PLC and SCADA report with Project explanation

1. AMITY UNIVERSITY
Rajasthan
A
TRAINING REPORT ON
PLC AND SCADA
SUBMITTED TO
Ms. Pushpa Gothwal
SUBMITTED BY
Priya Hada
B.tech(ECE) 7th
semester
October 31, 2014

2. CERTIFICATE
This is to certify that this project report PLC and SCADA is submitted by Priya
Hada, who carried out the project work under my supervision.I approve this
project for submission of the Bachelor of Engineering in the Department of
Electronics and Communication, Amity School of Engineering and Technol-
ogy,Amity University Rajasthan, affiliated to UGC.
FACULTY
Ms. Pushpa Gothwal
ASET(AUR)
i

3. ACKNOWLEDGMENT
It gives me immense pleasure to express my deepest sense of gratitude and sin-
cere thanks to my highly respected and esteemed guide Ms.Pushpa Gothwal,
Faculty of Amity School of Engineering and Technology, for her valuable guid-
ance, encouragement and help for completing this work. Her useful suggestions
for this whole work and co-operative behavior are sincerely acknowledged.
Priya Hada
(Student)
ii

4. Contents
CERTIFICATE i
ACKNOWLEDGMENT ii
1 INTRODUCTION TO AUTOMATION 1
2 Programmable Logic Controller 2
2.1 Features of PLCS . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 History of PLCS . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Components of PLC: . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 PLC OPERATION AND PLC SCAN CYCLE: . . . . . . . . . 4
2.5 Ladder Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Ladder Logic Programming . . . . . . . . . . . . . . . . . . . . 5
3 SCADA 8
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 WONDERWARE-INTOUCH . . . . . . . . . . . . . . . . . . 9
3.3 Manufacturers of SCADA . . . . . . . . . . . . . . . . . . . . 9
3.4 Features of SCADA . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4.1 Dynamic Process Graphics . . . . . . . . . . . . . . . . 10
3.4.2 Real-time and Historical Trends . . . . . . . . . . . . . 11
3.4.3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.4 Recipe Management . . . . . . . . . . . . . . . . . . . 12
3.4.5 Security . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.6 Device Connectivity . . . . . . . . . . . . . . . . . . . 14
3.4.7 Database Connectivity . . . . . . . . . . . . . . . . . . 14
3.4.8 Scripts . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Potential benefits of SCADA . . . . . . . . . . . . . . . . . . . 14
3.6 Where SCADA is used ? . . . . . . . . . . . . . . . . . . . . . 15
iii

5. 4 Project Using PLC: A Pharmaceutical plant 16
4.1 Project Objective: . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Hardware and Software Used: . . . . . . . . . . . . . . . . . . 16
4.3 Working of Project: . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Programming: . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Future Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Project Using SCADA:Bottle Filling & Capping Station 22
5.1 Project Objective: . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Software Used: . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Working of Project: . . . . . . . . . . . . . . . . . . . . . . . . 23
5.4 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.5 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.6 Future Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6 CONCLUSION 30
REFERENCES 31
iv

6. List of Figures
1 PLC scan cycle . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Basic Ladder Logic Program . . . . . . . . . . . . . . . . . . . 5
3 Basic Ladder Logic Program . . . . . . . . . . . . . . . . . . . 6
4 Basic Program to show input and output . . . . . . . . . . . . . 6
5 Examine if Closed . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 Output energize . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 Examine if Open . . . . . . . . . . . . . . . . . . . . . . . . . 7
8 Schematic of DPG . . . . . . . . . . . . . . . . . . . . . . . . 10
9 Schematic of Trend . . . . . . . . . . . . . . . . . . . . . . . . 11
10 Schematic of alarm . . . . . . . . . . . . . . . . . . . . . . . . 12
11 Schematic of Receipe management . . . . . . . . . . . . . . . . 12
12 Receipe manager window . . . . . . . . . . . . . . . . . . . . . 13
13 Schematic of security . . . . . . . . . . . . . . . . . . . . . . . 13
14 Schematic of PLC-1000 micrologix . . . . . . . . . . . . . . . 16
15 Flowchart of Project . . . . . . . . . . . . . . . . . . . . . . . . 17
16 Ladder diagram in De-energize state . . . . . . . . . . . . . . . 18
17 Rungs are Energize and Start button pressed . . . . . . . . . . . 18
18 Timer T4:0 counts 30 . . . . . . . . . . . . . . . . . . . . . . . 20
19 Timer T4:1 counts 20 . . . . . . . . . . . . . . . . . . . . . . . 21
20 Schematic of Object Properties . . . . . . . . . . . . . . . . . . 24
21 Window in develpoment mode in Window maker . . . . . . . . 25
22 Schematic of Window Script used . . . . . . . . . . . . . . . . 26
23 Filling of the bottle . . . . . . . . . . . . . . . . . . . . . . . . 27
24 Capping of the bottle . . . . . . . . . . . . . . . . . . . . . . . 28
25 Bottle is sent to storage after its filling and capping . . . . . . . 28
v

