and other software threats residing on the control host machine. Second is the threat of packet access to the network segments hosting SCADA devices. In many cases, there is rudimentary or no security on the actual packet control protocol, so anyone who can send packets to the SCADA device can control it. In many cases SCADA users assume that a VPN is sufficient protection and are unaware that physical access to SCADA-related network jacks and switches provides the ability to totally bypass all security on the control

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software and fully control those SCADA networks. These kinds of physical access attacks bypass firewall and VPN security and are best addressed by endpoint-to-endpoint authentication and authorization such as are commonly provided in the non-SCADA world by in-device SSL or other cryptographic techniques. Many vendors of SCADA and control products have begun to address these risks in a basic sense by developing lines of specialized industrial firewall and VPN solutions for TCP/IP-based SCADA networks. Additionally, application white listing solutions are being implemented because of their ability to prevent malware and unauthorized application changes without the performance impacts of traditional antivirus scans Also, the ISA Security Compliance Institute (ISCI) is emerging to formalize SCADA security testing starting as soon as 2009. ISCI is conceptually similar to private testing and certification that has been performed by vendors since 2007. Eventually, standards being defined by ISA99 WG4 will supersede the initial industry consortia efforts, but probably not before 2011 . The increased interest in SCADA vulnerabilities has resulted in vulnerability researchers discovering vulnerabilities in commercial SCADA software and more general offensive SCADA techniques presented to the general security community. In electric and gas utility SCADA systems, the vulnerability of the large installed base of wired and wireless serial communications links is addressed in some cases by applying bump-in-the-wire devices that employ authentication and Advanced Encryption Standard encryption rather than replacing all existing nodes. Security provides the ability to control whether or not specific operators are allowed to perform specific functions within an application. Security is based on the concept of the operator logging on to the application and entering a User Name and Password. (The application developer sets up each operator with a User Name, a pre-assigned Password and an Access Level via the Special/Security/Configure Users command wither in WindowMaker or Windows Viewer. When a new application is created, the default User Name is Administrator with an access level of 1999 (which allows access to all security commands).

21 SCADA companies:
Invensys Wonder ware In Touch

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Siemens WinCC (Earlier COROS) Allen Bradley RS View (Earlier Control View) Intellution ifix (Earlier Fix DMACS) GE Fanuc Simplicity

22. SCADA packages :

No. of I/Os- Wondeware In Touch comes is 64, 128,256,1000, and 64,000 tags package. Development+ Runtime + Network (DRN)/ Runtime + Network (R+N) and View Node D+R+N: With this packers development and editing of the application is possible, Runtime monitoring and control of the plant is possible and Networking is possible. R+N: With this package development and editing of the application is NOT possible, Runtime monitoring and control of the plant is possible and Networking is possible. Factory Focus: With this package developments and editing of the application is N OT possible, Runtime monitoring is possible but control of the plant is NOT possible and Networking is possible. This package is used a view node.

23. Licensing patterns used in the SCADA software:

Typically two types of licenses are used in the SCADA software: Dongle Key : It is a hardware lock which can be put on the communication port of the PC. Software Lock: Hare the software code is the license. Typically can put the code while installation or transfer the code from Floppy to harddisk.

24. EXE files used in Touch Software:

InTouch : It is an application manager. Using this you can create new

application. Move between various application. View: Window viewer. This will start Runtime application. From this you can monitor and control the plant. WM: WM.XE is Window maker. This will start the development package in InTouch. Using you can you can develop the application.

25. Types of Window use in scada:

Replace: Automatically closes any window (s) it intersect when it

appears on the screen including popup other replace type windows.

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Overlay: Appears on top of currently displayed window (s) and can be

larger than the window (s) it is overlaying. When an overlay window is closed, any window (s) that ware hidden behind it will reappear. Clicking on any on any visible portion of a window behind an overlay window will bring that window to the foreground as the active window.

Popup: Similar to an overlay window except, it always stays on top of

all other open windows (even if another window is clicked) Popup window usually require a response from the user in order to be removed.

26. Alarm and Events in scada:

Alarms and Events are the notifications used to inform operator of process activity. Alarms represent warnings of process conditions that could cause problems, and require an operator response. A typical Alarms is triggered when a process value exceeds a user defined limit. InTouch uses for types of alarm LOLO LO HI and HIHI.Events represent normal system status message, and do not require an operator response. A typical event is triggered when a certain system condition takes place, such as an operator logging into InTouch.

