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PLC AND SCADA USED FOR INDUSTRIAL AUTOMATION

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PLC AND SCADA USED FOR INDUSTRIAL
AUTOMATION
Author
KUNAL SINGH

1
 TABLE OF CONTENTS

ABSTRACT 5

LIST OF TABLES 6

LIST OF FIGURES 7

LIST OF KEYWORDS 8

1. INTRODUCTION
1.1 AUTOMATIC WATER MONATERING SYSTEM 9
1.2 PROBLEM STATEMENT 9
1.3 PLC AND SCADA 10
1.4 DIFFERENCE BETWEEN PLC AND SCADA 11
2. PLC 12
2.1 PLC ARCHITECTURE 13
2.2 WORKING OF A PLC 14
2.3 PROPOSED WORK 16
2.4 PROPOSED RESEARCH STRATERGY 18
2.5 BENEFIT OF SOCIETY 19
3. SCADA
3.1 OBJECTIVE OF SCADA 20
3.2 FUNCTIONS OF SCADA 21
3.3 USAGES OF SCADA 21
3.4 DOMAIN OF SCADA 21
3.5 REAL TIME MONATRING SYSTEM DESIGN 23
3.6 SCADA SYSTEM CONCEPT 24
3.7 SCADA ARCHITECTURE 24
3.8 SCADA SECURITY ISSUES 26
3.9 SCADA TRENDS 27
4. CONNECTION BETWEEN SCADA AND PLC 28
5. LITERATURE SURVEY 30
6. CONCLUSION 31
REFERENCE 32

2
 ABSTRACT

The rapid growing of the wide urban residential areas imposes the expansion as well as
the modernization of the existing water supply facilities. Process automation system based upon
utilization of an industrial PLC and PC systems including all the network components represents
the best way to improve the water distribution technological process. The system includes remote
terminal units - RTU, specific transducers and actuators distributed on a wide geographical area
and control and power panels for the pump stations. The reliable instrumentation connected to
PLC or RTU assure real time monitoring of the main technological parameters of large water
distribution networks. The data acquired of SCADA system (supervisory control and data
acquisition) represent the support for optimization of the process and data-driven decision
support system. The system uses HMI implemented on PC to ensure the process supervision and
remote control functions based on OPC technologies and wireless communication components
for WAN data transfer. The complete SCADA system for water distribution enable the user to
get a high operation safety of the network, a cost effective use of equipment, energy efficiency
and optimize the daily operation and maintenance procedures.

3
LIST OF TABLE

Table 1: Difference between PLC and SCADA

4
LIST OF FIGURES

Figure 2.1: Programmable logic controller

Figure 2.2: Internal structure of PLC
Figure 2.3: PLC working schematic
Figure 2.4: Working of PLC
Figure 2.5: Proposed design
Figure 2.6: Water level circuit
Figure 2.7: Solenoid valve
Figure 2.8: Flow sensor
Figure 2.9: Power supply
Figure 3.1: Basic block diagram
Figure 3.2: Real time monitoring system
Figure 3.3: Wireless connection of SCADA with PLC
Figure 4.1: Wireless SCADA

5
LIST OF KEYWORDS

Flow Sensor, PLC, Solenoid Valve, SCADA, Water Level Sensor, Automatic water
system(AWS)

6
 CHAPTER 1

INTRODUCTION

1.1 AUTOMATIC WATER MONITORING SYSTEM

Water is basic need of human being. Water Distribution is one of the important
process. Automation provides optimized solution to all problems of distribution of water system.
Now-a-days, Water distribution system faces so many problems like water leakage & improper
water supply. This leakage causes drastic reduction in pressure of water flowing through supply
line. Due to this, consumer gets less amount of water. By, considering above scenario we are
trying to find solution for the problem The main aim of this project is to provide effective water
supply to each consumer. In this project we are working on the distributed network under the
area of single water tank. Automation plays an increasingly significant role in the global
economy. It improves the performance and also reduces human efforts hence we are
implementing PLC based water distribution system. Initially we studied about the working of
distribution system of existing system.

Existing Technology:- Now-a-days, we seen lots of problem for water distribution system like
water leakage & improper water supply. This leakage causes drastic reduction in water flowing
through supply line. Due to this, consumer gets less amount of water. Hence, we need to develop
the system to reduce such problems which face by today’s WDS.

