This paper presents the automation of a liquid control process using a Festo compact process automation (PA) workstation. The workstation includes a programmable logic controller (PLC), input/output devices, storage tanks, heating/cooling systems, and sensors connected via Ethernet and Profibus. The process was automated in three stages: 1) Automatic control using PLC ladder logic programming. 2) Manual control and visualization with human-machine interface (HMI) screens. 3) Manual control and visualization with a supervisory control and data acquisition (SCADA) system. The results showed the workstation can effectively demonstrate an industrial process for training students in process automation.
The document discusses the evolution of process control systems from early pneumatic and analog electronic implementations to modern digital implementations using distributed control systems (DCS). It describes the key components and advantages of DCS, including flexibility, reliability, and the ability to implement advanced digital control strategies. DCS networks allow different control modes and distributed control for large, complex processes.
IRJET- Building Management System and its Network DesignIRJET Journal
This document discusses building management systems (BMS) and their network design. It provides an overview of what a BMS is and its main components, including hardware like control units, sensors and actuators. It describes the basic functions and working of a BMS, including monitoring various building systems from one central location. The document also provides examples of BMS implementations in areas like fire detection and alarms, security/CCTV surveillance, access control and elevator management. It concludes that a well-designed BMS can intelligently reduce costs, increase security and energy efficiency in commercial buildings.
Application of PLC’s for Automation of Processes in IndustriesIJERA Editor
The document discusses the use of programmable logic controllers (PLCs) for automation in industrial processes. It describes how PLCs were developed to overcome issues with hard-wired control systems, such as difficulties in reprogramming. PLCs offer benefits like cost effectiveness, flexibility, and reliability. The document then provides examples of PLC applications for automation in various industries, including textile dyeing machines, boiler systems for power plants, and induction steel heating furnaces. It also discusses PLC programming techniques and the salient features of PLCs, such as reliability, flexibility, ease of use, and fast scan times.
TRAINING REPORT ON INDUSTRIAL AUTOMATION- PLC SCADA, VARIABLE FREQUENCY DRIVEAKSHAY SACHAN
This document provides an overview of a training report on PLC, SCADA, and automation submitted by Akshay Sachan to the Electrical Engineering Department of the National Institute of Technology in Kurukshetra. The report includes an introduction to automation concepts, the history and introduction of programmable logic controllers, the architecture of PLCs including ladder diagrams, programming PLCs using ladder diagrams, applications of PLCs and SCADA systems, SCADA software and architecture, applications of SCADA, variable frequency drives, and a conclusion. Diagrams are provided to illustrate PLC internal architecture, simplified PLC structure, basic PLC sections, and ladder diagrams.
This document provides an overview of automation and programmable logic controllers (PLCs). It discusses the introduction of automation, its advantages and disadvantages. It then discusses PLCs in detail, including their history, architecture, programming languages used, and applications. The key points are:
1) Automation uses control systems like computers to reduce human intervention in industrial processes. It increases productivity and quality while reducing costs.
2) PLCs were developed to replace relay control systems. They have a CPU, memory, input/output modules and power supply. Ladder logic, function block diagrams and structured text are common programming languages.
3) PLCs are used widely in industrial automation to control devices like
overview of plc and dcs...
A general information about the common plcs used and how SCADA software is used for virtualising the entire plant equipments and sensors and control them within a single control room.
This document discusses Supervisory Control and Data Acquisition (SCADA) systems and Programmable Logic Controllers (PLCs). It describes the typical architecture of a three-layer SCADA system, including a supervisory control layer, process control layer, and field instrumentation layer. The process control layer often uses PLCs to control devices and sensors are in the field instrumentation layer. Benefits of SCADA systems include increased reliability, lower costs, and assisting operators with decision making, while disadvantages include high initial costs and security issues from internet accessibility.
This document outlines Work Package 1 for the SLOPE project which will take place from January to June 2014. The objectives are to define requirements, analyze the system, identify user needs, review current processes, define necessary data and sensors, and specify the system architecture and interfaces. Task 1.3 focuses on defining the Human Machine Interface (HMI) requirements, especially for on-field devices. It will be led by Graphitech and involve several other partners to mockup interfaces for different scenarios like planning, harvesting, and resource management. The HMI will need to support tasks like 3D forest visualization, machine operation, and an online enterprise resource planning system.
The document discusses the evolution of process control systems from early pneumatic and analog electronic implementations to modern digital implementations using distributed control systems (DCS). It describes the key components and advantages of DCS, including flexibility, reliability, and the ability to implement advanced digital control strategies. DCS networks allow different control modes and distributed control for large, complex processes.
IRJET- Building Management System and its Network DesignIRJET Journal
This document discusses building management systems (BMS) and their network design. It provides an overview of what a BMS is and its main components, including hardware like control units, sensors and actuators. It describes the basic functions and working of a BMS, including monitoring various building systems from one central location. The document also provides examples of BMS implementations in areas like fire detection and alarms, security/CCTV surveillance, access control and elevator management. It concludes that a well-designed BMS can intelligently reduce costs, increase security and energy efficiency in commercial buildings.
Application of PLC’s for Automation of Processes in IndustriesIJERA Editor
The document discusses the use of programmable logic controllers (PLCs) for automation in industrial processes. It describes how PLCs were developed to overcome issues with hard-wired control systems, such as difficulties in reprogramming. PLCs offer benefits like cost effectiveness, flexibility, and reliability. The document then provides examples of PLC applications for automation in various industries, including textile dyeing machines, boiler systems for power plants, and induction steel heating furnaces. It also discusses PLC programming techniques and the salient features of PLCs, such as reliability, flexibility, ease of use, and fast scan times.
TRAINING REPORT ON INDUSTRIAL AUTOMATION- PLC SCADA, VARIABLE FREQUENCY DRIVEAKSHAY SACHAN
This document provides an overview of a training report on PLC, SCADA, and automation submitted by Akshay Sachan to the Electrical Engineering Department of the National Institute of Technology in Kurukshetra. The report includes an introduction to automation concepts, the history and introduction of programmable logic controllers, the architecture of PLCs including ladder diagrams, programming PLCs using ladder diagrams, applications of PLCs and SCADA systems, SCADA software and architecture, applications of SCADA, variable frequency drives, and a conclusion. Diagrams are provided to illustrate PLC internal architecture, simplified PLC structure, basic PLC sections, and ladder diagrams.
This document provides an overview of automation and programmable logic controllers (PLCs). It discusses the introduction of automation, its advantages and disadvantages. It then discusses PLCs in detail, including their history, architecture, programming languages used, and applications. The key points are:
1) Automation uses control systems like computers to reduce human intervention in industrial processes. It increases productivity and quality while reducing costs.
2) PLCs were developed to replace relay control systems. They have a CPU, memory, input/output modules and power supply. Ladder logic, function block diagrams and structured text are common programming languages.
3) PLCs are used widely in industrial automation to control devices like
overview of plc and dcs...
