1 programmable logic controller based … logic... · vijeo citect scada software package...

International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 – 6480(Print),

ISSN 0976 – 6499(Online) Volume 5, Issue 9, September (2014), pp. 01-09 © IAEME

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PROGRAMMABLE LOGIC CONTROLLER BASED IMPLEMENTATION

OF SUPERVISORY CONTROL FOR SUGAR REFINERY

Jitendra Kumar Gupta1, Dr. Anil Kumar Sharma

2

M. Tech. Scholar1, Deptt. of Electronics Instrumentation & Control Engg.,

Professor & Principal2

, Deptt. of Electronics & Communication Engg.

Institute of Engineering & Technology, Alwar-301030 (Raj.), India

ABSTRACT

Supervisory Control is widely used in industrial control processes and implemented by

Supervisory Control & Data Acquisition (SCADA) system. SCADA system is developed for this

process with three layers - supervision layer, process control layer and field instrument layer. Vijeo

Citect SCADA software package (Schneider Electric) is used in supervisory layer, Programmable

logic controller (PLC) from Schneider Electric (BMX P34 2020) and Unity Pro XL (PLC

programming software) are used to build up process control layer, and field instruments (Solenoid

valves, pumps etc.) are used to build up field instrument layer. The aim of this paper is to implement

the hardware components for controlling the sugar refinery and to interface between master station

and control unit for controlling the data. PLC is the main hardware component of this system and it

is the programmable controller used to control the sugar refinery according to the downloaded

program in it.

Keywords: SCADA, PLC, MCS, MBF, VFD.

1. INTRODUCTION

Plant white sugar is produced by the double sulphitation process, so it contains lots of

sulphur, which is very harmful to human body as well as industrial components. The sulphur free

sugar (refined sugar) can be produced by sugar refinery, which doesn’t have the double sulphitation

process. Sugar refinery contains four systems – melting station (MS), melt clarification system

(MCS), multibed filter (MBF) and ion exchange (IEX). Raw sugar is transformed into the raw melt

in MS system. This raw melt is clarified, filtered, decolorized in MCS, MBF and IEX system

respectively. To maintain the quality of refined sugar, refinery should be automatically control. It can

be achieved by supervisory control, which is having software architecture interfaced with hardware

INTERNATIONAL JOURNAL OF ADVANCED RESEARCH IN ENGINEERING

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ISSN 0976 - 6480 (Print)

ISSN 0976 - 6499 (Online)

Volume 5, Issue 9, September (2014), pp. 01-09

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architecture. This supervisory system integrates the function of PLC and SCADA to control the

sugar refinery.

2. ARCHITECTURE OF SCADA SYSTEM

The system architecture of sugar refinery SCADA system is composed of two sub systems –

software architecture and hardware architecture explained below.

Hardware Architecture: The hardware architecture of sugar refinery SCADA system is shown in

Fig.-1. This architecture composed of three components, given as –

• Field Instruments, PLC / Remote Terminal Unit (RTU) as VFD.

• Communications Link – by any communication protocol as – MODBUS (RS485)

• Central Computer Station including SCADA software as SCADA server

Fig. 1: Hardware Architecture of Sugar Refinery SCADA

The PLC communicates with field devices as - VFD’s by serial line RS485. PLC exchanges

data with SCADA server through Ethernet. The PLC is equipped with input channels for sensing or

metering, output channels for control, indication or alarms and a communications port.

Software Architecture: Sugar refinery SCADA is developed according to the software architecture

shown in Fig. - 2 and having two main components: SCADA server application and SCADA client

application. The SCADA server application is multi-tasking and is based on database located in the

SCADA server. Data transferred from PLC are stored using several tables, which is called database.

The SCADA servers are responsible for data acquisition and data storing in database.

Fig. 2: Software Architecture of Sugar Refinery SCADA



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Data from VFD’s to PLC are transmitted through serial line RS485 using MODBUS RTU

communication protocol. Data transferred are relevant to the variables transmitted with each VFD

and to the VFD physical sequence on MODBUS. The SCADA server reads data from Ethernet port

of PLC using TCP/IP protocol. The SCADA client application uses the database actualized by the

server in order to realize SCADA, which consists of sugar refinery mimics, events lists, alarm lists,

graphical parameters’ trending and reporting etc.

3. COMMUNICATION BETWEEN SCADA AND PLC

Three of the most important part of a SCADA system is Master Station, Remote Terminal

Unit (PLC) and the communication between them. In order to have communication between them,

there must be a communication protocol. Communication protocols define the “set of rules” by

which devices on a network are able to communicate. Communication protocols basically define the

unique device address, structure of data packets, check for transmission errors by the receiving end

etc. The selection of communication protocols for SCADA is mainly depending upon the physical

connector with the communicating devices. Communication protocols can be categories as

proprietary or open protocols –

● Proprietary protocols are those developed by vendors for use with their own systems and

for which application information is not made publicly available e.g. CS31 (ABB Protocol.