Need for PLC:- Programmable Logic Controller plays vital role in automated water supply
system. PLC is used in stirrer motors, controlling pump station motor contactors and distributed
valves of the water. PLC programming is done using Ladder Diagram Language. Ladder
diagram is main schematic language commonly used in automation industrial control logic
systems. Specifically, our research idea focuses the proper method of water distribution system
using PLC and methodology required to protect the leakage of water and constant pressure
maintenance while water distribution. As the water is distributed by time shift method in the
conventional system, we are facing lot of problems such as wastage of water, leakage of water
etc. All these things are making the scarcity of water. So, in order to overcome the disadvantages
in the earlier systems, we are going to distribute the water using our proposed system. Water
supply system plays important role in urban infrastructure. Our system is implemented using
PLC/SCADA. The main objective of the automation of the water distribution system is to
prevent the wastage of water due to malicious mischief. To keep an eye on the vandal and the
stealing of water the SCADA unit has initiated red alarm pop-ups. The storage tank contains
Water Level Sensor being controlled and monitored. These Sensor convert physical parameters
into electrical signals. These Sensors are connected to electronic devices through the
PLC(Programmable logic Controllers). The PLC provides data to control room where the
SCADA servers present to store data from PLC and regulate the control system. Connection
between the PLC and SCADA server is established using direct technique.

1.2 PROBLEM STATEMENT

7
 In previous method, person supervisor will go to the pump station and open the valve for a
particular time period. Once the time over the supervisor have to go there again to close the
valve. It is time consuming. The proposed system is fully automated. Here human work and time
is reduced. The water wastages such as leakages, mankind laziness and operating error can be
avoided. In present system due to improper handling, there is unnecessary loss of water and it is
not properly distributed to the end users. Also the people may take extra water for their personal
use with the help of motor.

1.3 PLC AND SCADA

PLC or Programmable Logic Controller is a computer control system for the Automation
Industry. It is a special-purpose computer without a keyboard, hard drive, etc. PLC is one of the
demanding skills of the Electrical industry. Most organizations require a candidate having
knowledge of PLC.

SCADA stands for Supervisory Control and Data Acquisition. It is a computer system
designed to gather and analyse real-time data. It is used to control and monitor the equipment
and manufacturing processes in various industries in different fields such as water and waste
control, telecommunications, oil and gas refining, power generation, and transportation. SCADA
systems were used for the first time in the 1960s.

8
1.4 Difference between PLC and SCADA

Table 1: Difference between PLC and SCADA.

PLC SCADA

It stands for Programmable Logic It stands for Supervisory Control and Data
Controller. Acquisition.
It comprises CPU, I/O modules, and the It comprises of computers, GUI (Graphical
peripheral devices. User Interface), and networked data
communications.
It is hardware. It is software.

It is a system that controls motors and It is a system to run and monitor the plant
complex machines. processes.
It is a hardware device that can be of various It consists of several components that increase
types, as per the requirements. its capability.

9
 CHAPTER 2

PROGRAMMABLE LOGICAL CONTROLLER(PLC)

PLC is a digital computer control system adapted to control the robotic devices and other
manufacturing processes. It involves a basic study of Microcontrollers, digital circuits, and
designing skills.
It provides easy, flexible, high-reliability programmable controllers suitable for simple and harsh
environments. It monitors the state of input devices, takes decisions, and controls the output
devices. The applications include Robotics, water filling tanks, etc.
PLC ranges from small devices with few Input/Outputs to large devices with thousand of
Input/Outputs.
Thus, PLC is all about:

1. Controlling output devices based on pre- programmed parameters.

2. Recording run-time data to increase machine productivity and automotive processes.
3. Program that are designed to control machine operations.

Figure 2.1: Programmable logic controller

PLC was initially created in the United States for the replacement of relay systems.
The drawbacks of relays that make them unsuitable for the automotive industry are listed below:
1. The machine operation using relays logic was quite challenging and time-consuming. A
change in the logic of the machine makes the process complicated.
2. Relays also fail quickly compared to computer components.
3. It requires more run downtime.
4. Relay also consumes plentiful electricity, more space, and heat.
Hence, to overcome such drawbacks, PLC was created.

