PLC : Introduction A programmable logic controller, which is the usually called a PLC or programmable controllers is solid- state, digital,

industrial computer. Upon first glance, a programmable controller may seen to be no more than black box with wires bringing signals in and other wires sending signals out. It might also appear there some magic being done inside that somehow decides when field devices should be turned on. In actuality, there is no magic. PLC is a computer and someone had to tell it what to do. The PLC knows what to do through a program that was developed and then entered into its memory. The PLC is a computer, however without a set of instructions telling it what to do, it nothing more than a box full of electronic components. Without instructions, the black box that we call a PLC can do nothing. The user program is the list of instructions that tells the PLC what to do. 1.1 What is a PLC? The PLC can be classified as a solid state member of the computer family. A programmable controller is an industrial computer in which control devices such a limit switches, push buttons proximity or photoelectric sensors. Float switches or pressure switches to name a few, provide incoming control signals into the unit. An incoming control signals is called an input. Inputs interact with instructions specified in the under ladder program which tells the PLC how to react to the incoming signals. The user program also directs the PLC on how to control field device like motor starters, pilot lights, and solenoids. A signal going out of the PLC to control a field device is called an output. Figure 1 gives an overview of the interaction between the system inputs, PLC and its ladder program, and the pilot light output. A formal definition of a PLC comes from the National Electrical Manufacturers Association ( NMEA) : A programmable controller is a digitally operated electronic system designed for use in an industrial environment, which uses a programmable memory for the internal storage of use-orientation instructions for implementing specific functions such as logic, sequencing, timing, counting, and arithmetic to control, though digital or analog inputs and outputs, various types of machines or processor.

1.2 Features The PLC is the hardened industrial computer. A PLC is made so that it can survive in the manufacturing environment. Notebook and desktop personal computers are not designed for continuous use in the manufacturing environment. When a computer needs to reside in the harsh manufacturing environment, an industrially hardened computer that is designed to withstand stress is the correct choice. Industrial computers are designed to withstand the dirt, shock, vibration, high temperatures and wash downs found in the factory environment by incorporating the following features:1. PLC is small, easy to install units. A PLC is easy to install because all inputs and outputs connections are connected to terminals strips in a central location. 2. Air filters on intake fans. 3. Fans with ball bearing. 4. National electrical manufacturers Association (NMEA) 12,4 and 4X enclosure rating. 5. Shock mounted hard drives. 6. 0 to 55 degree centigrade compared to 0 to 40 degree centigrade operating environment. 7. Industrial computers are modular, which results in faster and easier repair. 8. Industrial computers do not need to be placed in a fan- cooled or air- conditioned enclosure with a viewing window. 9. Easier troubleshooting.

10. Total Response time = Input response + Programme execution time + output response time. 1.3 History of PLC Early machines were controlled by mechanical means using cams gears, levers and other basic mechanical devices. As the complexity grew, so did the need for a more sophisticated control system. These elements were wired as required to provide the control logic necessary for the particular type of machine operation. Relay and switch logic was cumbersome and time consuming to modify. Wiring had to be removed and replaced to provide for the new control scheme. This modification was difficult and time consuming to design and install and any small bug in the design could be a major problem to correct since it also required rewiring of the system. A new means to modify control circuitry was needed. The Development and testing ground for this new means was U.S auto Industry. The time period was the late 1960s and early 1970s and the result was the PLC. Automotive plants were confronted with a change of manufacturing techniques every time a model changed and, in some cases, for changes on the same model if improvements had to be made during the model year. The PLC provided an easy way to reprogram the wiring rather than actually rewiring the control system. The PLC that was developed during this time was not very easy to program. The language was cumbersome to write, requiring highly trained programmers. These early devices were merely relay replacements and could do very little else. Older PLCs were capable of only handling discrete inputs and outputs (i.e. ON-OFF type signals). While todays systems can accept and generate analog voltages and currents as well as wide range of voltage levels and pulsed signals. Unlike their personal computer cousin, they can typically withstand the vibration, shock, elevated temperature, and electrical noise to which manufacturing equipment is exposed. As more manufactures become involved in PLC production and developments, and PLC capabilities expand, the programming language is also expanding. Also, manufacturers tend to develop their own versions of ladder logic language. Comparison PLC 1. A plc is a type of MICROPROCESSOR 1. A microprocessor is the MICROCONTROLLLER 1. A microcontroller is a special

computer designed specifically for industrial applications. 1. All PLCs contain microprocessors.