27. Scripts in scada:

Is a way of writing logic in InTouch. InTouch has its own instructions and way of writing program: Application : Linked to the entire application. Windows : Linked to a specific window. Key : Linked to a specific key or key combination on the keyboard. Condition : Linked to a discrete tagname or expression. Data Change : Linked to a tagname and/or tagname field only.

28.Communication with software:

DDE settings for Excel:
App. Name Excel, Topic Name [book.xls]sheet1 Item Name Cell Address ie (R1C1) App. Name View Topic Name TAGNAME Item Name Name of tag

DDE settings for InTouch:

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SCADA systems have evolved through 3 generations as follows:

First generation: "Monolithic"In the first generation, computing was

done by mainframe computers. Networks did not exist at the time SCADA was developed. Thus SCADA systems were independent systems with no connectivity to other systems. Wide Area Networks were later designed by RTU vendors to communicate with the RTU. The communication protocols used were often proprietary at that time. The first-generation SCADA system was redundant since a back-up mainframe system was connected at the bus level and was used in the event of failure of the primary mainframe system.

Second generation: "Distributed"The processing was distributed

across multiple stations which were connected through a LAN and they shared information in real time. Each station was responsible for a particular task thus making the size and cost of each station less than the one used in First Generation. The network protocols used were still mostly proprietary, which led to significant security problems for any SCADA system that received attention from a hacker. Since the protocols were proprietary, very few people beyond the developers and hackers knew enough to determine how secure a SCADA installation was. Since both parties had vested interests in keeping security issues quiet, the security of a SCADA installation was often badly overestimated, if it was considered at all.

Third generation: "Networked"These are the current generation

SCADA systems which use open system architecture rather than a vendor-controlled proprietary environment. The SCADA system utilizes open standards and protocols, thus distributing functionality across a WAN rather than a LAN. It is easier to connect third party peripheral devices like printers, disk drives, and tape drives due to the use of open architecture. WAN protocols such as Internet Protocol (IP) are used for communication between the master station and communications equipment. Due to the usage of standard protocols and the fact that many networked SCADA systems are accessible from the Internet, the systems are potentially vulnerable to remote cyberattacks. On the other hand, the usage of standard protocols and security techniques means that standard security improvements are applicable to the SCADA systems, assuming they receive timely maintenance and updates.

30. Application Development:

Substation automation has taken center stage on the distribution side of power business in India. The Indian States R-APDRP (Restructured Accelerated Power Development and Reforms Program) has provided the thrust and focus on electric power loss reduction through reliable automated

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systems and adoption of information technology in the area of energy accounting. The backbone for sustaining the R-APDRP program is underscored by successful upgrades of legacy-system based substation automation. In the process, protection and automation of power supply systems have attained high priority. For the electrical distribution part of the business, improvements in technology are evident in the functional capabilities and value proposition offered by Electric SCADA (Supervisory Control And Data Acquisition Systems), in terms of infusion of intelligence into grids, increasing substation automation, real-time demand response pricing, and also complex forecasting models. SCADA is now viewed as an essential component to manage the smart grid. The transmission and distribution restructuring requires SCADA to become an integral part of the unique business processes of the electric power market to seamlessly unify the separate domains of generation, transmission, and distribution. Intelligent field devices and the resultant available data requirements for SCADA in transmission and distribution sub-stations drive demand. On consumption side of power business, the State owned Power Grid Corporation of Indias (PGCIL) is driving a power evacuation program, estimated to be $ 10 billion. Substation control devices center on the area of protection. It is not just the electromagnetic relays that have to give way to microprocessor based numeric relays. It now encompasses intelligent electronic devices (IEDs) Sequence Event Recorders (SERs), Remote Terminal Units (RTUs), transformer tap changers, and such others. All these devices and units with essential communication capabilities facilitating interconnectivity and links through local area network and HMIs makes the essential transformation from the legacy systems of yesteryears. Centralized Load Dispatch Centers have come into being, facilitating greater visibility across the entire operative range of substations or cluster of substations. It is no more a challenge with modernized SCADA in place to control circuit-breakers in remote areas and facilitate seamless load and fault management.

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30.1 Configuration : The development of the applications is typically

done in two stages. First the process parameters and associated information (e.g. relating to alarm conditions) are defined through some sort of parameter definition template and then the graphics, including trending and alarm displays are developed, and linked where appropriate to the process parameters. The products also provide an ASCII Export/Import facility for the configuration data (parameter definitions), which enables large numbers of parameters to be configured in a more efficient manner using an external editor such as Excel and then importing 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 different aspect of the configuration, including the graphics. The facilities provided by the products for configuring very large numbers of parameters are not very strong. However, this has not really been an issue so far for most of the products to-date, as large applications are typically about 50K I/O points and database population from within an ASCII editor such as Excel is still a workable option. On-line modifications to the configuration database and the graphics are generally possible with the appropriate level of privileges.