A general information about the common plcs used and how SCADA software is used for virtualising the entire plant equipments and sensors and control them within a single control room.
This document discusses Supervisory Control and Data Acquisition (SCADA) systems and Programmable Logic Controllers (PLCs). It describes the typical architecture of a three-layer SCADA system, including a supervisory control layer, process control layer, and field instrumentation layer. The process control layer often uses PLCs to control devices and sensors are in the field instrumentation layer. Benefits of SCADA systems include increased reliability, lower costs, and assisting operators with decision making, while disadvantages include high initial costs and security issues from internet accessibility.
This document outlines Work Package 1 for the SLOPE project which will take place from January to June 2014. The objectives are to define requirements, analyze the system, identify user needs, review current processes, define necessary data and sensors, and specify the system architecture and interfaces. Task 1.3 focuses on defining the Human Machine Interface (HMI) requirements, especially for on-field devices. It will be led by Graphitech and involve several other partners to mockup interfaces for different scenarios like planning, harvesting, and resource management. The HMI will need to support tasks like 3D forest visualization, machine operation, and an online enterprise resource planning system.
This document provides a report on industrial automation based on programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems. It includes an introduction to industrial automation, PLCs, and SCADA. The report was submitted in partial fulfillment of a Bachelor of Technology degree in electrical engineering and covers automation technologies used from June to July 2014 during an internship.
This document provides an overview of distributed control systems (DCS). It defines a DCS as a control system with distributed controllers located throughout the system to control subsystems, using proprietary communication protocols. The document describes the basic components of a DCS including field control stations, operator stations, and communication buses. It also outlines the different types of controller modes in a DCS.
The document discusses the Distributed Control System (DCS) at IFFCO Phulpur, located near Prayagraj, India. The IFFCO Phulpur facility produces ammonia and urea and has a production capacity of 0.824 MTPA for ammonia and 1.416 MTPA for urea, as well as other fertilizers. A DCS is a specially designed control system used to control large, complex industrial processes through distributed controllers connected by communication networks. The key components of a DCS include field devices, input/output modules, controllers located near field devices, a human-machine interface, and control engineering workstations.
Distributed Control System (Presentation)Thunder Bolt
A distributed control system (DCS) is a control system where control elements are distributed throughout a plant or process. Honeywell and Yokogawa introduced commercial DCS systems in 1975. A DCS includes field devices, controllers, HMIs, historians, and redundancy. It provides a single database, easier redundancy, and mitigation of processor failures, though complex failure diagnosis and cost are limitations. Major DCS vendors include ABB, Emerson, Honeywell, Siemens, and GE.
DCS is a distributed control system used to control large, complex industrial plants. It consists of three main stations - the engineering station which configures the system, the operator station which monitors the system, and automation stations which connect to field elements and control processes. DCS systems distribute control elements throughout a plant rather than centralizing them. This allows for greater flexibility and reliability. Common DCS systems include Siemens' Simatic PCS7, which uses programming languages like CFC and SFC and integrates process control capabilities. DCS is primarily used in large industries like chemical plants, oil refineries, and power grids.
FellowBuddy.com is an innovative platform that brings students together to share notes, exam papers, study guides, project reports and presentation for upcoming exams.
We connect Students who have an understanding of course material with Students who need help.
Benefits:-
# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
# Students can earn better grades, save time and study effectively
Our Vision & Mission – Simplifying Students Life
Our Belief – “The great breakthrough in your life comes when you realize it, that you can learn anything you need to learn; to accomplish any goal that you have set for yourself. This means there are no limits on what you can be, have or do.”
Like Us - https://www.facebook.com/FellowBuddycom
Practical Distributed Control Systems (DCS) for Engineers and TechniciansLiving Online
This workshop will cover the practical applications of the modern Distributed Control System (DCS). Whilst all control systems are distributed to a certain extent today and there is a definite merging of the concepts of a DCS, Programmable Logic Controller (PLC) and SCADA and despite the rapid growth in the use of PLC’s and SCADA systems, some of the advantages of a DCS can still be said to be Integrity and Engineering time.
Abnormal Situation Management and Intelligent Alarm Management is a very important DCS issue that provides significant advantages over PLC and SCADA systems.
Few DCSs do justice to the process in terms of controlling for superior performance – most of them merely do the basics and leave the rest to the operators. Operators tend to operate within their comfort zone; they don’t drive the process “like Vettel drives his Renault”. If more than one adverse condition developed at the same time and the system is too basic to act protectively, the operator would probably not be able to react adequately and risk a major deviation.
Not only is the process control functionality normally underdeveloped but on-line process and control system performance evaluation is rarely seen and alarm management is often badly done. Operators consequently have little feedback on their own performance and exceptional adverse conditions are often not handled as well as they should be. This workshop gives suggestions on dealing with these issues.
The losses in process performance due to the inadequately developed control functionality and the operator’s utilisation of the system are invisible in the conventional plant and process performance evaluation and reporting system; that is why it is so hard to make the case for eliminating these losses. Accounting for the invisible losses due to inferior control is not a simple matter, technically and managerially; so it is rarely attempted. A few suggestions are given in dealing with this.
Why are DCS generally so underutilised? Often because the vendor minimises the applications software development costs to be sure of winning the job, or because he does not know enough about the process or if it is a green-field situation, enough could not be known at commissioning time but no allowance was made to add the missing functionality during the ramp-up phase. Often the client does not have the technical skills in-house to realise the desired functionality is missing or to adequately specify the desired functionality.
This workshop examines all these issues and gives suggestions in dealing with them and whilst not being by any means exhaustive provides an excellent starting point for you in working with a DCS.
MORE INFORMATION: http://www.idc-online.com/content/practical-distributed-control-systems-dcs-engineers-technicians-2
Distributed Control Systems (DCS) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use set point control to control the flow of material through the plant.
The most common example is a set point control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or close until the fluidic flow process reaches the desired set point.
Large oil refineries have many thousands of I/O points and employ very large DCSs. Processes are not limited to fluidic flow through pipes, however, and can also include things like paper machines and their associated quality controls (see quality control system QCS), variable speed drives and motor control centers, cement kilns, mining operations, ore processing facilities, and many others.
Innovic India Private Limited provides industrial Training on DCS as well as other automationtechnologies like PLC, SCADA, HMI, VFD and many more.
For Core Engineering jobs and 100% Job Oriented Industrial Training
Feel free to contact us on: +91-9555405045/+91-9811253572
Email: group.innovic2gmail.com
Web: www.innovicindia.com
This document provides an overview of industrial automation and its components. It discusses programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and human-machine interfaces (HMIs). The key points covered include:
- PLCs were developed in the late 1960s to replace hard-wired relay systems and provide more flexibility. They have since become widely used in industrial automation.
- SCADA systems are used to monitor and control industrial processes across multiple sites. They acquire data from remote locations and allow centralized supervision.
- Other automation tools discussed are DCS, PAC, artificial neural networks, and various sensors used for data collection.