10
2.1 PLC ARCHITECTURE

A basic PLC system consists of the following sections:

Input/ Output Section: The input section or input module consists of devices like sensors,
switches, and many other real-world input sources. The input from the sources is connected to
the PLC through the input connector rails. The output section or output module can be a motor or
a solenoid or a lamp or a heater, whose functioning is controlled by varying the input signals.
CPU or Central Processing Unit: It is the brain of the PLC. It can be a hexagonal or an octal
microprocessor. It carries out all the processing related to the input signals in order to control the
output signals based on the control program.
Programming Device: It is the platform where the program or the control logic is written. It can
be a handheld device or a laptop or a computer itself.
Power Supply: It generally works on a power supply of about 24 V, used to power input and
output devices.
Memory: The memory is divided into two parts- The data memory and the program memory.
The program information or the control logic is stored in the user memory or the program
memory from where the CPU fetches the program instructions. The input and output signals and
the timer and counter signals are stored in the input and output external image memory
respectively.

Figure 2.2: Internal structure of PLC

11
2.2 WORKING OF A PLC

 The input sources convert the real-time analog electric signals to suitable digital electric
signals and these signals are applied to the PLC through the connector rails.
 These input signals are stored in the PLC external image memory in locations known as
bits. This is done by the CPU
 The control logic or the program instructions are written onto the programming device
through symbols or through mnemonics and stored in the user memory.
 The CPU fetches these instructions from the user memory and executes the input signals
by manipulating, computing, processing them to control the output devices.
 The execution results are then stored in the external image memory which controls the
output drives.
 The CPU also keeps a check on the output signals and keeps updating the contents of the
input image memory according to the changes in the output memory.
 The CPU also performs internal programming functions like setting and resetting of the
timer, checking the user memory.

Figure 2.3: PLC working schematic

12
Figure 2.4: Working of PLC

13
2.4 PROPOSED WORK

The hardware layout of the proposed system is shown in figure.2.2 Pumping section is connected
to PLC. If the water level goes below the set point the pump will automatically turn ON.
Checking the level in storage tank is the first process. If the level attains the set point, overall
system is started. The water is flow through the pump when the main solenoid valve opens. The
flow rate is measured with the help of pulse output from the flow sensor. The people can get
water until the set point is reached. Once the water usage attains solenoid valve is automatically
close. Once the main solenoid valve gets opened, the water flow through the pump. The water
level in the storage tank gets decreased. We can measure the water level using the sensor
attached to the storage tank. When the water decreased below 80% the pump is on.

Figure 2.5: Proposed design

14
Figure 2.6: Water level circuit

Figure 2.7: Solenoid valve

15
Solenoid valve is a two port valve. It will be used to turn on and off condition. In this system three
solenoid valves are used. 24V supply is given to the main solenoid valve. PLC output is connected to the
solenoid valve. The output from the PLC in the range of 24V DC. So it is necessary to give switch
function on and off the solenoid valve. If the water level in the storage tank is reached the 80%, main
solenoid valve is automatically turned on. The set point is fixed for solenoid valve. If anyone one of its
valve or both the valve attains the set point the solenoid valve is turned off. (Shown in Figure 2.4)
normally closed solenoid valve is used to control the flow rate.

Figure 2.8: Flow sensor

Flow sensor is used to measure the flow rate of the water. YF-S201 type of flow sensor is used (shown in
Figure 2.5). Flow sensor contains pin wheel in its. Pinwheel contains 6 teeth. The pulse output is comes
from the pin wheel sensor. If the teeth rotate at one time, it will give the pulse output according to the
specification of the flow sensor. From the pulse output easily measure the amount of water passed
through the pipe. The pulse is converted to voltage with the help of Hall Effect sensor. Flow sensor output
is in the range of 5V DC. So it is necessary to give signal conditioning. Optocoupler is used to amplifying
signal.

16
 Figure 2.9: Power supply

2.5 PROPOSED RESEARCH STRATEGY

Specifically, our research idea focuses the proper method of water distribution system using PLC
and methodology required to protect the leakage of water and constant pressure maintenance while water
distribution. As the water is distributed by time shift method in the conventional system, we are facing lot
of problems such as wastage of water. All these things are making the scarcity of water. So, in order to
overcome the disadvantages in the earlier systems, we are going to distribute the water using our
proposed system.

