By : ANKIT SHARMA VII SEM ECE JECRC

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SUN SHINE AUTOMATION INDIA LIMITED

SIEMENS Authorized Service Business Partner Automation & Drives Division.

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What is Automation ?
Automation is basically the delegation of human control function to technical equipment for

Increasing Productivity
Increasing Quality Reducing Cost Increasing Safety in working conditions
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Automation applied to plant

Productivity

Total Automation
Plant

Manufacturing Competitiveness Solution

Quality
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Labour Cost
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Programmable Logic Controller

Electronic Control using Logic Gates

Hard wired logic Control Manual Control

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A Programmable logical controller is a specialized computer used to control machines and processes. It uses a programmable memory to store instructions and specific functions that include ON/OFF control ,sequencing, arithmetic and data handling.

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Reduced space Energy saving Ease of maintenance Economical Greater life & reliability Tremendous flexibility Shorter project time Easier storage, archiving and documentation

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Too much work required in connecting wires. Difficulty with changes or replacements. Difficulty in finding errors; requiring skillful work force.

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The PLC is programmed interface between the field I/p element like limit switches, sensors, push button and the final control elements like actuator, solenoid/control valves, drives, hooters etc PLC consist of :1. Power Supply 2. CPU with Processor and Program memory 3. Input Module 4. Output Module 5. Comm Port 6. Programming Device [PC/Laptop]
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PLC Size
1. SMALL - it covers units with up to 128 I/Os and memories up to 2 Kbytes. - these PLCs are capable of providing simple to advance levels or machine controls. - have up to 2048 I/Os and memories up to 32 Kbytes.

2. MEDIUM

3. LARGE

- the most sophisticated units of the PLC family. They have up to 8192 I/Os and memories up to 750 Kbytes. - can control individual production processes or entire plant.
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Hardware configuration A pictorial view--CPU

Signal Module

Power supply

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Configuration of PLC : Siemens

CPU

I/O Modules
External Power Supply

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Configuration of PLC : Allen Bradley

CPU

I/O Modules
Power Supply

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Configuration of PLC : Modicon

Built in display for I/O (in-rack, AS-i) and Diag 8 Analog Inputs 1 Analog Output

Programming Terminal PC Connection

Up/Down Fast Counter

I/O Modules

Up Counter PCMCIA communications port PCMCIA memory expansion port

Unitelway Port for connection of up to 5 Slaves

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Function block diagrams (FBDs) Structured text (ST)

Instruction List (IL)

Sequential function charts (SFCs) Ladder logic.

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In PLC programming things (I\O) are Either True Or False

In case the inputs are true the rung becomes true and
an output occurs. It is a graphical language very popular for programming

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Power flows through these contacts when they are closed. The normally open (NO) is true when

the input or output status bit controlling the

contact is 1. The normally closed (NC) is true when the input or output status bit controlling the contact is 0.
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Machine controls, Packaging, Material handling, similar Sequential task as well as Process control.

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Modicon Allen Bradley Siemens ABB Mitsubishi GE Fanuc Omron Messung

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SCADA is Supervisory Control and Data Acquisition SCADA refers to a system that collects data from various sensors at factory or plant & then sends this data to central computer which manage or control data. SCADA is used to control chemical plant processes, oil and gas pipelines, electrical generation and transmission equipment, manufacturing facilities, water purification and distribution infrastructure, etc.
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Basic System Components

Typically, there are three major elements that

make up a SCADA system:

The master terminal unit (MTU)

The remote terminal unit (RTU)

The communications equipment

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 The MTU is known as Master Transmission Unit It is the heart of the system The MTU communicates with other peripheral devices in the facility like monitors, printers, and other The primary interface to the operator is the monitor or CRT . Representation of valves, pumps, etc. As incoming data changes, the screen is updated
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 Connected to sensors in the

process, converting sensor signal to digital

one and sending digital data to the supervisory system.

As the name suggest it is remotely located in

the plant that sends data to MTU. Relationship between MTU and RTU is

typically defined as a master and slave.

The major difference between the MTU and RTU is that the MTU initiates virtually all communications between the two.
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 Communication equipment is required for bidirectional communications between an RTU and the MTU. This can be done through public transmission media or atmospheric means SCADA systems are capable of communicating using a wide variety of media such as Fiber optics, dial-up, or dedicated voice grade telephone lines, or radio

frequency

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Features of typical SCADA software

Dynamic process graphic Real-time and Historical trending Alarms Recipe Management Security Device connectivity Database connectivity

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Example Alarm Page

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Example Trending Chart

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Wonder ware : In Touch Intellution : Fix DMACS Merz : Aspic Allen Bradley : Rsview Siemens : WinCC GE Fanuc : Cimplicity KPIT : ASTRA

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CONCLUSION
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" whatever part of the experiment they control. However, this aspect also depends to a significant extent on proper engineering.
PLC is an industrial computer control system that continuously monitors the state of input devices and makes decisions based upon a custom program to control the state of output devices. A digitally operating electronic system, designed for use in an industrial environment, which uses a programmable memory for the internal storage of user oriented instruction for implementing specific functions such as logic, sequencing, timing, counting, arithmetic, to control various types of machines or processes through digital or analog inputs.
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SCADA and Industrial Automation Security, http://www.scadasec.net http://www.ea.doe.gov/pdfs/21stepsbooklet.pdf Critical Infrastructure Protection: Challenges and Efforts to Secure Control Systems http://www.gao.gov/new.items/d04354.pdf Myths and Facts Behind Cyber Security of Industrial Controls http://www.pimaweb.org/conferences/ SCADA Gospel Archives (edited archives of the SCADA mailing list) http://members.iinet.net.au/~ianw/archive/book1

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