- The advantages
Distributed Control System (DCS) Applications, Selection & TroubleshootingpetroEDGE
Since the first Distributed Control System was installed in the late 1970’s, the concept of DCS has swept alternative control technologies from the field. The substantial growth, in the construction of plants in the traditional heavy process industries, such as power generation, refining, oil and gas, water and petrochemicals, is driving significant growth in the utilization of DCS. The broad architecture of a solution involves either a direct connection to physical equipment, such as switches, pumps and valves or connection via a fieldbus communication system.
This document discusses using a programmable logic controller (PLC) to automate the filling of bottles of various sizes on a conveyor belt. It provides background on the history and workings of PLCs. The project objectives are to use a PLC and sensors to control motors, pumps and other devices to fill bottles as they pass on the conveyor belt. The document outlines the tasks, provides ladder logic diagrams and simulations to program the PLC. It describes using pneumatic actuators controlled by the PLC to pick up and move bottles. The conclusion is that the PLC automation system for bottle filling was successfully designed and programmed.
The document provides an introduction to Advance Technology in Chandigarh, which offers technical education solutions and products. It then discusses Geeta Institute of Management and Technology in Kurukshetra, which offers various degree programs and has excellent infrastructure for training and student placement. The rest of the document covers topics on industrial automation, including an introduction to programmable logic controllers (PLCs), their history and need, basic PLC architecture, and components like the CPU and I/O interfaces.
This document provides an overview of a training report on programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and automation. It includes sections on the history and introduction of PLCs, the architecture of PLCs including the central processing unit and memory, programming PLCs using ladder logic, applications of PLCs and SCADA systems, the architecture of SCADA systems, and applications of automation in various industries. The training report was submitted to the Electrical Engineering department at the National Institute of Technology in Kurukshetra, India by a student as part of an internship on automation.
The control unit directs all operations in a computer system by generating relevant timing and control signals. It communicates with the arithmetic logic unit and main memory, instructing the ALU on operations and coordinating activities across the computer. Control units can be implemented using either hardwired or microprogrammed design. A hardwired control unit uses combinational logic circuits to directly generate signals, while a microprogrammed control unit executes a stored program of microinstructions to produce control signals.
In this session you will learn:
DCS Introduction
PLC
SCADA
General architecture of DCS
Process or application
Scan time
Input and Output requirement
Redundancy
RTU and LCU
PLC vs DCS
A Distributed Control System (DCS) integrates multiple process controllers and PLCs to monitor and control distributed equipment remotely. There are several types of DCS including Smart DCS and SixTrak IPm. When choosing a DCS system, factors like reliability, compatibility, graphical interface, processing speed, cost and ease of use must be considered. DCS systems have advantages like robustness, flexibility and security but also disadvantages like component costs and difficulty of programming and maintenance. Major DCS manufacturers include Honeywell, ABB and Siemens. In Saudi Arabia, DCS systems are used by companies like Saudi Aramco, power plants and factories.
This document discusses the differences between programmable logic controllers (PLCs) and distributed control systems (DCSs) in order to help determine which type of system is best suited for different applications. It outlines seven key questions to consider regarding the manufacturing process, product value, system requirements, operator needs, engineering expectations, and whether the application is hybrid in nature. PLCs are generally better for discrete and simple batch control, while DCSs are more suitable for complex batch processes and facilities that require flexibility and recipe management where system availability is critical. A hybrid system may be needed if an application requires both fast logic control and regulatory analog loop control.
Design of Industrial Automation Functional Specifications for PLCs, DCs and S...Living Online
This manual will be useful to both specifiers and implementers providing a theoretical grounding for preparing a control system functional specification for implementation on Industrial control systems consisting of PLC (Programmable Logic Controllers), HMI (Human Machine Interfaces / SCADA devices) or DCS (Distributed Control Systems).
FOR MORE INFORMATION: http://www.idc-online.com/content/design-industrial-automation-functional-specifications-plcs-dcss-and-scada-systems-15
Implementation of T-Junction Traffic Light Control System Using Simatic S7-20...IJERA Editor
A conventional traffic light control system is designed by using devices such as timers, relays and
contactors etc. The critical timing operation is required to be carried out under the existence of heavy
traffic situations. This conventional practice leads to many problems that need additional maintenance
cost and subsequent delay for a long time. With the help of a PLC, the requirement of fast automation
and effective optimization of traffic light control system can be achieved. Use of PLC helps us to
develop this process not only for traffic signal on the roads, but also on the movement of trains and
the transfer of containers in ports in maritime works. In order to provide a solution to the above
problem, this paper introduces an execution and implementation of T-junction traffic control system
using SEIMENS S7-200 PLC. Programming in PLC is written in ladder logic with the help of STEP7
MICROWIN software
O documento relata a partida entre Botafogo/PB e Juventude/RS pela Série D do Campeonato Brasileiro de 2013. O Botafogo/PB venceu por 2 a 0, com gols de Esteban aos 21 minutos do primeiro tempo e Rafael aos 2 minutos do segundo tempo. Houve cinco cartões amarelos distribuídos durante a partida para jogadores do Botafogo/PB.
La evaluación se define como la valoración de los procesos de enseñanza y aprendizaje a través del diálogo entre participantes para determinar si los aprendizajes han sido significativos. Tiene características como ser continua, integral, sistemática, flexible, interpretativa y participativa. Existen tres tipos de evaluación: inicial para determinar fortalezas, formativa durante el proceso para establecer el avance, y sumativa al final para medir competencias alcanzadas. Los participantes en la evaluación incluyen docentes, padres, estudiantes y compañeros.
This document provides a report on industrial automation based on programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems. It includes an introduction to industrial automation, PLCs, and SCADA. The report was submitted in partial fulfillment of a Bachelor of Technology degree in electrical engineering and covers automation technologies used from June to July 2014 during an internship.
This document provides an overview of distributed control systems (DCS). It defines a DCS as a control system with distributed controllers located throughout the system to control subsystems, using proprietary communication protocols. The document describes the basic components of a DCS including field control stations, operator stations, and communication buses. It also outlines the different types of controller modes in a DCS.
The document discusses the Distributed Control System (DCS) at IFFCO Phulpur, located near Prayagraj, India. The IFFCO Phulpur facility produces ammonia and urea and has a production capacity of 0.824 MTPA for ammonia and 1.416 MTPA for urea, as well as other fertilizers. A DCS is a specially designed control system used to control large, complex industrial processes through distributed controllers connected by communication networks. The key components of a DCS include field devices, input/output modules, controllers located near field devices, a human-machine interface, and control engineering workstations.
Distributed Control System (Presentation)Thunder Bolt
A distributed control system (DCS) is a control system where control elements are distributed throughout a plant or process. Honeywell and Yokogawa introduced commercial DCS systems in 1975. A DCS includes field devices, controllers, HMIs, historians, and redundancy. It provides a single database, easier redundancy, and mitigation of processor failures, though complex failure diagnosis and cost are limitations. Major DCS vendors include ABB, Emerson, Honeywell, Siemens, and GE.