Central Processing Unit (CPU) of a computer.

purpose computer system, usually programmed to perform a single task.

2. Not all microprocessors are used in PLCs.

2. Microcontrollers have microprocessors as a part of their system hardware.

2. A PLC can be stated as a 3. A microprocessor is only complete computer in itself with a microprocessor. one component of an electronic device and requires additional circuits, memories etc. before it can function.

3.A microcontroller is a small taskspecific computer. They contain microprocessors on-board to handle logic and instruction processing but they still must have all the essential elements of any computer system.

4. A PLC can be programmed or reprogrammed to control different types of devices using Ladder Logic et c. 6. Applications include automation and process based industries etc.

5. A general computer or microprocessor system can be tasked with a wide variety of jobs.

4. Usually a microcontroller is a programmed for a specific task and left alone to do it without further human input.

7. Applications include computers, telephone industry home appliances such as microwave.

5.Applications include monitoring water level in a tank etc.

Hardware Components: There are two fundamental uses of switches. First, switches are used for operator to send instructions to the control circuit. Second, switches may be installed on the moving parts of a machine to provide automatic feedback to the control system.
Push Button: The most common switch is the push button.

It is also the one that needs the least description because it is widely used in an automotive.

The momentary push button switch is activated when the button is pressed and deactivated when the button is released. The deactivation is done using an internal spring. The maintained push buttons switch activates when press, but remains activated when it is released. To deactivate it, it must be pressed a second time. For this reason, this type of switch is sometimes called a push- push switch. The contacts on switches can be of two types: There are normally open (N/O) and normally closed (N/C). Whenever, a switch is in its deactivated position, the N/O contacts will be open ( non- conducting ) and the N/C contacts will be closed ( conducting ) shows the schematic symbols for (a) a normally open push buttons and (b) a normally closed ( pushButtons. There is no internal electrical connection between different contact pairs on the same switch. Most industrial switches can have extra contacts piggy backed on the switch, so as many contacts as needed of either type can be added by the designer.

Selector Switches: A selector switch is also known as a rotary switch. An automobile ignition

switch and an oscilloscopes vertical gain and horizontal time base switches are examples of selector switches. Selector switches use the same symbol as a momentary pushbutton, except a lever is added to the top of the actuator as shown. The switch is open when the selector is turned to the left and closed when turned to the right. The switch has two sets of contacts. The top contacts are closed when the switch selector is turned to the left position and open when the selector is turned to right. The bottom set of contacts works exactly opposite. There is no electrical connection between the top and bottom pairs of contacts. For the switch, the control panel would be labeled with the STOP position to the left and the RUN position to the right.
Metal Detector Switch: It is another hardware component that works same as that of push-button

being sensitive to metal. It gets turned on when it gets into contact with metal and gets turned off when the metal contact is removed.

MANUFACTURE AND CLASSIFICATION

Manufacturer PLC Memory I/D Count Communications options General Electric VersaMax Nano 2K 6 input 4 Output Siemens Simatic S7- 200, 4 K Program 2 K CPU 221 Mitsubishi FXO data 1.6K 6 input 4 Output Up to 16 Serial, Profibusinputs DP,CC- Link Optional RS 485 Serial

Up to 14 Network outputs Rockwell MicroLogix 1K Up to 20 Serial, Data inputs Highway 485,

Up to 12 DeviceNet outputs General Electric VersaMax Micro Omran CPMNM1A 3K 100 Host link, NT Link, 1:1 Link Mitsubishi FX2N Micro Super Up to 16 K Up to 256 Serial and RS422/485 Profibus9K Up to 84 Serial, RS-485

DP and CC- Link. Omran CQMI 13 k Up to 256 Device, Net. CompoBus/ S; Host Link, NT Link,, 1:1 Link Siemens Simatic S7-300 6 to 512 K Upto 512 Point-to point discrete or links, AS128 analog Interface, profibus- DP, Profibus- FMS, Industrial Ethernet Rockwell SLC 500 Up to 64 K Up 4096 to Serial DH- 485, DH+, Device Net,

inputs and Control Net, outputs Omran Cvmi Up to 62 K Up 2048 Ethernet. to Ethernet, Sysmacnet, SysmaticLink controller Link, Device, Nete, Host Llink, NT Link. Mitsubishi AnN Series Up to 320 K Up 2048 to Modbusm Profibus- DP, Ethernet Rockwell ControlLogix 750- Kthru 8 M Up bytes 128.000 to Serial DH- 485, DH+, Device Net, Control Net, Ethernet