7. 1 INTRODUCTION TO AUTOMATION
Automation is the use of control systems such as computers, controllers to con-
trol industrial machinery and processes, to optimize productivity in the produc-
tion of goods and delivery of services. Automation is a step beyond mechaniza-
tion. Whereas mechanization provides human operators with machinery to as-
sist them with the muscular requirements of work, automation greatly decreases
the need for human sensory and mental requirements.
Automation Impacts:
1. It increases productivity and reduce cost.
2. It gives emphasis on flexibility and convertibility of manufacturing pro-
cess. Hence gives manufacturers the ability to easily switch from manu-
facturing Product A to manufacturing product B without completely re-
built the existing system/product lines.
3. Automation is now often applied primarily to increase quality in the man-
ufacturing process, where automation can increase quality substantially.
4. Increase the consistency of output.
5. Replacing humans in tasks done in dangerous environments.
Advantages of Automation:
1. Replacing human operators in tasks that involve hard physical or monotonous
work.Also task done in dangerous environments.
2. Performing tasks that are beyond human capabilities of size, weight, speed,
endurance, etc.
3. Economy improvement: Automation may improve in economy of enter-
prises, society or most of humanity.
Disadvantages of Automation:
1. Technology limits: Current technology is unable to automate all the de-
sired tasks.
2. Unpredictable development costs: The research and development cost of
automating a process may exceed the cost saved by the automation itself.
3. High initial cost: The automation of a new product or plant requires a
huge initial investment in comparison with the unit cost of the product.
1

8. 2 Programmable Logic Controller
A Programmable Logic Controller,is a digital computer used for automation of
industrial processes, such as control of machinery on factory assembly lines.It is
a solid state user programmable control system with functions to control logic,
sequencing, timing, arithmetic data manipulation and counting capabilities. It
can be viewed as an industrial computer that has a central processor unit, mem-
ory, input output interface and a programming device. The central processing
unit provides the intelligence of the controller. It accepts data, status infor-
mation from various sensing devices like limit switches, proximity switches,
executes the user control program stored in the memory and gives appropriate
output commands to devices such as solenoid valves, switches etc.
A constant demand for better and more efficient manufacturing and process
machinery has led to the requirement for higher quality and reliability in control
techniques. With the availability of intelligent, compact solid state electronic
devices, it has been possible to provide control systems that can reduce mainte-
nance, down time and improve productivity to a great extend.One of the latest
techniques in solid state controls that offers flexible and efficient operation to
the user is programmable controllers.
2.1 Features of PLCS
1. PLC is an industrial computer control system that continuously monitors
the state of input devices and makes decisions based upon a custom pro-
gram to control the state of output devices.
2. It is designed for multiple inputs and output arrangements, extended tem-
perature ranges, immunity to electrical noise, and resistance to vibration
and impact.
3. Almost any production process can greatly enhanced using this type of
control system, the biggest benefit in using a PLC is the ability to change
and replicate the operation or process while collecting and communicat-
ing vital information.
4. It is modular i.e. one can mix and match the types of input and output
devices to best suit one’s application.
2.2 History of PLCS
1. The first PLCS were designed and developed by Modicon as a relay re-
placer for GM and Landis.
2