DCS is a distributed control system used to control large, complex industrial plants. It consists of three main stations - the engineering station which configures the system, the operator station which monitors the system, and automation stations which connect to field elements and control processes. DCS systems distribute control elements throughout a plant rather than centralizing them. This allows for greater flexibility and reliability. Common DCS systems include Siemens' Simatic PCS7, which uses programming languages like CFC and SFC and integrates process control capabilities. DCS is primarily used in large industries like chemical plants, oil refineries, and power grids.
FellowBuddy.com is an innovative platform that brings students together to share notes, exam papers, study guides, project reports and presentation for upcoming exams.
We connect Students who have an understanding of course material with Students who need help.
Benefits:-
# Students can catch up on notes they missed because of an absence.
# Underachievers can find peer developed notes that break down lecture and study material in a way that they can understand
# Students can earn better grades, save time and study effectively
Our Vision & Mission – Simplifying Students Life
Our Belief – “The great breakthrough in your life comes when you realize it, that you can learn anything you need to learn; to accomplish any goal that you have set for yourself. This means there are no limits on what you can be, have or do.”
Like Us - https://www.facebook.com/FellowBuddycom
Practical Distributed Control Systems (DCS) for Engineers and TechniciansLiving Online
This workshop will cover the practical applications of the modern Distributed Control System (DCS). Whilst all control systems are distributed to a certain extent today and there is a definite merging of the concepts of a DCS, Programmable Logic Controller (PLC) and SCADA and despite the rapid growth in the use of PLC’s and SCADA systems, some of the advantages of a DCS can still be said to be Integrity and Engineering time.
Abnormal Situation Management and Intelligent Alarm Management is a very important DCS issue that provides significant advantages over PLC and SCADA systems.
Few DCSs do justice to the process in terms of controlling for superior performance – most of them merely do the basics and leave the rest to the operators. Operators tend to operate within their comfort zone; they don’t drive the process “like Vettel drives his Renault”. If more than one adverse condition developed at the same time and the system is too basic to act protectively, the operator would probably not be able to react adequately and risk a major deviation.
Not only is the process control functionality normally underdeveloped but on-line process and control system performance evaluation is rarely seen and alarm management is often badly done. Operators consequently have little feedback on their own performance and exceptional adverse conditions are often not handled as well as they should be. This workshop gives suggestions on dealing with these issues.
The losses in process performance due to the inadequately developed control functionality and the operator’s utilisation of the system are invisible in the conventional plant and process performance evaluation and reporting system; that is why it is so hard to make the case for eliminating these losses. Accounting for the invisible losses due to inferior control is not a simple matter, technically and managerially; so it is rarely attempted. A few suggestions are given in dealing with this.
Why are DCS generally so underutilised? Often because the vendor minimises the applications software development costs to be sure of winning the job, or because he does not know enough about the process or if it is a green-field situation, enough could not be known at commissioning time but no allowance was made to add the missing functionality during the ramp-up phase. Often the client does not have the technical skills in-house to realise the desired functionality is missing or to adequately specify the desired functionality.
This workshop examines all these issues and gives suggestions in dealing with them and whilst not being by any means exhaustive provides an excellent starting point for you in working with a DCS.
MORE INFORMATION: http://www.idc-online.com/content/practical-distributed-control-systems-dcs-engineers-technicians-2
Distributed Control Systems (DCS) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use set point control to control the flow of material through the plant.
The most common example is a set point control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or close until the fluidic flow process reaches the desired set point.
Large oil refineries have many thousands of I/O points and employ very large DCSs. Processes are not limited to fluidic flow through pipes, however, and can also include things like paper machines and their associated quality controls (see quality control system QCS), variable speed drives and motor control centers, cement kilns, mining operations, ore processing facilities, and many others.
Innovic India Private Limited provides industrial Training on DCS as well as other automationtechnologies like PLC, SCADA, HMI, VFD and many more.
For Core Engineering jobs and 100% Job Oriented Industrial Training
Feel free to contact us on: +91-9555405045/+91-9811253572
Email: group.innovic2gmail.com
Web: www.innovicindia.com
This document provides an overview of industrial automation and its components. It discusses programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and human-machine interfaces (HMIs). The key points covered include:
- PLCs were developed in the late 1960s to replace hard-wired relay systems and provide more flexibility. They have since become widely used in industrial automation.
- SCADA systems are used to monitor and control industrial processes across multiple sites. They acquire data from remote locations and allow centralized supervision.
- Other automation tools discussed are DCS, PAC, artificial neural networks, and various sensors used for data collection.
- The advantages
Distributed Control System (DCS) Applications, Selection & TroubleshootingpetroEDGE
Since the first Distributed Control System was installed in the late 1970’s, the concept of DCS has swept alternative control technologies from the field. The substantial growth, in the construction of plants in the traditional heavy process industries, such as power generation, refining, oil and gas, water and petrochemicals, is driving significant growth in the utilization of DCS. The broad architecture of a solution involves either a direct connection to physical equipment, such as switches, pumps and valves or connection via a fieldbus communication system.
This document discusses using a programmable logic controller (PLC) to automate the filling of bottles of various sizes on a conveyor belt. It provides background on the history and workings of PLCs. The project objectives are to use a PLC and sensors to control motors, pumps and other devices to fill bottles as they pass on the conveyor belt. The document outlines the tasks, provides ladder logic diagrams and simulations to program the PLC. It describes using pneumatic actuators controlled by the PLC to pick up and move bottles. The conclusion is that the PLC automation system for bottle filling was successfully designed and programmed.
The document provides an introduction to Advance Technology in Chandigarh, which offers technical education solutions and products. It then discusses Geeta Institute of Management and Technology in Kurukshetra, which offers various degree programs and has excellent infrastructure for training and student placement. The rest of the document covers topics on industrial automation, including an introduction to programmable logic controllers (PLCs), their history and need, basic PLC architecture, and components like the CPU and I/O interfaces.
This document provides an overview of a training report on programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and automation. It includes sections on the history and introduction of PLCs, the architecture of PLCs including the central processing unit and memory, programming PLCs using ladder logic, applications of PLCs and SCADA systems, the architecture of SCADA systems, and applications of automation in various industries. The training report was submitted to the Electrical Engineering department at the National Institute of Technology in Kurukshetra, India by a student as part of an internship on automation.
The control unit directs all operations in a computer system by generating relevant timing and control signals. It communicates with the arithmetic logic unit and main memory, instructing the ALU on operations and coordinating activities across the computer. Control units can be implemented using either hardwired or microprogrammed design. A hardwired control unit uses combinational logic circuits to directly generate signals, while a microprogrammed control unit executes a stored program of microinstructions to produce control signals.
