Formal report for the Industrial Control Project and Automation The Abstract General the main objective of this exercise is to comprehensively evaluate the SCADA system to understand the measures and procedures involved in developing a SCADA system. The setting and necessary commands were configures to execute the system. After a couple of minutes the, the systems transmission and creation of tag was established. Development of the SCADA screen was accomplished followed by testing to qualify the results obtained. The SCADA system is very useful in; factories, treatment plants, gas refineries and other areas. It is generally important in procuring accurate and precise machine control to monitor processes to ensure no errors occur. The Table of Content The Abstract ..................................................................................................................................................................... i The Introduction ........................................................................................................................................................... 1 The aims ........................................................................................................................................................................... 1 The methodology .......................................................................................................................................................... 1 The results ....................................................................................................................................................................... 4 The display’s main screen .................................................................................................................................... 4 SCADA - Water tank’s process rig ..................................................................................................................... 4 SCADE – The traffic light’s controller .............................................................................................................. 5 The discussion................................................................................................................................................................ 6 The modifications .................................................................................................................................................... 6 The display’s development .................................................................................................................................. 7 The conclusion ............................................................................................................................................................ 13 The Introduction SCADA is an abbreviation for Supervisory Control and Data Acquisition. . As the name indicates, it is not a full control system, but rather focuses on the supervisory level. Outcomes of data that the user inputs and the data provided by the sensor, to help in achieving the outlined goals are controlled by the ‘PLC’. PLC stands for programmable logic controls. The PLC follows the commands instructed with to output desired results. If the ladder program in put into use the PLC displays additional information. SCADA systems are used to monitor and control a plant or equipment in industries such as telecommunications, water and waste control, energy, oil and gas refining and transportation. A SCADA system gathers information, such as where a leak on a pipeline has occurred, transfers the information back to a central site, alerting the home station that the leak has occurred, carrying out necessary analysis and control, such as determining if the leak is critical, and displaying the information in a logical and organized fashion. Tag importation from the PLAC was among the procedures that were adopted to help in communication purposes. Few changes and modification were made on the PLC’s ladder programming to establish a solid interface with the SCADA. The modified system was then used to control traffic lights and to monitor water in a tank. The report’s set up includes the objectives, the methodology, the outcomes and the discussion. The objectives The main objective of this exercise is to put in work a mechanism capable of monitoring and controlling traffic lights and the PID controlled ‘process Rig’. The SCADA system is the central control unit of this exercise. Monitoring of the operations is carried out for the safety of the users of roads and the water tank. The methodology Initially, the necessary changes were made to the Process Rig’s ladder programming and also in the traffic light’s controller. Screenshots are used for presenting the operation. The Ethernet LAN enabled PLC communication. The list of tags was imported for both of the operations. Thereafter, the display screens were created. The process of testing was then carried out. Figure number 1 shows the tag list for the ‘Process Rig’ that gets controlled by the PID and for ‘Traffic Light’ controller. Figure number 1: The tag list The figure number 2 below shows the SCADA screens that show the ‘Process Rig’ on the main screen’s left hand side. Whereas, on the main screen’s right hand side, ‘traffic light’ controller has been shown. Another of the traffic light’ controller’s screen is shown in Figure number 2. That provides us with the colour display for the traffic lights. Two additional displays are provided by the Process Rig. The first one pertains to the display of buttons while the second one pertains to the graphic and numeric display. It also includes the trend lines. Figure number 2: The screen navigation The results The display’s main screen From figure 3, tank and traffic lights monitoring can be established through the ‘main screen’. The next page can be accessed by pressing the sub-screen button. Figure 3: The display of the main screen SCADA - Water tank’s process rig Figure number 4 shows the SCADA system pertaining to the operation that is controlled by the PID. The graph presents the tank’s water level and also shows the water’s set level. The buttons control the system’s stopping and starting. The POT gets removed and ‘slider’ gets introduced for the level’s setting. The SCADA screen also displays the values of‘Ki’, ‘Kd’, ‘Kp’, and the values of the ‘upper limits’. Figure 4 - The PID screen pertaining to the water tank The SCADA screen also shows the water’s level, the set value’s level and the discrepancy with the graphical representation. That is why the trend line’s value is greater than 