BATCH NO:6

INDUSTRIAL PARAMETERS
CONTROL USING PLC AND
SCADA

Our batch
V.jwala ragini
J.surendhra
V.s.s.madhav
N.Mahesh babu

Under the esteemed guidance

of

T.srinivasa
RaoAsst.prof
M.Tech(c&sp)

ABSTRACT
PLC and SCADA based distribution monitoring the
electrical parameters that can be any type, in this
project we are monitoring and controlling
temperature, pressure, flow, level.. and if in
case any fault occurs in system we it can be
eliminated and control by the personal computer
system.
The important and main concept of this project is
data acquisition and controlling by using SCADA
software Programminglogic controller.
Here PLC is the medium between electrical systems
and personal computer for SCADA to take input and
outputs. Automating electrical distributions systems
by implementing a SCADA system is the one of the
most cost effective for the improving reliability,
increasing utilization, power supply. So we can use
PLC and SCADA for more benefits.

Introduction
Now a days there are various electronic equipments
available for remote operation of power distribution system
control.
However,the main disadvantage of these systems is that
they can be operated only from short ranges and also less
reliable.
Thus,to overcome the above drawbacks,we are using
SCADA system.
PLC and SCADA Based Monitoring System the name itself
says that the electrical parameters can be monitored in
Computer (PC) by using SCADA Software.
PLC will collect data related to electrical parameters and
build a link with the consumer side i.e. the Windows OS
based PC.

LEVEL

PRESSURE

FLOW

TEMPERATU
RE

PLC &
SCADA
POWER
SUPPLY

PC
DISPLAY

Fig : Block diagram of the

system

ENERGY
ANALYSER

PRESSURE MEASUREMENT

Overview
Pressure (P ) expresses the magnitude of normal force (F-N)
per unit area (A-m2) applied on a surface

Units: Pa(= N/m2), psi(=lbf/in2), bar (=105 Pa=100 kPa), mbar (=100
Pa=1 hPa),
atm (=101.3 kPa), mmHg (or Torr), inHg, etc.
Note: For every Unit: hUnit=hectoUnit=100 Unit

Where Pabs : Absolute pressure

Patm : Atmospheric pressure
(standard is: 101.3 kPa =14.696 psi=760 mmHg=29.92 inHg)
Pgage : Gage pressure

Pressure Measuring Devices

Bourdon Gage:

http://www.efunda.com/DesignStandards/sensors/bourdon_tubes/images/Bourdon_tube_A.gif
http://www.cpigauges.com/images/gauges/WeldGageStlCsBM400psi.jp
g

http://www.hydraulicspneumatics.com/FPE/images/sensors1_1.jpg

Principles: change in curvature of the tube is proportional to

difference of pressure inside from that outside the tube
Applications: tire pressure, pressure at the top or along the walls
of tanks or vessels

Pressure Measuring Devices

Piezoresistive Gage

Principles: Pressure = Charge = Resistance = Voltage

Applications: Very accurate for small pressure differentials
e.g. Difference between indoor and outdoor
pressure

Pressure measuring devices

Pressure sensor

The Pressure Sensor uses anMPXV7007DPpiezoresistive

transducer designed to measure positive and negative
pressure.

TheMPXV7007DPis a dual-nozzle unit capable of measuring

differential pressure
The Pressure Sensor is a 5V analog device with a range of -7 to
+7 kPa, with high pressure read out in higher voltages.

 Applications
Hospital beds
Respiratory Systems
Airspeed measurements

Specifications

Pressure Range: -7 to + 7 kPa

Supply Voltage: 5V
High Sensitivity: 286mv/kPa
Response time: 1.0 ms

Types of temperature
sensors
RTD (Resistance Temperature
Detector)
Thermistor
Thermocouple

RTD, the basics

How it works:

Utilizes the fact that

resistance of a metal
changes with
temperature.

Make up:

Traditionally made up
of platinum, nickel,
iron or copper wound
around an insulator.

Temperature range:

From about -196C to

482C.
Thin Film RTD

RTD Advantages and Disadvantages

Advantages:
Stable
Very accurate
Change in
resistance is linear

Disadvantages:
Expensive
Current source
required
Small change in
resistance
Self heating
Less rugged than
thermocouples.

LEVEL MEASUREMENT
Accurate measurement of fluid or solid height
within a vessel
Required by many industrial processes

Level measuring devices are

generally used for the accurate
continuous measurement of volume
of fluid in containers

LEVEL GAUGES
(Sight Glass)

A visual indicator of the level of liquid

having a sealed cavity with at least
one transparent wall
used in conjunction with other industrial
level instruments
serves as a direct indicator for an operator
for monitoring

Basic Principle : The Manometer

equal pressures applied to both liquid

columns
height of liquid column is same in both
the storage tank and the gauge sight
glass

FLOAT

motion balance devices that move up and down

with liquid level
float must be of substantially
lesser density than the
substance of interest
must not corrode or react with
the substance
manual level measurement
hazardous and not applicable in
case of pressurized vessels

Turning Electrical Power

into Mechanical Work

About
It is a valve which is used to control the action of the air
movement.
Solenoid valve is used to mix and distribute the air by the
valve that generates the air.
The valve is controlled by using the electric current with
the help of solenoid.
There are two port valves, three port valves and multi
port valve.

Its Components

Magnetic Coil

Valve Stem

Valve Sheet

Inlet

Outlet

Plunger

Breakaway Pin.