2.6 BENEFITS TO THE SOCIETY

Automatic Water Distribution (AWD) system.

1. Provides balanced water distribution throughout the society.
2. Saves water and Power.
3. Automatic Water Distribution systems focuses on energy crisis.

17
 Chapter 3

SUPERVISORY CONTROL AND DATA ACQUISITION(SCADA)

A SCADA system refer to a system consisting of a number of remote terminal units (or
RTUs) collecting field data connected back to a master station via a communications system.

The master station displays the acquired data and also allows the operator to perform remote
control tasks. The accurate and timely data (normally real-time) allows for optimization of the
operation of the plant and process.

A further benefit is more efficient, reliable and most importantly, safer operations. This all
results in a lower cost of operation compared to earlier non-automated systems. A successful
SCADA installation depends on utilizing proven and reliable technology, with adequate and
comprehensive training of all personnel in the operation of the system.

3.1 OBJECTIVE OF SCADA

The important objectives of SCADA are to listed below:

Monitoring : Continuous monitoring of the parameters of voltage , current, etc..

Measurement: Measurement of variables for processing.
Data Acquisition: Frequent acquisition of data from RTUs and Data Loggers / Phasor data
Concentrators (PDC).
Data Communication: Transmission andreceiving of large amounts of data from field to control
centre’s.
Control: Online real time control for closed loop and open loop processes.
Automation:: Automatic tasks of switching of transmission lines, CBs, etc.

Benefits of SCADA

The important benefits can be addresses as the following functions:

1. Continuous monitoring of process.
2. Real time control.
3. Automation and Protection.
4. Remote control and operation.

18
3.2 FUNCTIONS OF SCADA

The important functions of an SCADA are listed below.

1. Data Acquisition
2. Information Display
3. Supervisory Control
4. Alarm Processing
5. Information Storage and Reports
6. Sequence of Event Acquisition
7. Data Calculation
8. Special RTU Processing/Control

3.3 USAGE OF SCADA

SCADA can be used to manage any kind of equipment. Typically, SCADA systems are used
to automate complex industrial processes where human control is difficult.

For example in systems where there are more control factors unable to be managed by operators
in a control center.

3.4 SCADA DOMAIN

SCADA systems are widely used for control in the following domains

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.

3. Buildings, facilities and environments: Facility managers use SCADA to control HVAC,
refrigeration units, lighting and entry systems.

4. Manufacturing: SCADA systems manage parts inventories for just-in-time manufacturing,

regulate industrial automation and robots, and monitor process and quality control.

5. Mass transit: Transit authorities use SCADA to regulate electricity to subways, trams and
trolley buses; to automate traffic signals for rail systems; to track and locate trains and buses; and
to control railroad crossing gates.

6. Traffic signals: SCADA regulates traffic lights, controls traffic flow and detects out-of-order
signals.

19
Figure 3.1: Basic block diagram

20
3.5 REAL TIME MONATERING SYSTEM DIAGRAM

Figure 3.2: Real time monitoring system

3.5.1 Features of SCADA

The following are the important features of a SCADA from an control point of view. SCADA is
capable of the following

1. Acquire quantitative measurements immediately and over time

2. Detect, Diagnose and correct problems as soon as they arise
3. Measure trends over time and prepare reports and charts
4. Discover and eliminate bottlenecks over time and improve efficiency
5. Ability to Control large and complex processes with a few specialized staff.

SCADA provides the facility to fine-tune the operators experiential knowledge in to the system.
Sensors can be placed at every critical point in the process to be managed and controlled. As
SCADA technology improves, more sensors can be placed to improve efficiency. SCADA has

21
the ability to view the operation of large power process in real time through software. GIS
(Geographical Information System) is one such software widely used in electric power
applications. With such am=n ability it is possible to correct errors and diagnostics. So even for
very complex manufacturing processes, large electrical plants, etc., you can have an eagle-eye
view of every event while it’s happening — and that means you have a knowledge base from
which to correct errors and improve efficiency. With SCADA, you can do more, at less cost,
providing a direct increase in profitability.