Plc Manufacturing Companies Modicon from Allen Bradely Siemens ABB OMRON Mistubushi GE Fanuc LG Phillip Yokogava 3.2 Types of PLC 1. Compact type (Number of input are fined). e.g. Zelio, Twido. 2. Modular type or rack type ( Number of input increase or decrease requirement).e.g. Allen bradley 3.2.1 Zelio PLC Manufacturer Software Twido PLC Manufacturer Software Comm Protocol Connector Comm port Plc Series : : : : : : Schnieder Twido soft Modbus urial 8 Pin Mini Din RS 485 TWDLCAA 24DRF : : Schneider Electrical Zelio soft 2 according to France USA Germany USA Japan South Korea. South Korea Japan U.K Japan

PROGRAMMING A PROGRAMMABLE CONTROLLER

The PLC can do nothing without someone developing a program and loading this user program into the CPUs memory. Once the CPU has the program in memory and has been put into run

mode, it can look at inputs and a result of solving the user program ladder logic instructions it can control the outputs and their associated field devices. There are multiple ways to program a PLC. 1. One of the oldest methods of programming a PLC is by pressing buttons on a handheld programming terminal to enter a user program a PLC. 2. The most popular method of PLC programming is using a personal desktop computer and either a DOS or Windows operating system to run the manufacturers software for the specific PLC. Illustrates the choice of an SLC 500 handheld terminal or a personal computer for programming. Allen Bradley SLC 500 programming options. Either a handheld programmer or a personal computer can be used to program the PLC. (Used with permission of Rockwell Automation). 3. PLC programming can be accomplished using a notebook personal computer running PLC programming software and a Personal computer Memory Card International Association ( PCMCIA) interface card, or in some cases, a direct connection between the personal computer serial port and the PLC CPU. 4. Using the industrial computer and the PLC manufacturers program software. 5. Using third- party open software and running a personal computer as the PLCs CPU. 4.1 Programming Devices A program device is needed to enter, modify and troubleshooting the PLC program, or to check the condition of the processor. Once the program has been entered and the PLC is running, the

programming device may be disconnected. Three types of programmers are generally used 1. Hand held ( smaller, cheaper portable but limited display capability and few functions) 2. Dedicated desktop user- friendly, designed or industrial use, portable but costly, limited PLCs can be programmed, limited documentation and limited graphics capability. 3. Personal computer with software available for all major brands of PLCs, the PC today is the most common programming device. It can store program on floppy disc/hand disc. If for some reason the program is lost the restoration of the program is simple.

On line programming changing programs while the processor and driven equipments running, must be done by persons with a complete understanding of circuit operation and the process or driven equipment. Off line programming the programming is being developed off line (without being connected to the process or driven equipment). Since few program are ever created without mistakes, it is the most common and safest method of programming. After testing and verifying the program offline, the PLC can be put in the ON LINE mode for final verification and operation. 4.2 Programming Languages of PLC IEC 1131-3 is the international standard for programmable controller programming languages. The following is a list of programming languages specified by this standard:
1. 2. 3. 4. 5.

Ladder diagram (LD) Sequential Function Charts (SFC) Function Block Diagram (FBD) Structured Text (ST) Instruction List (IL)

One of the primary benefits of the standard is that it allows multiple languages to be used within the same programmable controller. This allows the program developer to select the language best suited to each particular task. Ladder Logic Ladder logic is the main programming method used for PLC's. As mentioned before, ladder logic has been developed to mimic relay logic. The decision to use the relay logic diagrams was a strategic one. By selecting ladder logic as the main programming method, the amount of retraining needed for engineers and trades people was greatly reduced. The first PLC was programmed with a technique that was based on relay logic wiring schematics. This eliminated the need to teach the electricians, technicians and engineers how to program - so this programming method has stuck and it is the most common technique for programming in today's PLC. Mnemonic Instruction