Fig:solenoid valve

Application
These are applicable in controlling the hydraulic action.
These are used for mixing and distributing the air.
These are applicable in RO purifier.
These are applicable in the dust collectors.

Automation History
1.MANUAL CONTROL

5.PL
C

2.PNEUMATIC
CONTROL

3.HARD WIRE LOGIC

CONTROL

4.ELECTRONIC CONTROL
USING GATES

Automation Tools
Different types of automation tools exist:
ANN - Artificial neural network
DCS - Distributed Control System
HMI - Human Machine Interface
SCADA - Supervisory Control and Data Acquisition
PLC - Programmable Logic Controller
PAC - Programmable automation controller
Instrumentation
Motion control
Robotics

SCADA SYSTEM

SCADAstands forsupervisory control and data

acquisition.
It generally refers to an industrial control system: a
computer system monitoring and controlling a process.
The process can be industrial, infrastructure or facilitybased.
Supervisory

Control and Data Acquisition System refers

to a system that enables an electric utility to monitor,
coordinate, control and operate distribution components
and devices in a real-time mode from remote locations
with acquisition of data for analysis and planning, from
one central location

BOILER

Features of SCADA
DYNAMIC REPRESENTATION ALAR
MS

TREN
DS

SCRIPT
S

Contd...

Features of SCADA
RECIP
E

SECURIT
Y

DATABASE
CONNECTIVITY

DEVICE
CONNECTIVITY

SCADA SOFTWARES
WONDERWARE - INTOUCH
ALLEN BRADLEY- RSVIEW32
SEIMENS

- WINCC

GE FANUC
KPIT

- CIMPLICITY

- ASTRA
AND MANY MORE

PLCs

E NS
M
E
I
S

ALLEN BRADLEY

PLC(PROGRAMMABLE LOGIC
CONTROLLER)
Programmable Logic Controller (PLC) is an industrial computer
that monitors inputs, makes decisions based on its program and
controls outputs to automate a process or machine.

The automation of many different processes, such as controlling

machines or factory assembly lines, is done through the use of small
computers called a programmable logic controllers (PLCs).

WHY PLC?
To reduce human efforts .
To get maximum efficiency from machine and control them with
human logic .
To reduce complex circuitry of entire system .
To eliminate the high costs associated with inflexible, relay-controlled
systems.

UNDERSTANDING OF PLC
(Example
)
Machine can be controlled by PLC without human efforts

MAJOR COMPONENTS OF A PLC

POWER
SUPPLY

From
SENSORS
Pushbuttons,
contacts,
limit switches,
etc.

I M
N O
P D
U U
T L
E

O M
PROCESSOR

PROGRAMMING
DEVICE

U
T
P
U
T

O
D
U
L
E

To
OUTPUT
Solenoids,
contactors,
alarms
etc.

COMPONENTS
INPUT
/OUTPUT
1.(INPUT
MODULES
accepts and)
converts signals from sensors into a

logic signal
Ex. : Switches, Pushbuttons.
2. OUTPUT MODULES that convert control instructions a signal that can
be used by actuators.
Ex. : lamps, alarm.

INPUT

PUSH BUTTONS

OUTPUT

PLC

COMPONENTS

(CPU ,MEMORY)

3. CENTRAL PROCESSING UNIT(CPU)

It is the brain of PLC and governs the activities of the entire PLC systems
The CPU consists of following blocks :
Arithmetic Logic Unit (ALU),
Internal memory of CPU
Internal timers ,counters and Flags .

PROCESSOR

The various operations performed are :

Scanning I/O bus traffic control,
Program execution,
Peripheral and External device communication,
Data handling and self diagnostics.
4. MEMORY is the component that stores information, programs and data in
a PLC.
Types of memories used in PLCs are read only memory (ROM) and
random access memory (RAM).

COMPONENTS

(POWER SUPPLY,

PROGRAMMING DEVICE)

5. POWER SUPPLY
Provides the voltage needed to run the primary PLC
components.
6. PROGRAMMING DEVICE
The programming terminal is used for programming
the PLC and monitoring/sequencing PLCs
operation.

POWER
SUPPLY

PROGRAMMING
DEVICE

PLC OPERATION
CHECK INPUT STATUS
First the PLC takes a look at each
I/O to determine if it is on or off.
EXECUTE PROGRAM
Next the PLC executes the program
one instruction at a time.
UPDATE OUTPUT STATUS
Finally the PLC updates the status of
the outputs .It updates the outputs
based on which inputs were on during
the first step.

PLC PROGRAMMING
Ladder logic is a programming language used to develop software for
PLC used in industrial control applications.
RUNGES

RAIL

RAIL

ELEMENTS OF LADDER LOGIC

NORMALLY OPEN

NORMALLY CLOSED

(CONTACT)

(CONTACT)

COILS

LADDER LOGIC EXAMPLE

OR OPERATION
A

In the above diagram, it can be seen that either

input A or B is be true (1), or both are true, then the
output C is true (1).

AREAS OF APPLICATION
Manufacturing / Machining
Food / Beverage
Textile Industry
Travel Industry
Aerospace
Printing Industry

ADVANTAGES

Accurate and consistent

information

Improved availability of system

Faster fault identification

Increased
Production

Contd...

ADVANTAGES

Reduced
Cost

Improved Safety
Conditions

Maintenance of Quality &

Quantity

DISADVANTAGES
PLC Devices Are Proprietary
Initial Costs Are High
There's Too Much Work Required In
Connecting Wires

Unemployment Rate Increases