3.6 SCADA SYSTEM CONCEPT

SCADA refers to the centralized systems that control and monitor the entire sites, or they
are the complex systems spread out over large areas. Nearly all the control actions are
automatically performed by the remote terminal units (RTUs) or by the programmable logic
controllers (PLCs).The restrictions to the host control functions are supervisory level
intervention or basic overriding. For example, the PLC (in an industrial process) controls the
flow of cooling water, the SCADA system allows any changes related to the alarm conditions
and set points for the flow (such as high temperature, loss of flow, etc) to be recorded and
displayed.

3.7 SCADA ARCHITECTURE

3.7.1 Monolithic: The First Generation

In the first generation, mainframe systems were used for computing. At the time SCADA
was developed, networks did not exist. Therefore, the SCADA systems did not have any
connectivity to other systems, meaning they were independent systems. Later on, RTU vendors
designed the Wide Area Networks that helped in communication with RTU. The usage of
communication protocols at that time was proprietary. If the mainframe system failed, there was
a back-up mainframe, connected at the bus level.

3.7.2 Distributed: The Second Generation

The information between multiple stations was shared in real time through LAN and the
processing was distributed between various multiple stations. The cost and size of the stations
were reduced in comparison to the ones used in the first generation. The protocols used for the
networks were still proprietary, which caused many security issues for SCADA systems. Due to
the proprietary nature of the protocols, very few people actually knew how secure the SCADA
installation was.

22
3.7.3 Networked: The Third Generation

The SCADA system used today belong to this generation. The communication between the
system and the master station is done through the WAN protocols like the Internet Protocols (IP).
Since the standard protocols used and the networked SCADA systems can be accessed through
the internet, the vulnerability of the system is increased. However, the usage of security
techniques and standard protocols means that security improvements can be applied in SCADA
systems.

Figure 3.3: Wireless connection of SCADA with PLC

23
3.8 SCADA SECURITY ISSUES

Security of SCADA-based systems is being questioned, as they are potential targets to

cyberterrorism/cyberwarfare attacks. There is an erroneous belief that SCADA networks are safe
enough because they are secured physically. It is also wrongly believed that SCADA networks
are safe enough because they are disconnected from the Internet. SCADA systems also are used
for monitoring and controlling physical processes, like distribution of water, traffic lights,
electricity transmissions, gas transportation and oil pipelines and other systems used in the
modern society. Security is extremely important because destruction of the systems would have
very bad consequences.

There are two major threats. The first one is unauthorized access to
software, be it human access or intentionally induced changes, virus infections or other problems
that can affect the control host machine. The second threat is related to the packet access to
network segments that host SCADA devices. In numerous cases, there remains less or no
security on actual packet control protocol; therefore, any person sending packets to SCADA
device is in position to control it. Often, SCADA users infer that VPN is sufficient protection,
and remain oblivious to the fact that physical access to network switches and jacks related to
SCADA provides the capacity to bypass the security on control software and control SCADA
networks. SCADA vendors are addressing these risks by developing specialized industrial VPN
and firewall solutions for SCADA networks that are based on TCP/IP. Also, white-listing
solutions have been implemented due to their ability to prevent unauthorized application
changes.

24
3.9 SCADA TRENDS

1. In the late 1990s instead of using the RS-485, manufacturers used open message
structures like Modbus ASCII and Modbus RTU (both developed by Modicon). By 2000,
almost all I O makers offered fully open interfacing like Modbus TCP instead of the IP
and Ethernet.

2. SCADA systems are now in line with the standard networking technologies. The old
proprietary standards are being replaced by the TCP/IP and Ethernet protocols. However,
due to certain characteristics of frame-based network communication technology,
Ethernet networks have been accepted by the majority of markets for HMI SCADA.

3. The ‘Next Generation’ protocols using XML web services and other modern web
technologies, make themselves more IT supportable. A few examples of these protocols
include Wonderware’s SuiteLink, GE Fanuc’s Proficy, I Gear’s Data Transport Utility,
Rockwell Automation’s FactoryTalk and OPC-UA.