In this session you will learn:
DCS Introduction
PLC
SCADA
General architecture of DCS
Process or application
Scan time
Input and Output requirement
Redundancy
RTU and LCU
PLC vs DCS
A Distributed Control System (DCS) integrates multiple process controllers and PLCs to monitor and control distributed equipment remotely. There are several types of DCS including Smart DCS and SixTrak IPm. When choosing a DCS system, factors like reliability, compatibility, graphical interface, processing speed, cost and ease of use must be considered. DCS systems have advantages like robustness, flexibility and security but also disadvantages like component costs and difficulty of programming and maintenance. Major DCS manufacturers include Honeywell, ABB and Siemens. In Saudi Arabia, DCS systems are used by companies like Saudi Aramco, power plants and factories.
This document discusses the differences between programmable logic controllers (PLCs) and distributed control systems (DCSs) in order to help determine which type of system is best suited for different applications. It outlines seven key questions to consider regarding the manufacturing process, product value, system requirements, operator needs, engineering expectations, and whether the application is hybrid in nature. PLCs are generally better for discrete and simple batch control, while DCSs are more suitable for complex batch processes and facilities that require flexibility and recipe management where system availability is critical. A hybrid system may be needed if an application requires both fast logic control and regulatory analog loop control.
Design of Industrial Automation Functional Specifications for PLCs, DCs and S...Living Online
This manual will be useful to both specifiers and implementers providing a theoretical grounding for preparing a control system functional specification for implementation on Industrial control systems consisting of PLC (Programmable Logic Controllers), HMI (Human Machine Interfaces / SCADA devices) or DCS (Distributed Control Systems).
FOR MORE INFORMATION: http://www.idc-online.com/content/design-industrial-automation-functional-specifications-plcs-dcss-and-scada-systems-15
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problem, this paper introduces an execution and implementation of T-junction traffic control system
using SEIMENS S7-200 PLC. Programming in PLC is written in ladder logic with the help of STEP7
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This document describes the simulation and modeling of a 3-floor elevator system using a programmable logic controller (PLC). The authors created ladder logic programs to control the elevator's movement, door opening and closing, and response to call buttons. They used software like Siemens PLCSIM, TIA Portal and Step 7 to program a Siemens S-Series PLC and simulate the system. The simulation was able to move the virtual elevator car between floors and open and close the doors appropriately in response to inputs. While functional, the authors noted areas that could be improved like adding weight sensors for safety and load balancing. Overall, the document outlines the methodology, components, and results of the authors' effort to model a
Feasible Interfacing and Programming of Industrial Control Technology Unit wi...theijes
This document discusses the interfacing and programming of an industrial control technology unit with PLCs and robots. It begins with an abstract that describes how the unit assembles components using sensors, actuators, and a PLC for control. A PLC program is presented to control the unit and interface it with a 6-axis robot for workpiece transfer using a pneumatic gripper. The document then reviews literature on using PLCs compared to microprocessors for industrial control. It presents the project requirements, software used, and PLC and robot programming methods. The conclusion discusses the benefits of PLCs for industrial control and their interfacing with robots.
Introduction to Digital Computer Control Systemturna67
The document provides an overview of digital computer control systems and their history. It discusses:
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2. The development of direct digital control systems in the 1960s and how distributed control architectures addressed limitations of centralized systems.
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Visualisation application based on Wonderware InTouch is presented in this article. This software is an engineering tool created for visualisation and control of industrial processes, meeting all guidelines of SCADA systems (Supervisory Control and Data Acquisition) and HMI (Human Machine Interface). It is also a part of Wonderware System Platform. This platform is a set of services and applications using ArchestrA technology. The authors showed the options of technical solutions in creating visualisation applications and supervision and control of large and complex control objects.
This document describes the design and implementation of a microcontroller-based system to monitor and control home appliances. The system uses an AT89C52 microcontroller interfaced with a PC running Visual Basic 6.0 software via a serial port. The microcontroller monitors the current drawn by two electrical sockets using an analog-to-digital converter. It can also switch the sockets on and off under control of the PC interface. The system provides over/under voltage protection for loads and overcurrent protection for each socket.
Implementation of Customised SCADA for Cartoner Packaging machine for Cost Ef...IRJET Journal
This document describes the implementation of a customized SCADA system for a cartoner packaging machine using Visual Basic to provide a lower cost solution. The SCADA system allows real-time monitoring of the packaging process. It communicates with a PLC that controls the machine via a serial Modbus connection. Visual Basic is used to develop the human-machine interface, allowing trending and visualization of the packaging process. This provides benefits like reduced downtime and easier troubleshooting compared to using just the PLC's ladder logic programming.
Simulation and Implementation of PLC Based for Detecting Burned Potato Chips ...ijtsrd
This paper describes about to use the PLC techniques for automation of industrial product manufacturing to achieve high throughput and improved quality and consistency. In this system, PLC is used the heart of the system. Light dependent sensor, push button switch, light source, conveyor and blower is controlled by PLC. The proposed system of operation is devised by ladder diagram. Software implementation is used for demonstrating the ease of operation with this control along with tuning of the entire system is offered. This paper presents a study by simulation and experimental models for proposed system of PLCs. In this paper, consideration was given to the design of an HMI for an automated burn chips removed from conveyor which can be operated automatically by the press of start buttons. The design stages included screen interfacing for the HMI, programming the HMI by assigning tags, integration into Step 7 brand of PLC using Ethernet, simulation of the program using "PLCSIM" and the programming codes of the automated burn chips. The designed HMI will be useful to manufacturing industries having industrial automated systems. Htet Htet Aung | Thu Zar Thein "Simulation and Implementation of PLC Based for Detecting Burned Potato Chips and Remove using PLCSIM and HMI" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-5 , August 2019, URL: https://www.ijtsrd.com/papers/ijtsrd26724.pdf Paper URL: https://www.ijtsrd.com/engineering/electronics-and-communication-engineering/26724/simulation-and-implementation-of-plc-based-for-detecting-burned-potato-chips-and-remove-using-plcsim-and-hmi/htet-htet-aung
This document provides an overview of power system automation and SCADA (Supervisory Control and Data Acquisition) systems. It defines SCADA and describes its typical components like HMIs, RTUs, PLCs and communication infrastructure. It also outlines applications of SCADA in power generation, distribution and transmission systems. Benefits of SCADA include increased efficiency, reliability and reduced manual labor through remote monitoring and control of power systems. The document concludes that SCADA provides a common framework for experiment control and ensures consistent operator experience across different parts of complex power systems.
This document discusses the design and implementation of a SCADA system to control an induction motor. It begins with an introduction to SCADA technology and its applications. It then describes the hardware components used, including the induction motor, PLC, and other electrical components. The document outlines the working of the overall control system, with the PLC controlling the motor based on inputs to the SCADA interface. It also discusses the development of the SCADA interface and screens to monitor and control the motor remotely. Screenshots are provided of the SCADA screens under different operating conditions of the induction motor.