30.2Development 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

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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 runtime. 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

31 Evolution:
SCADA vendors release one major version and one to two additional minor versions once per year. These products evolve thus very rapidly so as to take advantage of new market opportunities, to meet new requirements of their customers and to take advantage of new technologies. As was already mentioned, most of the SCADA products that were evaluated decompose the process in "atomic" parameters to which a Tag-name is associated. This is impractical in the case of very large processes when very large sets of Tags need to be configured. As the industrial applications are increasing in size, new SCADA versions are now being designed to handle devices and even entire systems as full entities (classes) that encapsulate all their specific attributes and functionality. In addition, they will also support multi-team development. As far as new technologies are concerned, the SCADA products are now adopting: Web technology, ActiveX, Java, etc. OPC as a means for communicating internally between the client and server modules. It should thus be possible to connect OPC compliant third party modules to that SCADA product.

32. Benefits of SCADA:

The benefits one can expect from adopting a SCADA system for the control of experimental 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.

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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. Control units

function as PLCs, RTUs, or DCUs. Control units perform advanced measurement and control independent of the central computer. PID control continues, even if communications to the main computer are lost. Control units have many channel types to measure most available sensors. Systems are compatible with our own or other vendors' HMI software packages. Control units have their own UPS; during ac power loss, they continue to measure and store time-stamped data. Control units provide on-board statistical and mathematical processing. Systems are easily expandable: add new sites or add sensors to existing sites. Control units have wide operating temperature ranges and operate in rugged environments.

33. Commnucation of plc and scada:

A Programmable Logic Controller, PLC, or Programmable Controller is a digital computer used for automation of industrial processes, such as control of machinery on factory assembly lines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory. A PLC is an example of a real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result.PLC and Programmable Logic Controller are registered trademarks of the Allen-Bradley Company.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. More recently they were also applied for the controls of smaller size particle detectors such as the L3 moon detector and the NA48 experiment, to name just two examples at CERN.CADA 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. .

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34. Difference between PLC and SCADA:

Sn o.
1.

PLC
PLC is Programmable Logic Controllers, a PLC is just a controller to do some works. It may be a brick with lots of terminals on it for wires and control something more or less by itself. Traditional PLC are migrating toward to traditional DCS for instants Fisher Delta V. For application in small or medium plant many people use a PLC (Allen Bradley) and also use DCS (Delta V, PlantScappe). If you have a small plant, it is better to set PLC or DCS system which has a system starting at 5 I/O and going up to 500 I/O.

SCADA
SCADA is Supervisory Control And Data Acquisition. SCADA is more complex and typically contains number of systems such as communications, data logging, server access, etc. SCADA may be used mostly by utilities and include data exchange requirement and protocols. SCADA is just that supervisory and data acquisition. It usually is not in plant but it used to supervise multiple small sites. In industry SCDA often do monitoring systems with little RTU at each well site.

2.

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3. PLC is always connected to its data source, so it does not need to maintain a database of current values. Redundancy is usually handled by parallel equipment, not by diffusion of information around a distributed database. SCADA needs to get secure data and control over a potentially slow, unreliable communications medium, and needs to maintain a database for prompt operator display. It frequently needs to do event processing and data quality validation. Redundancy is usually handled in distributed manner.

35. SCADA Software:

The supervisory computer consists of a PC running either Campbell Scientific's HMI software or another vendor's software. InTouch, Intellution, Lookout, and other software packages can be used in conjunction with our OPC client/server software application. Like other HMI software packages, our software provides a graphical interface that the operator uses to view the status of remote sites, acknowledge alarms, and control the units.

35.1SCADA Example Application:

Sno .
1.

Digram

Name
Sedimentation Tank Clarifier Generator

About
Monitor on/off status of pumps Control coliform, TSS, and on/off status of pumps Monitor torque Control on/off status and torque alarms Monitor and control temperatures and flow rates within exhaust heat recovery unit and heat exchanger Monitor on/off status of pumps and blowers, dissolved oxygen, flow rate, and wetwell level Control on/off st Monitor ORP Control Cl2and SO2 injection

2. 3.

4.

Trickling Filter

5.