There are other methods to program PLCs. One of the earliest techniques involved mnemonic instructions. These instructions can be derived directly from the ladder logic diagrams and entered into the PLC through a simple programming terminal. Sequential Function Charts (SFC) SFC have been developed to accommodate the programming of more advanced systems. These are similar to flowcharts, but much more powerful. This method is much different from flowcharts because it does not have to follow a single path through the flowchart. Structured Text (ST) Programming has been developed as a more modern programming language. It is quite similar to languages such as BASIC and Pascal. Structured Text (ST) is a high level textual language that is a Pascal like language. It is very flexible and intuitive for writing control algorithms. Function Block Diagram (FBD) FBD is another graphical programming language. The main concept is the data flow that start from inputs and passes in block(s) and generate the output. 4.3 Rung 1. A rung of ladder diagram code can contain both input and output instructions. a) Input instructions perform a comparison or test and set the rung state based on the outcome. b) Normally left justified on the rung. 2. Output instructions examine the rung state and execute some operation or function. a) In some cases output instructions can set the rung state. b) Normally right justified on the rung.

Fig 4.1 Rung

4.4 Logics for Basic Gates

Table III Logics Symbols

LOGIC SYMBOLS logic element Logic Element Function AND Output If All Of the Control Inputs On OR Output if any one of the control input is on MIS-STD 80 6B Symbol Electric Relay Logic Symbol Logic NOT Output if NAND Output if all NOR Output if any of the control inputs are on

single control control input input signal is off signals are on

Electrical Switch Logic Symbol 4.5 Timer and Counter One of the major enhancements to the original programmable controller was to add timing and counting abilities. Early PLCs had optional timing circuit cards that the user could slide into the CPU to add timer or counter functionality to the PLC. Timing cards had physical solid- state timing chips installed on slide- in timer boards. Todays PLC uses modern microprocessor technology and have timers and counters included in the instructions set. 4.5.1 Timer A timer consists of the following parts: timer address, preset value, time base and accumulated value. There are bits associated with the current state of the timer called status

bits. The timer address is a timer unique identifier in PLC memory. A timer instruction is one element. A timer element is made up of three 16- bits words:1.

Word zero contains the three states bit, EN, TT and DN (status bits will be covered as we introduce each timer instruction).

2. 3.

Word one is for the present value. Word two is for the accumulated value.

4.5.1.1 The ON Delay Timer Instruction

Uses the on- delay timer instruction program a time delay before an instruction becomes true. Timer Addressing Timer addressing is as follows: T (Timer file number): (Timer element number). The timer address T4:0 is addressing timer file 4, timer element 0. 4.5.1.2 OFF- Delay Timer Instruction

Uses the off-delay timer instructions if you want to program a time delay to being after rung inputs go false. As an example, an external cooling fan on a motor is to run all the time the motor is running and for 100 seconds after the motor is returned off. This involves a 100- second offdelay timers. The 100- second timing cycle begins when the motor is turned off. Figure

illustrates an off- delay timer, which Allen Bradley calls a timer off delay and its associated ladder rungs.

TIMER INSTRUCTIONS Instructions Use this instruction to On- Delay Functional description

Program a time delay to When you want an action to begin a specified before become true instruction time after the input become true.

Off- Delay

Program a time delay to If an external cooling fan on a motor is to run all begin after rung inputs to the time the motor is running and for five minutes false. after the motor is turned off, you have a five minute off- delay timer. The five- minute timing cycle begins when the motor is turned off.

Retentive

Retain accumulated value Use a retentive timer to track the running time of through power losses, a motor for maintenance purposes. Each time the

processor mode change. motor is turned off, the timer will remember the Or rung state going from elapsed time. Next time the motor is turned on, true to false the time will increase from that point. When you want to reset this timer, use a reset instruction.

Reset

Reset the accumulated Typically used to reset a retentive timers value of a timer or accumulated value to zero. counter

4.5.2 Counter Every PLC has counter instructions Although most PLC counter work the same the instructions symbols used and method of programming will change for different manufactures. The typical counter counts from 0 to a predetermined values, called the preset value. The counter which counts from 0 to a desired value is called count-up or up-counter and the counter which counts down is called a desired value to 0 is called down- counter or count- down counter. A counter instruction is one element. A counter element is made up of three 16- bits words. Thus the counter instructions contain three parts. 4.5.2.1 The Count-Up Instruction Use the count-up instruction if you want to counter to increment one decimal value each time it registers a rung transition from false to true.