India has many no of renewable energy resources. In that Biomass Gasifier plays a major role as an alternate energy
source. But it facing lot of practical problems on operation due to shortage of manpower and also several problems may
happen in these gasifiers. To overcome the above problems we go for automatic control systems in this gasifier. Therefore we
can neglect the human efforts, errors and operators of the gasifier won’t get affected by the out coming gases from the
gasifiers due to this automation. The gasifier itself works according to the program which we have given. Automation is done
in the miscellaneous function, fuel feeding system and all biomass gasifier control system by using PLC (Programmable Logic
Controller). And then we develop the ladder logic program for sequence of operation in gasifier control system. In this system
the ladder logic function is programmed by using INDRALOGIC software and the hardware component of PLC is Rexroth
Bosch product.
Keywords: Programmable logic controller (PLC), Biomass gasifier, Indralogic.
A Survey on Smart DRIP Irrigation SystemIRJET Journal
This document summarizes a survey on a proposed smart drip irrigation system. The key points are:
1) The proposed system uses sensors to monitor soil conditions and weather. It sends this data to an Android app via a base station to allow remote control and monitoring of the irrigation system.
2) The smart system aims to automate irrigation based on environmental conditions rather than schedules, reducing water use and increasing crop yields.
3) Researchers believe this Internet of Things approach could make irrigation more efficient and beneficial for farmers by allowing remote control from any location.
IRJET-Automation of Boring Machine using PLC and HMIIRJET Journal
The document describes automating a boring machine using a programmable logic controller (PLC) and human-machine interface (HMI). Key points:
1) The existing manual boring machine produces parts with low quality and accuracy. Automating it using a PLC, servo drives, and HMI can reduce manual work and improve productivity and accuracy.
2) The automation system uses a PLC to control servo motors and other outputs based on inputs like switches. An HMI allows operators to input commands and view outputs.
3) Simulation results show the automated machine doubled production rate compared to the manual machine, reduced waste, and increased batch completion per hour. The automation was successfully implemented and improved the boring process
This document is a presentation by Yogesh Zodge on artificial intelligence, PLCs, and SCADA systems. It discusses several key topics:
1. It defines automation and lists several types including industrial, scientific, building, and office automation.
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IRJET-A Study of Programmable Logic Controllers (PLC) and Graphical User Inte...IRJET Journal
This document discusses programmable logic controllers (PLCs) and their use in industrial automation. It begins with an abstract that outlines how PLCs are widely used to control industrial machines and presents experiments for students to learn about various PLC applications. The next sections describe the basic components of a PLC system, including input/output modules, the central processing unit, and programming software. Ladder logic programming is discussed as a common method to control PLCs. The document concludes that the presented educational approach on PLCs is effective for teaching students about industrial automation and control systems.
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Deployment of the Festo PA Workstation for Undergraduate Training on Industrial Process Automation
1. The International Journal Of Engineering And Science (IJES)
|| Volume || 5 || Issue || 11 || Pages || PP 58-67 || 2016 ||
ISSN (e): 2319 – 1813 ISSN (p): 2319 – 1805
www.theijes.com The IJES Page 58
Deployment of the Festo PA Workstation for Undergraduate
Training on Industrial Process Automation
Patrick Onotu1
, Uche M. Dimkpagu2
1
Department of Electrical/Electronic EngineeringTechnology Akanu Ibiam Federal Polytechnic, Unwana,
Ebonyi State, Nigeria
2
Department of Electrical/Electronic EngineeringTechnology Akanu Ibiam Federal Polytechnic, Unwana,
Ebonyi State, Nigeria
--------------------------------------------------------ABSTRACT-----------------------------------------------------------
Industrial automation involves the use of machines, control systems and information technologies in optimizing
productivity in the production of goods and delivery of services. The Festo compact process automation (PA)
workstation is a piece of laboratory equipment designed for the training of process automation engineers. It
consist of programmable logic controller (PLC) rack, output devices (including several valves, a motor, a
centrifugal pump etc), input devices (including flow sensor, heat sensor, level sensor, pressure sensor),
switches, network of pipes, two storage tanks a heating and a cooling system. This paper presents the
automation of liquid control process implemented on the PA workstation using PLC programming, manual
liquid process control using Human Machine Interface (HMI) and Supervisory Control and Data Acquisition
(SCADA) system. These devices and systems are all networked together with the workstation through Ethernet
and Field-Bus (Profibus) technology. Process visualization from HMI and SCADA runtime screens are
presented and analyzed to validate the integrity of the PA workstation in implementing process control. The
results obtained shows that the workstation can mimic most industrial processes and deployable for the
enhancement of students’ training on process automation.
Keywords: Industrial automation, Festo compact workstation, Programmable Logic Controllers, HMI and
SCADA systems.
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Date of Submission: 05 November 2016 Date of Accepted: 18 November 2016
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I. INTRODUCTION
Automation can simply be defined as the use of machines, control systems and information technologies
in the production of goods and delivery of services. An industrial automation system, also known as Process
Automation System (PAS) is used to automatically control most industrial processes. From the analysis
presentedin [1], an industrial process could involve the following:
a) Change of energy state, such as from hot to cold, or liquid to gas and distillation of water;
b) Change of composition, as occurs in a chemical reaction or in mixing;
c) Change of dimensions, as in breaking of coal;
d) Change in level, as in reservoir or tank filling;
e) Change in media velocity, as in a reservoir feed pipe,
f) Maintaining a pressure level, as in a water distribution network.
The above processes are as seen in chemical industries, oil refineries, paper and pulp factories etc. The
PAS often uses a network of various interconnect sensors, controllers, operator terminals and actuators in
conjunction with computer technology and software engineering and it is associated with Supervisory Control
and Data Acquisition (SCADA) systems, a technology used to remotely control processes.
In this paper, automating a liquid control process with the use of PLC, HMI, SCADA system and Field-
Bus technologies in a compact process automation workstation is demonstrated. The task involves heating,
cooling and circulation of water through the workstation, the indication of critical water levels, temperature and
flow rate in a closed-loop control system. The task is analogous to industrial process automation especially in
water processing industries and helps visualize the big picture of automating a process.
The task is divided into three stages namely:
a) Automatic process control using step 7 PLC programming software in ladder;
b) Manual process control and visualization with HMI screens; and
c) Manual process control and visualization with SCADA system and Field-bus technology.
2. Deployment of the Festo PA Workstation for Undergraduate Training on Industrial Process Automation
www.theijes.com The IJES Page 59
The paper is structured such that the background information on PLC, HMI, SCADA and Field-Bus are
detailed in section II. The methods used in implementing this project and the equipments are detailed in section
III. The PLC program, the HMI screens and the SCADA system designs and implementations with Screen shots
are presented in section IV while the result from the implementation are discussed in section V.
The introduction of the paper should explain the nature of the problem, previous work, purpose, and the
contribution of the paper. The contents of each section may be provided to understand easily about the paper.
II.PROCESS AUTOMATION DEVICES AND SYSTEMS
2.1 Programmable Logic Controller
A programmable logic controller (PLC) is a special form of microprocessor-based controller that uses
programmable memory to store instructions and to implement functions such as logic, sequencing, timing,
counting, and arithmetic in order to control machines and processes [2].