15s. An increase in the error (discrepancy) is observed, upon varying the set level. Thereafter, the tank’s level tends towards the set level in order to reduce the observed error. Upon reaching the steady state, the discrepancy equals 0. Figure number 5: The time response of the PID SCADE – The traffic light’scontroller Figure number 6 represents more of the traffic light controller’s display on the SCADA screen. The screen shows the lights for the side road, the pedestrian walk and for the main road. Switches, in the form of buttons have been provided for the nigh mode, day mode and for the emergency mode. The main road and the side road are provided with the necessary sensors and with the instruction loops as shown. Figure number 6– The traffic lights and the screen for the intersection The discussion The modifications A few modifications are needed in order to integrate the PLC’s ladder programming with the SCADA program. It is most important to modify the start and stop buttons’ controlling SCADA. The ‘XIO’ and “XIC” switches are added. This can also be in figure number 7 upon starting the PLC software. Figure number 7: The modifications for starting and stopping the pump The SCADA switches for the OFF and for the ON functionalities are configured to the rung for changing the set level. SCADA’s switches also control the unlatch and latch bits. Figure number 8 – SCADA’s control bits In a similar way, the PLC’s traffic light controller’s portion was modified. The SCADA switches control the unlatch and latch bits. And the XIO and XIC switches are used for testing the OFF or ON conditions. These switches are installed right next to the sensor checks for the pedestrian, side and the main roads. Figure number 9 highlights those changes that have been carried out. Figure number 9 – The traffic controller’s modifications The display’s development For the display’s development, SCADA controls are used. The display button for ‘Goto’ In order to navigate from the previous panel to the adjacent one, the ‘Goto’ buttons are used. These buttons facilitate navigation between the main screen, the PID screen and to the next screen.. Figure number 10 focuses on these settings. Figure number 10- The go-to function’s display buttons The button for ‘return to display’ The inverse task is performed with the help of the ‘Return to Display’ button. Hence it enables us to navigate back to the previous display. For example it enables returning from the “traffic light” view to the ‘trend graphs’ view. The colour animation based drawing This functionality is used in the SCADE for “traffic lights”, in the ‘main SCADA’ and in the ‘PID SCADA’. For instance, green colour represents the ‘ON’ state while dark green stands for the ‘OFF’ state. In a similar way, red colour can be used for the ‘ON’ state and dark red for the ‘OFF’ state. Hence light colours represent ‘ON’ while dark colours represent the ‘OFF’ state. Figure number 11– colour based animation The momentary push button Buttons and tags are used for simulating push buttons and for controlling variables. Figure number 12 focuses on this. That is why, apart from the PID waveform’s display, the ‘momentary push-buttons’ are used almost everywhere. Figure number 12 – The traffic light’s pushbutton Water tank level’s bar graph Bar graphs were used forshowing the required information on the PID’s screen. The Figure number 13 focuses on this. Its aim was to simulate the slider. The POT controls the slider in the PLC, for varying the set water level. Figure number 13– The bar for the tank’s water level The numeric values’ input cursor In order to get the values forKi’, ‘Kd’, ‘Kp’, and the integration’s ‘upper limit’ the input cursor was used. When the numeric values are entered, the associated filed values and the variables are displayed. Figure number 14 – Numeric value’s input cursor The objects in the library SCADA enables us to utilise variousready-made objects. Primarily the ‘trend’ object was used, along with the ‘tank’ object. The tank’s colour stands for the water level as shown in Figure number15. Figure number 15– The tank The water’s level, the set level and the discrepancy can be seen on the ‘trend’ object, ashighlighted by Figure number 16. For the line type, the line width and the three values, the colours are selected. Figure number16 – The screen for the trendlines For connecting the SCADE program to the PLC, Figure number 17 shows the Ethernet LAN setup. Figure number 17 – Communicational setup The conclusion For the purpose of industrial control and automation, SCADA is immensely useful. It involves the process of importing tags from PLC and the creation of the communicational setup. Thereafter, SCADA’s display screens need to be developed and the complete system needs to be tested. The requisite modifications also need to be performed. The ability to control and display numerous operations without causing any time delay makes the use of SCADA advantageous. The two main operations are displayed on the main screen. SCADA makes it easy to modify and control the necessary operations. Navigation to the adjacent screen can be carried out by clicking on the sub-screen. On the other screen, different control processes and ‘display info’ can be viewed and varied. A few modifications are carried out for the proper interfacing of PLC’s ladder programming with SCADA. The water tank’s process rig project and the traffic light’s controller based project were accomplished with SCADA’s help. SCADE enables the use of the library of various objects that can be configured, for example for the trend or for the tank. For enhancing user friendliness, the displays’ design must be done in such a way so as to make the monitoring of processes and data entry easy. These adjustments lead to an increased reliability. They also ensure smooth real-time operation. The Ethernet LAN is used for communication, by utilising the ‘standard protocol’. Despite these advantages, it needs to be realised that SCADA’s tools cost more and they requirethe presence of experienced operators for their continual working and design modification. Using the N7:0 registers for tagging the variable entitled mean “Set_Level” can enhance the performance. Moreover, the use of signs ‘warning ‘audiovisual’ is required for enhancing the system’s design.For improved reliability, the data servers (OPC) can be used. This can be done while utilising various controllers. In the end, to reiterate some of SCADA’s advantages, it also enables data logging and the use of libraries in tandem, making it quite useful.
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