Chlorine Contact Tank

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6. Digester Monitor and temperature control

36 SCADA Sensors: Almost any sensor may be used with the

measurement and control system, allowing customization for each operation. Each of our control units features a variety of channel types for flexibility in measuring many different types of sensors. For example, magnetic flowmeters can be measured using pulse counting channels instead of being measured as a 4-20 mA signal. Likewise, ultrasonic level transmitters can be measured using SDI-12 protocol on digital ports instead of as a 4-20 mA signal. Our control units also provide extensive signal conditioning and are easily expandable.

37. Example of plc:

As an example, say the facility needs to store water in a tank. The water is drawn from the tank by another system, as needed, and our example system must manage the water level in the tank. Using only digital signals, the PLC has two digital inputs from float switches (tank empty and tank full). The PLC uses a digital output to open and close the inlet valve into the tank. If both float switches are off (down) or only the 'tank empty' switch is on, the PLC will open the valve to let more water in. Once the 'tank full' switch is on, the PLC will automatically shut the inlet to stop the water from overflowing. If only the 'tank full' switch is on, something is wrong because once the water reaches a float switch, the switch will stay on because it is floating, thus, when both float switches are on, the tank is full. Two float switches are used to prevent a 'flutter' (a ripple or a wave) condition where any water usage activates the pump for a very short time and then deactivates for a short time, and so on, causing the system to wear out faster. An analog system might use a load cell (scale) that weighs the tank, and an adjustable (throttling) valve. The PLC could use a PID feedback loop to control the valve opening. The load cell is connected to an analog input and the valve is connected to an analog output. This system fills the tank faster when there is less water in the tank. If the water level drops rapidly, the valve can be opened wide. If water is only dripping out of the tank, the valve adjusts to slowly drip water back into the tank. A real system might combine both approaches, using float switches and simple valves to prevent spills, and a rate sensor and rate valve to optimize refill rates. Backup and maintenance methods can make a real system very complicated.

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AUTOMATION 37.1 Programming For Start/Stop of Motor by PLC: Often we

have a little green "start" button to turn on a motor, and we want to turn it off with a big red "Stop" button.

--+----[ ]--+----[\]----( )--| start | stop run | | +----[ ]--+ run

The

pushbutton

switch

connected

to

input X1 serves as the "Start" switch, while the switch connected to input X2 serves as the "Stop." Another contact in the program, named Y1, uses the output coil status as a seal-in contact, directly, so that the motor contactor will continue to be energized after the "Start" pushbutton switch is released. You can see the normally-closed contact X2 appear in a colored block, showing that it is in a closed ("electrically conducting") state.

Starting of Motor: If we were to press the "Start" button, input X1 would energize, thus "closing" the X1 contact in the program, sending "power" to the Y1 "coil," energizing the Y1 output and applying 120 volt AC power to the real motor contactor coil. The parallel Y1 contact will also "close," thus latching the "circuit" in an energized state:

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To Stop the Motor:

To stop the motor, we must momentarily press the "Stop" pushbutton, which will energize the X2 input and "open" the normally-closed "contact," breaking continuity to the Y1 "coil:" When the "Stop" pushbutton is released, input X2 will de-energize, returning "contact" X2 to its normal, "closed" state. The motor, however, will not start again until the "Start" pushbutton is actuated, because the "seal-in" of Y1 has been lost:

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AUTOMATION 37.2 Lamp Glows when at Input Switch is Actuated:

It must be understood that the X1 contact, Y1 coil, connecting wires, and "power" appearing in the personal computer's display are all virtual. They do not exist as real electrical components. They exist as commands in a computer program -- a piece of software only -- that just happens to resemble a real relay schematic diagram. Equally important to understand is that the personal computer used to display and edit the PLC's program is not necessary for the PLC's continued operation. Once a program has been loaded to the PLC from the personal computer, the personal computer may be unplugged from the PLC, and the PLC will continue to follow the programmed commands. I include the personal computer display in these illustrations for your sake only, in aiding to understand the relationship between real-life conditions (switch closure and lamp status) and the program's status ("power" through virtual contacts and virtual coils). The true power and versatility of a PLC is revealed when we want to alter the behavior of a control system. Since the PLC is a programmable device, we can alter its behavior by changing the commands we give it, without having to reconfigure the electrical components connected to it. For example, suppose we wanted to make this switch-and-lamp circuit function in an inverted fashion: push the button to make the lamp turn off, and release it to make it turn on. The "hardware" solution would require that a normallyclosed pushbutton switch be substituted for the normally-open switch currently in place. The "software" solution is much easier: just alter the program so that contact X1 is normally-closed rather than normally-open.