4.5.2.2 The Count Down Instruction Use this instruction if you want to count down over the range of + 32, 767 to 32,768. Each time the instruction sees a false-to-true transition, the accumulated value will be decremented by one count.

COUNTER INSTRUCTIONS Instructions Count up Use this instruction to Functional Description

Count from zero up to a Counting the number of parts produced during a desired value specific work shift, or in the current batch. Also, counting the number of rejects from this batch.

Count down

Count down from a desired An operator interface display shows the operator the value to zero number of parts remaining to be made for a lot of 100 parts ordered.

SCOPE OF PLC
A PLC (Programmable Logic Controller) is one of the main devices used in industry to implement: monitoring, logic, control, or other events/functions impossible (or to complicated) to be done mechanically. With respect to embedded systems, a PLC is in fact an embedded system running a program to provide the various functions PLCs typically provide. 5.1 Advantages of PLC
1. 2.

Flexibility: One single Programmable Logic Controller can easily run many machines. Correcting Errors: In old days, with wired relay-type panels, any program alterations required time for rewiring of panels and devices. With PLC control any change in circuit design or sequence is as simple as retyping the logic. Correcting errors in PLC is extremely short and cost effective.

3.

Space Efficient: Today's Programmable Logic Control memory is getting bigger and bigger this means that we can generate more and more contacts, coils, timers, sequencers, counters and so on. We can have thousands of contact timers and counters in a single PLC. Imagine what it would be like to have so many things in one panel.

4.

Low Cost: Prices of Programmable Logic Controlers vary from few hundreds to few thousands. This is nothing compared to the prices of the contact and coils and timers that you would pay to match the same things. Add to that the installation cost, the shipping cost and so on.

5.

Testing: A Programmable Logic Control program can be tested and evaluated in a lab. The program can be tested, validated and corrected saving very valuable time.

6.

Visual observation: When running a PLC program a visual operation can be seen on the screen. Hence troubleshooting a circuit is really quick, easy and simpler.

7.

Changes and error correction system easier: If one system will be modified or corrected, the change is only done on the programs contained in computers, in a relatively short time, after that it downloaded to the PLC. If not using a PLC, for example relays the amendments made by altering the wiring cables. This course takes a long time

8.

Cheaper: PLC is capable of simplifying a lot of cabling compared to a relay. So the price of a PLC at a price cheaper than some fruit relay capable of doing the wiring for the same amount with a PLC. PLC includes relays, timers, counters, sequencers, and other functions.

9.

Operating speed: PLC operation speed is faster than the relay. Speed PLC scan time is determined by its in units of milliseconds.

10.

Resistant character test: Solid state devices are more resistant than the relay and test mechanical or electrical timers. PLC is a solid state device that is more resistant test.

11.

Simplifies the control system components: The PLC also have counters, relays and other components, so it does not require components such as additional. Use of relays requires counters, timers or other components as additional equipment.

12.

Documentation: Printout of the PLC can be directly obtained and do not need to see the blueprint of his circuit. Unlike the printout relay circuit cannot be obtained.

13.

Security: Changing the PLC cannot be done unless the PLC is not locked and programmed. So there is no unauthorized person can change the PLC program for a PLC is locked.

14.

Can make changes by reprogramming: Since the PLC can be programmed quickly reset the production process that mixes can be completed. For example part B will be executed but sections of A is still in the process, the process in section B can be reprogrammed in seconds.

15.

Addition of faster circuits: Users can add a circuit controller at any time quickly, without requiring great effort and cost as in conventional controllers.

5.2 Disadvantages of the PLC

1. The drivers of Hilo in the area of weighbridge queue have to keep their idling of engines and their pressure up of brake in light option anticipation. 2. It is not likely for the system to distinguish between burnt and unburnt cane. It means that the favoring old system of one tandem or the burnt cane has must be discarded 3. There's too much work required in connecting wires. 4. There's difficulty with changes or replacements. 5. Its always difficult to find errors; and require skillful work force. 6. When a problem occurs, hold-up time is indefinite, usually long. 7. 5.3 Limitations of PLC The system now has some limitations even though these could be reduced by program changes or method changes the allocation of light sequence: 1. The hauliers with interconnects have a advantage of payload over standard trailers as the light ratio options in the sequence is presently based on loads number only, and is not weighted based on the payload differences. 2. If there is haulier with a small tonnage would occurrence huge delays if allocated a detailed light. 3. It should a vehicle progress to the wrong system tandem is ignorant of this and another load is not called even though it is requisite. This trouble could be programmed out with a routine of time delay. 5.4 Trouble Shooting Careful start up procedures is necessary to prevent the damage to the driven equipment and PLC or more important injury to personal. Prior to binging a system start up procedure, it is important to check and verify that the system has been installed according to the manufacturers

specifications and that the installation, meets local, state and national codes. Special attention be given to system grounding. Before applying power to the controller following is to be ensured 1. Verifying that incoming power matches the jumper selected voltage setting of the power supply.