9. 2. The primary reason for designing such a device was eliminating the large
cost involved in replacing the complicated relay based machine control
systems for major U.S. car manufacturers.
3. These controllers eliminated the need of rewiring and adding additional
hardware for every new configuration of logic.
4. The first PLC, model 084, was invented by Dick Morley in 1969.
5. The first commercial successful PLC, the 184, was introduced in 1973
and was designed by Michel Greenberg.
2.3 Components of PLC:
The PLC mainly consists of a CPU, memory areas, and appropriate circuits to
receive input/output data. We can actually consider the PLC to be a box full
of hundreds or thousands of separate relays, counters, timers and data storage
locations. They don’t physically exist but rather they are simulated and can
be considered software counters, timers, etc. Each component of a PLC has a
specific function:
1. The CPU is the brain of a PLC system. It consists of the microprocessor,
memory integrated circuits and circuits necessary to store and retrieve
information from memory. It also includes communication ports to the
peripherals, other PLCs or programming terminals. The job of the pro-
cessor is to monitor status or state of input devices, scan and solve the
logic of a user program, and control on or off state of output devices.
2. Counters - These are simulated counters and they can be programmed to
count pulses. Typically these counters can count up, down or both up and
down. Since they are simulated they are limited in their counting speed.
Some manufacturers also include high-speed counters that are hardware
based. We can think of these as physically existing.
3. Timers - These come in many varieties and increments. The most com-
mon type is an on-delay type. Others include off-delay and both retentive
and non-retentive types. Increments vary from 1 millisecond to 1 second.
4. Output Relays (coils) - These are connected to the outside world. They
physically exist and send on/off signals to solenoids, lights, etc. They can
be transistors, relays depending upon the model chosen.
5. Data Storage - Typically there are registers assigned to simply store data.
They are usually used as temporary storage for math or data manipulation.
3

10. They can also typically be used to store data when power is removed from
the PLC. Upon power-up they will still have the same contents as before
power was removed
2.4 PLC OPERATION AND PLC SCAN CYCLE:
There are four basic steps in the operation of all PLCS which continually take
place in a repeating loop.
1. Input Scan: Detects the state of all input devices that are connected to the
PLC.
2. Program Scan: Executes the user created program logic.
3. Output Scan: Energizes or de-energize output devices that are connected
to the PLC. Depending on the PLC design, this process of updating the
output devices may be done at the end of program execution or updated
immediately upon execution of its corresponding logic statement in the
user program
4. Housekeeping: This step includes communications with programming
terminals, internal diagnostics etc.
PLC SCAN CYCLE: The completion of a cycle of the controller is called
a Scan. The scan time needed to complete a full cycle by the controller gives
the measure of the speed of execution for the PLC.
Figure 1: PLC scan cycle
SCAN TIME Time taken by PLC to execute these three steps (Checking
Input status, Executing Program, Updating Output Status) is denoted by its scan
time.
4

11. 2.5 Ladder Logic
Ladder logic is one form of drawing electrical logic schematics, and is a graph-
ical language very popular for programming PLCS. Ladder logic was originally
invented to describe logic made from relays. The name is based on the observa-
tion that programs in this language resemble ladders, with two vertical ”rails”
and a series of horizontal ”rungs” between them.
Figure 2: Basic Ladder Logic Program
2.6 Ladder Logic Programming
Introduction
Ladder logic are the most common programming language used to program
a PLC. Ladder logic was one of the first programming approaches used in PLCS
because it borrowed heavily from the relay diagrams that plant electricians al-
ready knew.
A program in ladder logic, also called a ladder diagram, is similar to a
schematic for a set of relay circuits. Ladder logic is widely used to program
PLCS, where sequential control of a process or manufacturing operation is re-
quired. Ladder logic is useful for simple but critical control systems, or for
reworking old hardwired relay circuits. As programmable logic controllers be-
5

12. Figure 3: Basic Ladder Logic Program
came more sophisticated it has also been used in very complex automation sys-
tems.A simplified ladder logic circuit with one input and one output. The logic
of the rung above is such:
Figure 4: Basic Program to show input and output
1. If Input1 is ON (or true) - power (logic) completes the circuit from the
left rail to the right rail - and Output1 turns ON (or true).
2. If Input1 is OFF (or false) - then the circuit is not completed and logic
does not flow to the right - and Output 1 is OFF (or false).
With just a handful of basic symbols such as a normally open contact, normally
closed contact, normally open coil, normally closed coil, timer and counter most
logical conditions can be represented.
Examine if Closed
Figure 5: Examine if Closed
This can be used to represent any input to the control logic such as a switch
or sensor, a contact from an output, or an internal output. When solved the
referenced input is examined for a true (logical 1) condition. If it is true, the
contact will close and allow logic to flow from left to right. If the status is
6