4. Some vendors have started offering application-specific SCADA systems that are hosted
on remote platforms all over the Internet. Hence, there is no need to install systems at the
user-end facility. Major concerns are related to the Internet connection reliability,
security and latency. The SCADA systems are becoming omnipresent day by day.
However, there are still some security issues.

25
 Chapter 4

CONNECTION BEYWEEN SCADA AND PLC

4.1 WIRELESS SCADA ARCHITECTURE

Wireless SCADA replaces or extends the fieldbus to the internet. This means that the Master
Station can be on a different network or location. In Figure 3, you can see the architecture of
SCADA which is connected through the internet. Like a normal SCADA, it has
RTUs/PLCs/IEDs. Along with the fieldbus, the internet is an extension. The main problem in
extending SCADA to a larger scope are the lines that will connect the field devices such as RTU,
PLC, IED and sensors. It could be very costly and may encounter communication loss because of
the distance. It is also impractical to connect. That is why having wireless communication can
solve this problems.
The Wireless SCADA could also include the user-access to SCADA website. This is for the
smaller SCADA operators that can avail the services provided by the SCADA service provider.
It can either be a company that uses SCADA exclusively. Another component of SCADA is the
Customer Application which allows report generation or billing. This is setup like a private
network so that only the master station can have access to the remote assets. The master also has
an extension that acts as a web server so that the SCADA users and customers can access the
data through the SCADA provider website.

Figure 4.1: Wireless SCADA

26
4.2 PROS AND CONS

Connecting SCADA wirelessly may carry on the vulnerability of a wireless network.

Communication between devices can be easily intercepted and altered specially if it is not
encrypted. Outsiders may gain control of the wireless network and control the devices. Also
wireless network are less stable compared to wired network. One may ask why we need to
connect SCADA on even though there are a lot of issues surrounding it.
The answer is because of many advantages it presents
 Wide area connectivity and pervasive
 Routable
 Parallel Polling
 Redundancy and Hot Standby
 Large addressing range
 Integration of IT to Automation and Monitoring Networks
 Standardization

27
 Chapter 5
5.1 Literature survey

Today is the age internet, AI and ML and every one using smart devices such as
mobile phone laptop wrist band, the best feature of this device is connect through
wireless networking topology. Now a days all the devices are coming with AI and ML
features so this devices are self monitoring and error less. In the older days such as in
1980 or 1990 or even in 2000, we don’t have these types of technology so that for this job
we are hiring some people to do this job, but this monitoring task in not so easy so that
there have a lot of issue due to lack of knowledge. For that engineer develop this
technology to solve this issue but that time still there have a issue due to less data. For
that two computer scientist name larry page and sergin bin invented a search engine
called google and after a revolution is arrises in the field of computer science and today
more than two billion devices connected to internet and daily billions of people are daily
connected through the internet and this field is called internet net of things (IOT). Due to
this technology lots of peoples lost his and her job. But in the industries point of view the
main motive is to invest less money and get more and more profit. As a point of view of a
ECE engineer we try to develop a system called automatic monitoring system in the field
of STP and combines with IOT, SCADA and PLC to make a efficient system that
working with TCP or OSI model to connect with internet and sending all the data to
system and the monitoring system gives all information about in the case of the STP
which motor is on, how much water level etc.

28
 Chapter 6
6. CONCLUSION

As of 2010, Wireless technology has spread widely within business and industrial sites. Wireless
SCADA is required in those applications when wireline communications to the remote site is
prohibitively expensive or it is too time consuming to construct wireline communications. In
particular types of industry like Oil & Gas or Water & Wastewater, wireless SCADA is often the
only solution due to the remoteness of the sites. Wireless SCADA replaces or extends the
fieldbus to the internet. It can reduce the cost of installing the system. It is also easy to expand. In
this paper we described an Architecture of SCADA in wireless mode. The transmission of
communication through the internet, its advantages and disadvantages are also presented.

29
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[3] Ramleela Khare, Dr Filipe Rodrigues E Melo ―Automation Of Water Distribution Plan
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[5] N.B. Bhawakar ,D.P.Pande;Literature Review for Automated Water Supply with Monitoring
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[6] T. Baranidharan, A.Chinnaduri, J.Karithikeyan; “Automated Water Distribution System

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