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38. Human Machine Interface:

A Human-Machine Interface or HMI is the apparatus which presents process data to a human operator, and through which the human operator controls the process. An HMI is usually linked to the SCADA system's databases and software programs, to provide trending, diagnostic data, and management information such as scheduled maintenance procedures, logistic information, detailed schematics for a particular sensor or machine, and expert-system troubleshooting guides. The HMI system usually presents the information to the operating personnel graphically, in the form of a mimic diagram. This means that the operator can see a schematic representation of the plant being controlled. For example, a picture of a pump connected to a pipe can show the operator that the pump is running and how much fluid it is pumping through the pipe at the moment. The operator can then switch the pump off. The HMI software will show the flow rate of the fluid in the pipe decrease in real time. Mimic diagrams may consist of line graphics and schematic symbols to represent process elements, or may consist of digital photographs of the process equipment overlain with animated symbols. The HMI package for the SCADA system typically includes a drawing program that the operators or system maintenance personnel use to change the way these points are represented in the interface. These representations can be as simple as an on-screen traffic light, which represents the state of an actual traffic light in the field, or as complex as a multi-projector display representing the position of all of the elevators in a skyscraper or all of the trains on a railway. An important part of most SCADA implementations are alarms. An alarm is a digital status point that has either the value NORMAL or ALARM. Alarms can

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be created in such a way that when their requirements are met, they are activated. An example of an alarm is the "fuel tank empty" light in a car. The SCADA operator's attention is drawn to the part of the system requiring attention by the alarm. Emails and text messages are often sent along with an alarm activation alerting managers along with the SCADA operator.

39. Remote Terminal Unit (RTU):

The RTU connects to physical equipment. Typically, an RTU converts the electrical signals from the equipment to digital values such as the open/closed status from a switch or a valve, or measurements such as pressure, flow, voltage or current. By converting and sending these electrical signals out to equipment the RTU can control equipment, such as opening or closing a switch or a valve, or setting the speed of a pump.

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AUTOMATION 39.1 Supervisory Station:

The term "Supervisory Station" refers to the servers and software responsible for communicating with the field equipment (RTUs, PLCs, etc), and then to the HMI software running on workstations in the control room, or elsewhere. In smaller SCADA systems, the master station may be composed of a single PC. In larger SCADA systems, the master station may include multiple servers, distributed software applications, and disaster recovery sites. To increase the integrity of the system the multiple servers will often be configured in a dual-redundant or hot-standby formation providing continuous control and monitoring in the event of a server failure. Initially, more "open" platforms such as Linux were not as widely used due to the highly dynamic development environment and because a SCADA customer that was able to afford the field hardware and devices to be controlled could usually also purchase UNIX or OpenVMS licenses. Today, all major operating systems are used for both master station servers and HMI workstations.

39.2 Operational philosophy:

For some installations, the costs that would result from the control system failing are extremely high. Possibly even lives could be lost. Hardware for some SCADA systems is ruggedized to withstand temperature, vibration, and voltage extremes, but in most critical installations reliability is enhanced by having redundant hardware and communications channels, up to the point of having multiple fully equipped control centres. A failing part can be quickly identified and its functionality automatically taken over by backup hardware. A failed part can often be replaced without interrupting the process. The reliability of such systems can be calculated statistically and is stated as the mean time to failure, which is a variant of mean time between failures. The calculated mean time to failure of such high reliability systems can be on the order of centuries.

40. Conclusion:

SCADA is used for the constructive working not for the destructive work using a SCADA system for their controls ensures a common framework not only for the development of the specific applications but also for operating the detectors. Operators experience the same "look and feel"

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whatever part of the experiment they control. However, this aspect also depends to a significant extent on proper engineering.

41.References:
A.Daneels, W.Salter, "Technology Survey Summary of Study Report", ITCO/98-08-09, CERN, Geneva 26th Aug 1998. A.Daneels, W.Salter, "Selection and Evaluation of Commercial SCADA Systems for the Controls of the CERN LHC Experiments", Proceedings of the 1999 International Conference on Accelerator and Large Experimental Physics Control Systems, Trieste, 1999, p.353. G.Baribaud et al., "Recommendations for the Use of Fieldbuses at CERN in the LHC Era", Proceedings of the 1997 International Conference on Accelerator and Large Experimental Physics Control Systems, Beijing, 1997, p.285.

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