13. FALSE (logical 0), the contact is open and logic will NOT flow from left to
right.
Output energize
This can be used to represent any discrete output from the control logic.
When ”solved” if the logic to the left of the coil is TRUE, the referenced output
is TRUE (logical 1).
Figure 6: Output energize
Examine if Open
When solved the referenced input is examined for an OFF condition. If the
status is OFF (logical 0) power (logic) will flow from left to right. If the status
is ON, power will not flow.
Figure 7: Examine if Open
Basic Timers and Counters
A timer is simply a control block that takes an input and changes an output
based on time. It is used for providing delay. There are two basic types of
timers. An On-Delay Timer takes an input, waits a specific amount of time,
allows logic to flow after the delay. An Off-Delay Timer allows logic to flow
to an output and keeps that output true until the set amount of time has passed,
then turns it false, hence off-delay.
A counter simply counts the number of events that occur on an input. There
are two basic types of counters called up counters and down counters. As its
name implies, whenever a triggering event occurs, an up counter increments the
counter, while a down counter decrements the counter whenever a triggering
event occurs.
7

14. 3 SCADA
3.1 Introduction
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 hard-
ware to which it is interfaced, in general via PLC. SCADA systems are now
also penetrating the experimental physics laboratories for the controls of ancil-
lary systems such as cooling, ventilation, power distribution, etc. More recently
they were also applied for the controls of smaller size particle detectors such as
the L3 moon detector and the NA48 experiment, to name just two examples at
CERN.
SCADA systems have made substantial progress over the recent years in
terms of functionality, scalability, performance and openness such that they are
an alternative to in house development even for very demanding and complex
control systems as those of physics experiments.
The process can be industrial, infrastructure or facility based as described
below:
1. Industrial Process: it includes those of manufacturing, production, power
generation, fabrication and refining and process may be in continuous,
batch, repetitive or discrete modes.
2. Infrastructure Process: it may be public or private, and water treatment
and distribution, wastewater collection and treatment, oil and gas pipelines,
electrical power transmission and distribution, and large communication
systems.
3. Facility Process: it occur both in public facilities and private ones, in-
cluding buildings, airports, ships and space stations. They monitor and
control HVAC, access and energy consumption.
A SCADA System usually consists of the following Subsystems:
1. A Human-Machine Interface (HMI) is the apparatus which presents pro-
cess data to a human operator, and through this, the human operator mon-
itors and controls the process.
2. A supervisory (computer) system, gathering (acquiring) data on the pro-
cess and sending commands (control) to the process.
8

15. 3. Remote Terminal Units (RTU) connecting to sensors in the process, con-
verting sensor signals to digital data and sending digital data to the super-
visory system.
4. Programmable Logic Controller (PLC) used as field devices because they
are more economical, versatile, flexible, and configurable than special-
purpose RTUs.
5. Communication infrastructure connecting the supervisory system to the
Remote Terminal Units.
3.2 WONDERWARE-INTOUCH
Intouch is worlds leading supervisory control and data acquisition software.
The InTouch software package consist of Tags (Memory + I/O). The package is
available in 64, 256, 1000 and 64,000 Tags with the three options:
1. D+R+N ( Development +Run + Networking)
2. R+N ( Run +Networking )
3. Factory focus
With DRN package one can develop as well as run the application but in case
of RN one cannot develop/modify the application. The application can be de-
veloped by using DRN package and can be installed on RN package.
3.3 Manufacturers of SCADA
1. Allen Bradley : RS View
2. Siemens: win cc
3. Wonderware : Intouch
3.4 Features of SCADA
1. Dynamic Process Graphic
2. Alarm summary
3. Alarm history
9