● Open protocols are those for which all application information is in the public domain,

permitting any vendor to develop devices and software that can use the protocol e.g. Modbus.

As there are numerous vendors of automation equipment which all use their own protocols to

communicate with, in addition to the large variety of network interfaces, it is difficult to carry out

software which can be used for all variations. To make it easier for software developers to

communicate with this large variety of automation equipment, a standard communication interface

was needed. To address the above two problems as - various networks being incompatible and

unable to communicate with each other, the International Organization for Standardization (ISO)

develops a reference model for all network schemes, which is known as Open Systems

Interconnection (OSI). With this reference model, the software developer can create programs which

are hardware independent.

To be able to create a standard and implement it quickly, the industry decided to use

Microsoft’s Component Object Model (COM) and Distributed COM (DCOM) as the basis for the

communication interface. The communication interface was named OLE for Process Control (OPC).

COM is used to communicate between processes on one computer, whilst DCOM is used to

communicate between processes on different computers. So OPC works as a server/client solution,

where the user creates clients which ask for data from the server. The server can be on the same

computer as the client (COM), or on another computer (DCOM). The server then handles all

communication with the automation equipment. The main benefit of the server/client model is that

one server can support several clients. In this case, OPC is used to the interface the SCADA with

PLC systems and field devices as VFD’s are communicated with PLC by the use of Modbus serial

protocol. The OPC technology is utilized for data exchange between SCADA and PLC. Vijeo citect

works like an OPC client and Modicon BMX M340 2020 PC access software package works as OPC

serves.

International Journal of Advanced Resea

ISSN 0976 – 6499(Online) Volume 5, Issue

4. CONTROL PHILOSOPHY OF

In project design, the control philosophy (function description) provides the outlines for

control methodology of all the system. This methodology establishes a control hierarchy with clearly

defined functionality levels and it simplifies the development. On the basis of control

process & instrumentation diagram and list of instruments required for the automation has to be

developed. The control philosophy is provided for every system of sugar refinery as

Control Philosophy of Sweet Water (SW) Tank leve

maintain between the low set point and high set point of level by the use of the solenoid valve (SV)

provided in the SW inlet line of this tank. The level set points should be provided by the operator

from the SCADA system. In auto mode, SV operates according to the level of the tank and in manual

mode, SV operates according to the manual on / off command provided by the operator from the

SCADA. The auto / manual mode is selected by the selector switch provided on

5. DEVELOPMENT OF LOGIC

Control logic (program) should develop on the basis of the control philosophy of plant. The

control logic has been developed by

software is different for every series of PLC’s e.g. for Schneider Electric PLC’s (Modicon etc), PLC

programming software is Unity Pro XL. In this project, M340 2020 PLC is used along with Unity

pro XL software, which supports five

function block diagram (FBD), sequential function chart (SFC), Instruction list (IL) and structured

text (ST). All of these programming languages can be used together in the same project. In this

project, LD and FBD has used.

Logic of Level Control of Sweet Water (SW) Tank:

(SW) Tank level described in topic 4

control are given below in Fig. - 3 and T

Fig. 3: Level Control Logic of Sweet Water Tank in Unity Pro XL software

International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976

6499(Online) Volume 5, Issue 9, September (2014), pp. 01-09 © IAEME

4

SUGAR REFINERY

control philosophy (function description) provides the outlines for


defined functionality levels and it simplifies the development. On the basis of control


developed. The control philosophy is provided for every system of sugar refinery as

Control Philosophy of Sweet Water (SW) Tank level: The level of sweet water tank should be



DA system. In auto mode, SV operates according to the level of the tank and in manual


SCADA. The auto / manual mode is selected by the selector switch provided on the control panel.

should develop on the basis of the control philosophy of plant. The

ed by the PLC programming software. Generally, PLC programming

y series of PLC’s e.g. for Schneider Electric PLC’s (Modicon etc), PLC


supports five types of programming languages as - ladder diagram (LD


All of these programming languages can be used together in the same project. In this

Sweet Water (SW) Tank: As per the control philosophy of Sweet Water

in topic 4, the program and variable description of sweet water tank level

3 and Table- 1 respectively.

Level Control Logic of Sweet Water Tank in Unity Pro XL software

rch in Engineering and Technology (IJARET), ISSN 0976 – 6480(Print),

control philosophy (function description) provides the outlines for


defined functionality levels and it simplifies the development. On the basis of control philosophy,


developed. The control philosophy is provided for every system of sugar refinery as – MS, MCS etc.