Input devices in the form of sensors and switches and output devices in the form of motors and valves
in the system to be controlled are connected to the PLC. The PLC is then supplied a sequence of instructions
which is stored in its memory. The controller performs its function by monitoring the inputs and outputs
according to these instructions or program. A PLC is very flexible in usage in that to perform a different control
task, another set of instructions are downloaded into its memory and no need of any rewiring or reconfigurations.
Therefore, the same controller can be used to implement a wide range of control tasks and this is an advantage
over other types of controllers [3]. The structure of a PLC system is shown in figure 1.
2.1.1 Merits and Demerits of PLC
As seen in [4] some of the advantages of PLCs are as follows:
a) Optimised for industrial application to withstand vibrations, temperature, humidity and noise;
b) Easily expanded with more inputs/outputs, controllers and other cards;
c) Software based therefore easy to reprogram and to add functionality without rewiring;
d) Controllable and Reliable due to showing fault codes when there is a hardware or software problem;
e) One Controller Box, instead of a lot of components
f) Takes up a lot less space since the PLCs are made more compact;
g) Cost effective for medium to large systems;
h) Repeatable 24/7 operation;
i) Faster due to quicker transistor switching time compared to an inductive relay.
The following are the disadvantages:
a) Cost ineffective on a very small scale (although very small PLCs are available)
b) Cannot handle large amounts of data like (video, sound files etc.)
Fig.1. PLC hardware system
2.2 Human Machine Interface
A Human Machine Interface (HMI) is a system that provides the interface between a system operator
and a process. Though the PLC is the actual unit which controls this process there is an interface between the
operator and the HMI running on WinCC flexible and an interface between WinCC flexible and the PLC. The
HMI system performs the following tasks:
3. Deployment of the Festo PA Workstation for Undergraduate Training on Industrial Process Automation
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a) Provides process visualization;
b) Allows operator control of the process;
c) Display alarms and messages;
d) Archiving process values and alarms etc.
2.3 Supervisory Control and Data Acquisition System
Supervisory Control and Data Acquisition System (SCADA) is a real time industrial process control
system used to centrally monitor and control remote or local industrial equipment such as motors, valves, pumps,
relays, sensors, etc. SCADA has a wide range of application in controlling chemical plant processes, oil and gas
pipelines, electrical generation and transmission equipment, manufacturing facilities, water purification and
distribution infrastructure etc. It is a system consisting of a number of remote terminal units (RTUs) collecting
field data connected back to a master station via a communication system. The structure of a SCADA system is
shown in figure 2 below.
2.3.1 Benefits of SCADA
a) Improved operation of the system;
b) Increased productivity of the personnel;
c) Improved safety of the system due to better information and improved control;
d) Protection of the plant equipment;
e) Safeguarding the environment from a failure of the system;
f) Improved energy savings due to optimization of the plant;
g) Improved and quicker receipt of data so that clients can be invoiced more quickly and accurately [4].
2.4 Networking of the Automation System
The schematic diagram of an automation system involving SCADA system, HMI and PLC with Profibus and
Ethernet communication media is shown below. This illustrates how the devices and systems are networked to
local and remote process control.
Fig. 2.Schematic diagram of an automation system
III. MATERIALS AND METHODS
Figure 3 below shows an overview of the components and structure of the Festo compact process automation
(PA) workstation as a network of sensors, actuators, pump, valves, water tanks, heater, cooler and PLC rack [5].
4. Deployment of the Festo PA Workstation for Undergraduate Training on Industrial Process Automation
www.theijes.com The IJES Page 61
Fig. 3. Festo PA workstation
(Source: Festo Module Commission Documentation)
The PLC installed on the workstation is the Simatic S7 300 with 314-6EH04OABO central processing
unit (CPU). The HMI device also mounted on the platform is the six inch Simatic Touch Panel TP170PN/DP. A
SCADA system is connected to the station via Automation System, Simatic PCS7 AS RTX with a soft PLC and
an external I/O unit, Simatic ET 200M/Link [5]. The above workstation is designed such that the following can
be performed on the process elements:
a) Heating of water with the electric heater located in the lower tank;
b) Cooling of water with the cooler located below the profile plate;
c) Pumping of water from the lower tank into the upper tank and back through the pneumatic 2-way ball valve;
d) Water level measurement using the ultrasonic, capacitive and float level sensors;
e) Water temperature measurement using the temperature sensor;
f) Water flow measurement using the flow sensor;
g) Water pressure measurement using the pressure sensor;
h) Implementation of automatic and manual process using PLC, HMI, SCADA and Field-Bus technology.
Fig. 4. P & ID of Festo PA workstation
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IV. IMPLEMENTATION OF THE PROCESS AUTOMATION
4.1 PLC Implementation
The following flowchart shows the algorithm for automating the process control using PLC.
Fig. 5 Process automation flowchart
This algorithm was implemented using ladder programming language and the results are discussed below in
result discussion section. The said ladder program cannot be presented here due to its volume.
4.2 HMI Implementation
Four HMI Screens, shown in figure 6, were designed to manually control and visualise the process namely:
The Main_Screen which carries the label and task of this project and a link to the other three screens;
The Process screen on which the pictorial implemention of the entire process is displayed;
Data_Trending screen on which the variation of temperature with respect to time is displayed graphically; and
Alarms&Messages screen on which an alarm or warning message is displayed for any critical water temperature.
The other three screens can be switched to and back from the Main_Screen.
The events of different switches were set to switch on the M101, M102, M121, M111 and E104. Switches with
graphics were used to match a switch with its corresponding output device as shown on the process screen of
figure 6(b) for easy identification. Three I/O fields were tagged with analogue inputs AI_Flow, AI_Level and
AI_Temp parameter scaling functions to display the real-time flow rate, upper tank level and temperature
respectively [6].
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(a)
(b)
(c)
(d)
Fig. 6. (a) Main_Screen (b) Process (c) Data_Trending
(d) Alarms&Messages
4.3 Implementation with PCS7 SCADA System
The Simatic process control system (PCS 7) is a software package used in conjunction with WinCC graphic
designer installed in theEngineering System (ES) to implement a SCADA operation [7]. The ES is connected to
an Automation System (AS) using an Ethernet cable and the AS is connected to the plant using profibus. System
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network configuration is carried out to enable data communication. In this project an AS with a virtual PLC is
used in conjunction with the Festo compact PA workstation as the process plant. The SCADA
picture designed for the above process is presented in figure 7 below.
(a)
(b)
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(c)
Fig. 7. SCADA screen shot of (a) the pictorial design (b) runtime before process start and (c) alarm and warning
settings
As shown in figure 7(b), the storage tank is filled and heating can start. Temperature upper and lower limit
alarms are set at 28°C and 20°C respectively from figure 7(c).
V. RESULT DISCUSSION
5.1 PLC Implementation
The program for the Siemens PLC was written using step 7 ladder language. The program was
downloaded into the PLC and used to implement the liquid heating and cooling control. The results of the
implementation showed that process automation can be effectively demonstrated with Festo PA workstation to a
high control precision. It is impossible to present the ladder language here due to its volume but available as an
appendix.