16. 4. Real time trend
5. Historical time trend
6. Security (Application Security)
7. Data base connectivity
8. Device connectivity
9. Scripts
10. Recipe management
3.4.1 Dynamic Process Graphics
1. Using this feature, one can develop graphics which can resemble the
plant.
2. The graphic can include Reactor, Valves, Pumps, agitators, conveyors as
well as other equipment and machinery used in the plant.
3. The status of the equipment running / stopped can be shown using differ-
ent color / animations.
4. Typically the SCADA Software will have many ready to use symbols for
proper representation which can be used in any type of industry.
Figure 8: Schematic of DPG
10

17. 3.4.2 Real-time and Historical Trends
1. This facility is used for representing the data in graphical form.
2. Typically the trends plots the value with reference to the time.
3. Real-time data will plot the real-time value fixed period of time while
historical data stored value which can be viewed on demand.
4. Depending upon the storing capacity of the hard-disk on can specify the
no of days the data can be stored .
5. Some SCADA software show real-time and historical trends in single
graphics while few others use separate tools.
Figure 9: Schematic of Trend
3.4.3 Alarms
1. Every plant need proper monitoring and control of the process parame-
ters.
2. Alarms represent warnings of process conditions that could cause prob-
lems, and require an operator response.
3. Generally alarms are implemented by using the lamps or hooters in field
but in SCADA it can be represented using animation.
4. In many SCADA software, four type of alarm limits are used ie HI, HIHI,
LOW, LOW LOW.
11

18. Figure 10: Schematic of alarm
3.4.4 Recipe Management
1. In many case we use the same plant for manufacturing different prod-
uct range. for example an oil blending plant can manufacture power oil,
transformer oil, automobile oil.
2. The recipe management is facility is used to maintain various recipes of
different products and implement it on the process.
3. The recipe can be stored in a single server and it can be fetched by any
client server from any area to run the process.
Figure 11: Schematic of Receipe management
12

19. Figure 12: Receipe manager window
3.4.5 Security
Figure 13: Schematic of security
1. Every SCADA Software has various levels of security for securing the
application by avoiding unauthorized access.
2. Depending upon the access level given the operator / engineers is allowed
to do the task. In the most of the case, operators are allowed only to op-
13

20. erate the plant while maintenance engineers can do the application modi-
fications.
3. The security can be given for individuals as well as for groups.
3.4.6 Device Connectivity
1. Every Control hardware has its own communication protocol for commu-
nicating with different hardware / software. Some of the leading com-
munication protocol include Modbus, Profibus, Ethernet, Dh+, DH 485,
Devicenet, Control net.
2. The Scada Software needs device driver software for communication with
PLC or other control hardware.
3. More the driver software available better is the device connectivity. Most
of the SCADA software used in the industry have connectivity with most
of the leading control system.
3.4.7 Database Connectivity
1. In many plants, it is important to download the real-time information to
the Management information system. In this case the database connectiv-
ity is must.
2. Many SCADA software don’t have their own database. Hence for storage
and reporting they use third party database like MS Acess or SQL.
3.4.8 Scripts
1. Script is a way of writing logic in SCADA software, every SCADA soft-
ware has its own instruction and way of writing programme.
2. Use scripts, one can develop complex applications. You can create your
own functions to suit the requirement. execution.
3. Various types of scripts make project execution simpler for programmer.
3.5 Potential benefits of SCADA
The benefits one can expect from adopting a SCADA system for the control of
experimental physics facilities can be summarised as follows:
14

21. 1. The amount of specific development that needs to be performed by the
end-user is limited, especially with suitable engineering.
2. Reliability and robustness: These systems are used for mission critical
industrial processes where reliability and performance are paramount.
In addition, specific development is performed within a well-established
framework that enhances reliability and robustness.
3. Technical support and maintenance by the vendor.
3.6 Where SCADA is used ?
1. Electric power generation, transmission and distribution: Electric utilities
use SCADA systems to detect current flow and line voltage, to monitor
the operation of circuit breakers, and to take sections of the power grid
online or offline.
2. Water and sewage: State and municipal water utilities use SCADA to
monitor and regulate water flow, reservoir levels, pipe pressure and other
factors. Industrial Processes such as Manufacutring.
15