2. Verify that a hardwired safety circuit or other emergency stop device has been installed and is in open position. 3. Check all power and communication cables to ensure that connector pins are straight and not bent or pulled out. 4. Connect all cables making sure that connectors are fully inserted into their sockets secure connectors as applicable. 5. Ensure that modules are securely held in the I/O rack.

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 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. SCADA runs on a PC and is generally connected to various PLCs and other peripheral devices. It enables you to generate applications for the most demanding requirements of plant engineers, operators, managers tailored precisely to the needs of each plant. SCADA constantly gathers a data from the plant in real-time, stores and processes it in the database, evaluates and generates alarms. Displays information to plant operators to plant operators, supervisors and managers and can issued instructions to PLCs on the plant floor. 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. Features of SCADA 1. Dynamic Process graphic mimics developed in SCADA software should resemble the process mimic. SCADA should have good library of symbols so that you can develop the mimic as per requirements. Once the operator sees the screen he should know what is going on in the plant. 2. Real time and Historical Trend: The trends play very important role in the process operation. If our batch fails or the plant trips, we simply go to historical trend data and do the analysis. We can have better look of the parameters through the trends. Ex: we

commission a SCADA system for Acid Regeneration plant where the plant has to be operated on 850- deg temperature. If the operator operates the plant at 900 deg you can imagine how much additional LPG he is putting into the reactor. Again what will happen to the bricks of the reactor? So the production managers first job will be to go through the trends how the operators are operating the plant. Even when the plant trips there are more than 25 probable reasons for the same but you go through the history trends, its very easy to identify the problems. 3. Alarms have a very vertical role in automation. Generally we have alarm states for each inputs/outputs like your temperature should not cross 80 deg or lever should be less than 60. So if the parameter goes in Alarm state then operator should be intimated with the alarm. Most of the SCADA software support our types of alarms like LOLO, LO, HI and HIHI. Dead band the value of dead band defines the range after which a high low alarm condition returns to normal. 4. Alarms are most important of plant control applications because the operator must know instantly when something goes wrong. It is often equally important to have a record of alarm and whether an alarm was acknowledged. An alarm occurs when something goes wrong. It can signal that a device or process has ceased operating within acceptable, predefined limits or it can indicate breakdown, wear or process malfunction. 5. Recipe Management is an additional feature. Some SCADA software support it, some do not. Most of the plants are manufacturing multi products. When you have different product to manufacture, you just have to load the recipe of the particular product. 6. Security is one facility people generally look for. You can allocate certain facilities or features to the operator, process people, engineering department and maintenance department for example operators should only operate system, he should not be able change the application. The engineers should have access to changing the application developed. 7. Device connectivity we will find there are hundreds of automation software manufacturer like Modicon, Siemens, Allen Bradley, Yokogawa, ABB. Everybody has their own way to communication or we can say they have their own communication protocol. SCADA software should have connectivity to the different h/w used in automation. It should not happen that for Modicon I am buying one software and for Seimens another on. The

software like Aspic or Wonderware has connectivity to almost all hardware used in automation. 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. 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: 1. Web technology, ActiveX, Java, etc. 2. 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. Architecture : 7.4.1 Hardware Architecture One distinguishes two basic layers in a SCADA system: the "client layer" which caters for the man machine interaction and the "data server layer" which handles most of the process data control activities. The data servers communicate with devices in the field through process controllers. Process controllers, e.g. PLCs, are connected to the data servers either directly or via networks or field buses that are proprietary (e.g. Siemens H1), or non-proprietary (e.g. Profibus). Data servers are connected to each other and to client stations via an Ethernet LAN. The data servers and client stations are NT platforms but for many products the client stations may also be W95 machines.