5.2 HMI Control
HMI screens were designed as shown in figure 6 and used to run the process specified in section IV
above manually by switching on/off E104, M111, M121 and M102 directly and visually determining when to
start/stop heating, cooling and circulation. For automatic operation, the program in section 4 was written in
ladder in an operating station running Siemens Step7 programming software and downloaded to the PLC after its
configuration. The activities of the PLC were displayed on the HMI screens designed for specific tasks. The
following are the displayed activities:
Stage 1 – The start button was pressed when the heating condition was satisfied and heating started. When the
temperature was greater than 26°C, valve 121 opened, M101 switched on and cooling started automatically as
programmed. The Process screen shows the increase in flow rate to confirm water pumping through the cooling
circuit as there is no increase in the upper tank level. Temperature = 26.74°C and flow rate = 3.47litre/min
Stage 2 - As the temperature dropped below 25°C, cooling circuit was closed while valve 111 opened to allow
cold water into the upper tank automatically. The upper tank level began increasing. The flow rate also increased
as more water is allowed through the new channel.
Stage 3 – There was an increase in the temperature from 25.5°C to 27.3°C with respect to time. A sudden
increase in temperature was observed as soon as cooling started and triggered the alarm. This was shown in the
signal trend.
Stage 4 - The proximity sensors B113 and B114 were in the off states meaning that the cold water has been
pumped into the upper tank. The lower tank level reduced to minimum while the upper tank has risen to
8.45litres as programmed.
Stage 5 - The pneumatic valve M102 opened when B113 was off to empty the upper tank back into the lower
tank. The upper tank level now at 2.13 litres while the lower tank proximity sensor B114 was back on.
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5.3 Alarms and Messages
A sudden increase in temperature was observed at the point of opening of the cooling circuit, the reset
indicator light powered on as programmed. The start button indicator light was powered on and a warning
message displayed on the HMI Alarms&Messages screen when the temperature of the water was greater than
25.8°C. This alerted the operator that the set point of the water temperature is almost reached and necessary
actions should be taken. No action was necessary in response to the alarm because the heating already stopped
before its trigger.
5.4 Stop/Reset Buttons and the Auto_Mode Switch
The stop button was programmed for process termination in an emergency. The button was pressed
during the cooling of water and M101 and M121 were switched off, with no regards to the conditions of the
comparators, in confirmation of its function. The reset button was used to continue the process by resetting
M150.0 and also the alarm. The Auto_mode switch on the HMI Process screen is tagged with the start button
and performs same function.
5.5 SCADA Control
In figure 8 (a) E104 was switched on (indicated by its green colour) and the water heated to 27.05°C,
the intended upper limit was 27°C. The storage tank was filled before heating (B113 and B114 were green
indicating their on state). A warning message was flagged as the water temperature was above 26°C as indicated
by the yellow colour on the alarm bar. A uniform rise in temperature with time was displayed using the designed
temperature trend on the bottom right hand side of the screen.
In figure 8 (b) a sudden rise in temperature, above 29°C, was observed as the cooling circuit was
opened, this triggered an extreme temperature alarm shown by the red colour on the alarm bar. E104 turned
white indicating it’s off state while pump P101 turned green indicating it’s on state. M121 was on (green)
showing circulation of cold water.
The water was cooled as shown in figure 8 (a) below the lower set point of 25°C and the cold water
pumped into the upper tank through M111 with V103 closed and V101 opened until B113 and B114 turned off.
P101was then switched off with flow rate approximately zero indicated by the white colour of B102.
The temperature trending shows a uniform decrease until M111 was opened at 24.92°C. This triggered
a disturbance in the temperature fall as shown in figure 8 (a). In figure 8 (b) M102 and V112 were then opened
to empty the upper tank into the lower tank. As the water level passes B113 and B114 alarm was triggered
calling for the close of M102. The alarm was acknowledged thereafter.As the water flows into the storage tank,
due to the temperature difference between water in the two tanks, a sharp drop in temperature from 24.5°C and
24.05°C was observed and it reflected in the trend of figure 8 (b). Further drop to 23.73°C was observed when
the pump was switched off. The water temperature remained approximately at this value until the end of the
process. The lower limit alarm was never triggered.
(a)
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(b)
Fig. 8. SCADA screen shots of (a) heating start, warning and temperature trending (b) cooling start, alarm and
temperature trending
VI. PERFORMANCE EVALUATION AND CONCLUSION
A liquid control process has been implemented with PLC, HMI, SCADA/Field-Bus technologies. The
process control was automated using Simatic step 7 PLC programming in ladder and manually implemented with
HMI device and SCADA system. The automated process control with PLC produced the best control results as
set points of water temperature and level for the opening and closing control valves and starting and stopping of
the pump were all accurately adhered to. In the manual process control with HMI device there was always a time
lag between a set point and the required corresponding actions due to human error. These delays were more
pronounced with SCADA system because of the components switching procedure and could be unfavorable in
production and manufacturing control system applications were attention is paid to precision. These delays are
evident in figure 7 (a) and (b), before the cooling circuit was opened the temperature had risen to 27.95°C where
the upper limit was 27°C.
It is worthy of note, therefore, that for accuracy of process control specifications and improved
productivity level, automatic operations should be employed in process industries where possible. These will
help check human errors and improve plant safety and availability. As were observed in the automated part of
this project, there were no time delays between starting of the pump and opening valves and pumping water from
the storage tank after the lower level sensor turned off.
In conclusion, the possible liquid process control with the available devices on the Festo platform have
been implemented and results discussed in details. It has been clearly shown that various automatic control
activities can be demonstrated in the laboratory making undergraduate training a lot easier. The deployment of
this workstation can help improve the practical experiences of automation and control students prior to
graduation.
REFERENCES
[1]. Hongwei Z. (2012). Introduction to Industrial Automation and Process Control. Faculty of Arts Computing, Engineering and
Sciences. England. Sheffield Hallam University.
[2]. Bolton W. (2009). Programmable Logic Controllers. [Electronic Book]. 5th Edition. Oxford. Elsevier Ltd. Book from Engineering
Village last accessed 1st May, 2013 at: http://wobl.engineeringvillage.com/
[3]. Wesseler M. (2012). PLC programming. Faculty of Arts, Computing, Engineering and Sciences. England. Sheffield Hallam
University
[4]. Hongwei Z. (2012). SCADA, Field-bus and DCS. Faculty of Arts, Computing, Engineering and Sciences. England. Sheffield Hallam
University.
[5]. Festo (2001). Collection of Data Sheets. Festo Didactic GmbH & Co.
[6]. Festo (2012). Cooling Unit with Heat Exchanger. [Online]. Last accessed 1st May, 2013 at:
[7]. http://www.festo-didactic.com/int-en/learning-systems/process-automation/accessories/cooling-unit-with-heat-exchanger/
[8]. Siemens (2008). Simatic HMI WinCC User Manual.