22. 4 Project Using PLC: A Pharmaceutical plant
4.1 Project Objective:
To design a pharmaceutical plant using Programmable Logic Controller for
manufacturing of a medicine in which two different liquid should mix in equal
quantity and then this mixture should be heat for 20 seconds on a constant tem-
perature of 100 ◦
C.
4.2 Hardware and Software Used:
1. PLC: Allen Bradley Micro Logix 1000 with 10 Input / Output.
The MicroLogix 1000 programmable controller is a packaged controller
containing a power supply, input circuits, output circuits, and a processor.
The controller is available in 10 I/O, 16 I/O and 32 I/O configurations, as
well as an analog version with 20 discrete I/O and 5 analog I/O.
Figure 14: Schematic of PLC-1000 micrologix
2. Programming Software: Rockwell software RS Logix 500 English
This family of products has been developed to operate on Microsoft Win-
dows operating systems. It Supports the Allen-Bradley SLC 500 and Mi-
cro Logix families of processors. RSLogix 500 benefits include:
(a) Cross-reference information
(b) Drag-and-drop editing
16

23. (c) Diagnostics
(d) Dependable communications
3. Communication Software: RS Linx.
4. Programming Language: Ladder Logic.
5. Communication Protocol: RS 232
6. Other Hardware: Push Buttons, Light Emitting Diode.
4.3 Working of Project:
As specified in the objective, the process involves mixing of two different liq-
uids in equal quantities. The process is start by pressing the START button.
When the START button is pressed, the two liquids starts mixing, this is indi-
cated by glowing of two output LED. Next, after a time lapse of 20, seconds the
third LED glows indicating that the mixture is heated for 20 seconds, at 100◦
C.
After this, STOP button is pressed to stop the process.
Figure 15: Flowchart of Project
17

24. 4.4 Programming:
1. Figure with explanation
Figure 16: Ladder diagram in De-energize state
Figure 17: Rungs are Energize and Start button pressed
18

25. Rung 0000:
(a) The START switch is represented by XIC I:0/0 and the STOP switch
is represented by XIO I:0/1. I represent input. The output is a binary
bit B3:0/0.When START button is pressed the input I:0/0 is HIGH
and input I:0/1 is already HIGH because its XIO. This energizes the
output B3:0/0.
(b) Holding circuit is implemented by attaching B3:0/0 as input with
I:0/0. This ensures that B3:0/0 remains energized or HIGH even if
the force is removed from START button.
(c) If STOP button is pressed i.e. STOP is HIGH then XIO I:0/1 goes
LOW. This creates a break in the circuit, therefore, de-energizing
the output B3:0/0.
Rung 0001:
(a) B3:0/0 acts as input to the TON timer T4:0/0 with preset value 30
and accumulator value 0.
(b) When B3:0/0 goes HIGH, the accumulator value of the timer T4:0/0
starts increasing until it becomes equal to the preset.
(c) When accumulator value becomes equal to the preset value the DN
bit of the timer goes HIGH.
Rung 0002:
(a) B3:0/0 acts as the input to two parallel outputs O:0/0 and O:0/1.
These outputs represent the output LED.
(b) When B3:0/0 goes HIGH, the outputs O:0/0 and O:0/1 are energized
and the two LED glow. In the context of the project this represents
that two liquids are being mixed in a container.
Rung 0003:
(a) The DN bit of timer T4:0 i.e. T4:0/DN acts as input to the timer
T4:1.
(b) This T4:1 indicates the time for which the mixture of the two liquids
is to be heated at 100 ◦
C.
19

26. 2. Figure with explanation
Figure 18: Timer T4:0 counts 30
Rung 0003:
(a) As stated above when accumulator value becomes equal to the preset
value the DN bit of the timer T4:0 goes HIGH. When this happens
the accumulator value of TON timer T4:1 starts to increase till it
reaches the value equal to that of preset (=20).
Rung 0004:
(a) The DN bit of T4:1 i.e. T4:1/DN is connected to the output O:0/2.
The O:0/2 represents the third output LED.
3. Figure with explanation
Rung 0004:
(a) As soon as T4:1/DN goes HIGH, the output O:0/2 is energized and
the third LED starts to glow.
(b) The glowing of third LED indicated that the heating of the mixture
is completed.
(c) After this the STOP button (I:0/1) is pressed i.e. XIO I:0/1 goes
LOW and the whole process is reset.
20