7.4.2 Software Architecture The products are multi-tasking and are based upon a real-time database (RTDB) located in one or more servers. Servers are responsible for data acquisition and handling (e.g. polling controllers, alarm checking, calculations, logging and archiving) on a set of parameters, typically those they are connected to. Manufacturers of SCADA Modicon (Telemecanique) Allen Bradly Siemens KPIT Intelution Wonderware Usefulness of SCADA 7.6.1 Production department 1. Real time production status: manufacturing status is updated in real time in direct communication to operator and control device. 2. Production schedules: production schedules can be viewed and updated directly. 3. Production information management: production specific information is distributed to all. 7.6.2 Quality department Visual look : RS View : win cc : ASTRA : Aspic : Intouch

1. Date integrity and quality control is improved by using a common interface. 2. It is an open platform for statistical analysis. 3. Consolidation of manufacturing & Lab data. 7.6.3 Maintenance department 1. Improved troubleshooting and de- bugging: direct connection to wide variety of the devices, displays troubleshooting reduced diagnostic/ debugging time. 2. Plant can be viewed remotely. Notification can include pagers, e-mails, and phones. 3. C0-ordinationi between maintenance and management reduces unscheduled downtime 7.6.4 Enterprise department 1. Corporate information and real time production data can be gathered and viewe3d from anywhere within your operations. 2. User specific information ensures better informed decision 3. Data exchange with standard database and Enterprise systems provides integrated information solutions. 7.6.5 Engineering department Integrated Automation solutions reduce design and configuration time 1. Common configuration platform offers flexibility for constant configuration in all areas. 2. Capable of connecting to wide variety of systems. Reduces start up time and system training with industry proved open interfaces. 7.6.6 Manufacturing department 1. Unscheduled down time is reduced due swift alarm detection and event driven information. 2. Makes operations easier and more repeatable with its real time functionality. 3. Secured real time operation is maintained with windows. Application of SCADA 7.7.1 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.

7.7.2 Development Tools The following development tools are provided as standard: 1. 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 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 run-time. 2. 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. 3. A scripting language 4. An Application Program Interface (API) supporting C, C++, VB. 7.7.3 Bottling of Soft Drinks The bottling of soft-drink in a plant is done by using SCADA software. The plant used for this bottling is highly automated and hence SCADA software finds application here. The process makes use of the conveyer belt, on which the bottles move for filling. The motion of the conveyer belt is so programmed such that the conveyer belt stops the bottle below the nozzle for only that much time that is required for the bottle to get filled. After that the conveyer belt is moved further and second bottle is undergone the same process. The other part of this plant which is programmed is the tank containing the drink. This tank is also programmed in a way that the liquid will come out in that much amount only which is required to fill the bottle and this tank is in synchronization with the conveyer belt such that the liquid will come out only when the bottle is exactly below the nozzle of the tank. As the bottles are filled, they are carried by the same conveyer belt to the placing racks.

Automation: ''Automation'' or industrial automation or numerical control is the use of control

systems such as computers to control industry industrial machinery and industrial process

processes, reducing the need for human intervention. In the scope of industrialization, automation is a step beyond mechanization. Whereas ''mechanization'' provided human operators with machinery to assist them with the ''physical'' requirements of work, ''automation'' greatly reduces the need for human ''sensory'' and ''mental'' requirements as well. Processes and systems can also be automated. Automation plays an increasingly important role in the global economy and in daily experience. Engineers strive to combine automated devices with mathematical and organizational tools to create complex systems for a rapidly expanding range of applications and human activities. Many roles for humans in industrial processes presently lie beyond the scope of automation. Human-level pattern recognition, language recognition, and language production ability are well beyond the capabilities of modern mechanical and computer systems. Tasks requiring subjective assessment or synthesis of complex sensory data, such as scents and sounds, as well as high-level tasks such as strategic planning, currently require human expertise. In imany cases, the use of humans is more cost-effective than mechanical approaches even where automation of industrial tasks is possible. Specialised hardened computers, referred to as programmable logic controllers (PLCs), are frequently used to synchronize the flow of inputs from (physical) sensors and events with the flow of outputs to actuators and events. This leads to precisely controlled actions that permit a tight control of almost any industrial process. Automation Tools: Different types of automation tools exist: 1. ANN - Artificial neural network 2. DCS - Distributed Control System 3. HMI - Human Machine Interface 4. SCADA - Supervisory Control and Data Acquisition 5. PLC - Programmable Logic Controller