27. Figure 19: Timer T4:1 counts 20
4.5 Results
The two liquids were mixed (indicated by glowing of first two LED) and the
mixture was heated for 20 seconds (indicated by glowing of the third LED).
4.6 Future Scope
1. When connected with SCADA using the Device Connectivity feature of
SCADA, the project can implemented with Recipe Management feature
of SCADA. This way we can change the ingredients of the mixture.
2. This project can be extended to filling of the mixture into different bottles
then labeling and packing them i.e. making a fully automated medicinal
syrup manufacturing plant.
21

28. 5 Project Using SCADA:Bottle Filling & Capping
Station
5.1 Project Objective:
To design a ”Bottle filling and Capping Station” using Wonder ware Intouch
SCADA.
5.2 Software Used:
Wonderware Intouch version 9.0
Wonderware is a brand of industrial software sold by Schneider Electric.
Wonderware was part of Invensys PLC, and Invensys PLC was acquired in
January 2014 by Schneider Electric. Wonderware software is used in diverse
industries, including: Facilities Management, Food and Beverage, Mining and
Metals, Power, Oil and Gas, and Water and Waste water. Wonderware Intouch
software is an open and extensible Supervisory HMI and SCADA solution that
enables the rapid creation of standardized, reusable visualization applications
and deployment across an entire enterprise. InTouch SCADA consists of three
major programs:
1. Application Manager,
2. Window Maker
3. Window Viewer
The InTouch Application Manager organizes the applications created by the
user. InTouch Application Manager is used to create new applications, open
existing applications in either Window Maker or Window Viewer, delete ap-
plications, and run the InTouch DBDump and DBLoad Tagname Dictionary
utility programs. It also is used to configure Window Viewer as an NT ser-
vice, to configure Network Application Development (NAD) for client-based
and server-based architectures etc.
Window Maker is the development environment, where object-oriented graph-
ics are used to create animated, touch-sensitive display windows. These display
windows can be connected to industrial I/O systems and other Microsoft Win-
dows applications.
Window Viewer is the run time environment used to display the graphic
windows created in Window Maker. Window Viewer executes InTouch Quick
22

29. Scripts, performs historical data logging and reporting, processes alarm logging
and reporting, and can function as a client and a server for DDE communication
protocols.
5.3 Working of Project:
The project is made in Window Maker and executed in Window Viewer. In
window viewer, the project would run as:
When the switch is turned on, a bottle will be filled to full by three different
tanks filled with different liquids as indicated by their color. Liquid poured to
the bottle when its presence under the tank is sensed. Then a clamper brings
down the cap to the mouth of bottle, places it there and then returns back to its
original position. The bottle is capped is then moved to the storage.
5.4 Programming
1. In the Intouch Application Manager, we select file → New → Create new
Application. This creates a new Intouch application.
2. When we double click on this application, it opens Intouch Window maker.
3. In Window maker we select File →New Window. A dialog box appears
asking for name, window type, window color and other properties.
4. We name the window as ”bottle fill transfer”, window type as replace,
frame style as single and click on OK. A window appears as per defined
by us.
5. Next we click on the wizard icon. The Wizard Selection window appears
in which there are various options of the graphical objects.
6. We select a fixture switch from the Switches option of the Wizard selec-
tion window. The rest all other graphical objects will be picked from the
symbol factory option.
7. In the Wizard Selection window, we select symbol factory option and then
double click it. This opens the symbol factory window.
8. In the symbol factory window there are various categories of the graphical
objects like Tanks, Containers etc. We select the different objects as per
our requirement.
23

30. 9. For all the objects taken from the symbol factory, we perform Break Cell
operation so that we are able to change their properties as per our require-
ment Following is the figure showing the list of the properties available
for each object from Symbol Factory:
Figure 20: Schematic of Object Properties
10. For our project we require bottle, cap, tanks, clamper, conveyor belt etc.
these objects are picked up the symbol factory and other objects like
wheels, door etc. are built by us using the basic shapes.
11. Next we place the objects as per the industrial setup and modify the ob-
jects property. For example, all the tanks must be full initially and the
liquid level of the tank should decrease by 20% whenever the tank fills
the bottle. For this we double click on the tank, select vertical under fill
option. We give the tag name A and then specify the values of maximum
and minimum fill percentages along with the values of the A.
12. Similarly other properties of the objects are changed.
24

31. 13. The finished window is shown as below:
Figure 21: Window in develpoment mode in Window maker
14. We see that there are different bottles under the tanks whereas in the run
time we require only one of them. This is done keeping in mind the
visibility of each bottle.
15. Visibility is a property which is required when we want to use the same
properties of an object for more than once with different values of tag
name. In Intouch this is not allowed, therefore we make duplicate of the
object, then modify their properties and apply the visibility property.
16. Visibility comes under the category of miscellaneous property. One more
miscellaneous property which we have used in this project is orientation.
We have used this property to show the rotation of the wheels of the con-
veyor belt so that the conveyor appears to be moving.
17. Since there is no manual work i.e. no slider is being used, window script
has to be used for incrementing the value of the counter, whose tag name
is used as the expression for all other objects.
25

32. 18. The script written for this project is shown below:
Figure 22: Schematic of Window Script used
19. There are two parts in the script:
(a) On Show: how the things should appear as soon as the window
viewer is started.
(b) While showing: how things will appear once the task starts to run
on window viewer.
20. As shown in the figure the window script follows simple ”if-else if-else”
with logical operators ”and-or-not”.
26

33. 21. In the script we can see that the value of A is incremented when its value
is less than 100 and the switch is kept on. As soon as it becomes equal to
100, the value of A is reset to 0 and the process repeats itself in an infinite
loop until the switch is put off.
22. Now, we test our project in window viewer. For this we click on ”Run-
time!” icon at the top right corner of the tool bar.
23. This option takes us to the run- time environment. As soon as Window
Viewer is started we see that it follows the instructions of ”On Show” until
the switch is turned on. As soon as the switch is turned on, it follows the
instructions of ”While Showing”.
24. In case we find some anomaly in execution, we need to switch to Window
Maker for rectifying it. For this we click on the ”development!” icon
placed at the top right corner of the Window Viewer.
25. We can change our script and properties of the various objects used in
Window Viewer but test its execution in Window Maker. The functions
of both are different.
26. The following snapshot shows the execution of the program:
(a) Filling of the bottle by the last tank.
Figure 23: Filling of the bottle
27

34. (b) Capping of the bottle by the clamper.
Figure 24: Capping of the bottle
(c) Bottle is sent to storage after its filling and capping.
Figure 25: Bottle is sent to storage after its filling and capping
27. This process continues to execute repeatedly until the witch is turned off.
28

35. 5.5 Results
The design of ”Bottle Filling and Capping Station” is successfully implemented
in Intouch SCADA.
5.6 Future Scope
This project can be implemented practically when SCADA is connected with
PLC. More enhanced features can be added up to it. Some features are:
1. Automatic Labelling of Bottles.
2. Defected Bottles such as bottles without cap or less in weight should be
automatically removed.
3. Automatic pick up of bottle after filling it up.
29

36. 6 CONCLUSION
With the speed of changing technology today it is easy to lose sight or knowl-
edge of the basic theory or operation of programmable logic. Most people sim-
ply use the hardware to produce the results they desire. Hopefully, this report
has given the reader a deeper insight into the inner workings of programmable
logic and its role in mechanical operations. The idea of programmable logic is
very simple to understand, but it is the complex programs that run in the lad-
der diagrams that make them difficult for the common user to fully understand.
Hopefully this has alleviated some of that confusion.
SCADA is used for the constructive working, using a SCADA system for
control ensures a common framework not only for the development of the spe-
cific applications but also for operating the detectors. Operators experience the
same ”look and feel” whatever part of the experiment they control. However,
this aspect also depends to a significant extent on proper engineering.
30

37. References
[1] Richard A. Cox, ”Technicians Guide to Programmable Controllers” , 4th
edition, Vikash Publishing House, New Delhi.
[2] J. R. Hackworth, F.D. Hackworth, ”Programmable Logic Controllers Pro-
gramming Methods and Applications” Pearson Education, New Delhi
[3] J. W. Webb, R A Reis , ”Programmable Logic Controllers Principle and
Applications” 5th edition, Prentice Hall of India ltd., New Delhi
[4] literature.rockwellautomation.com/idc/groups
31