The level of sweet water tank should be



DA system. In auto mode, SV operates according to the level of the tank and in manual


the control panel.

should develop on the basis of the control philosophy of plant. The

the PLC programming software. Generally, PLC programming

y series of PLC’s e.g. for Schneider Electric PLC’s (Modicon etc), PLC


ladder diagram (LD),


All of these programming languages can be used together in the same project. In this

As per the control philosophy of Sweet Water

, the program and variable description of sweet water tank level

Level Control Logic of Sweet Water Tank in Unity Pro XL software



5

The description of function blocks (FB) used in this program is given as -

LT (Less Than) FB: It is used for the less than comparison between two analog inputs. The output

of LT FB (OUT) is high when the input 1 (IN1) is low to the input 2 (IN2).

GT (Greater Than) FB: It is used for the greater than comparison between two analog inputs. The

output of GT FB is high when the input 1 (IN1) is high to the input 2 (IN2).

SR (Set Reset) FB: It works as a SR flips flop. The output of SR FB (Q1) is high, when the input to

set (S1) becomes high & input to Reset (R) is low and output of SR (Set Reset) FB (Q1) is low, when

the input to Reset (R) becomes high & the input to set (S1) is low.

SEL (Selection) FB: It is used for the selection between the two analog inputs. The output of SEL

(selection) FB is IN0, when the selection input (G) is low and output of SEL (selection) FB is IN1,

when the selection input (G) is high.

AND FB: It is used to AND all the inputs. The output of AND FB is high when all the inputs of this

FB are high.

Program Description: When the tank level becomes low to the low set point of the level, then OUT

of LT is high and it set (i.e. 1) the output (Q1) of SR FB. The output of SR FB reset (i.e. 0) only

when the tank level becomes high to the high set point of the level. The output of the SR block

passes through the SEL FB if the auto selected form the SCADA which is the selection bit (G) of

SEL FB. If manual selected, then the solenoid valve (SV) will on /off through the SV on/off

command. The output of the SEL FB passes through the AND FB when the remote selected from the

panel.

Table 1: Variable description of analog input scaling program

Tag Name Data Type Source / Destination Comment

IEX_am_sel EBOOL L/R selector switch

on the Panel

Local/Remote selection

“0” – Local, “1” –

Remote

IEX_SV_SW_MANUAL

BOOL From SCADA Auto/Manual selection

i.e. “0” – Manual, “1” –

Auto

IEX_SV_SW_MAN_CMD BOOL From SCADA SV on/off command

SCALED_SWEET_WATE

R_TANK_LEVEL

REAL From Field Sweet water tank level

MS_SW_LOW_SP REAL From SCADA low set point of level

MS_SW_HIGH_SP REAL From SCADA high set point of level

IEX_SV_OPEN_CMD EBOOL DO to Field Command to SV

6. DEVELOPMENT OF SCADA GRAPHICS

A personnel computer (PC) with Schneider Electric’s Vijeo Citect software is used to

develop the sugar refinery graphic mimics (pages). Vijeo Citect can implement SCADA

functionalities such as – Realize the graphics, alarms, events, tends, reporting of the historical data.

The graphic pages can be developed by the use of various objects as – indicators (symbols), buttons,



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analog display, analog entry, trend display etc. Some sugar refinery SCADA screens developed as

per the control philosophy is given below -

Fig.4: Graphic Page of Melter

Fig.5: Graphic Page of MCS



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Fig.6: Graphic Page of MBF-1

Fig.7: Graphic Page of Ion Exchange

7. RESULT ANALYSIS

This section discusses the result analysis of implementation of supervisory control in sugar

refinery based on PLC. The analysis has been taken during the trial run of the supervisory control of

Sugar refinery and six parameters have been analyzed, which are given in Table 2.



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Table 2: Results of the Refinery

S. No. Parameters Unit Value Result

1. Color reduction across MCS % 35-40 39.9

2. Color reduction across IEX % 70-75 82.5

3. Refined Sugar Color (R1+R2+R3) I.U. <= 30 23.82

4. Throughput of raw melt M3/Hour 25 25.3

5. Capacity Outlet of refined Sugar TPD >= 350 353.03

The refined sugar color, which is very important in sugar production plant and also, in selling

of sugar in market has been, obtained 23.82 ICUMSA (I.U.) during the trial run. ICUMSA is the unit

to measure the sugar quality. This is the main result of sugar refinery. The color reduction of sugar

by refinery is also shown by the picture in Fig. - 7. The dark yellow color sugar is the raw sugar and

the white color sugar is the refined sugar.

Fig. 8: Pictorial view of Color Reduction by Refinery

8. CONCLUSION

This paper has illustrated an implementation of supervisory control of Sugar refinery based

on PLC. A complete SCADA system is developed using PLC programming and SCADA graphics

for supervisory control of Sugar refinery. The resultant supervisory control system of sugar

production using sugar refinery has more benefits over the double sulphitation process of sugar

production. This system provides the following advantages.

• Refined sugar is sulphur free of 23.8 I.U.

• Afferent time reduction in electrical and instrumentation fault detection and maintenance

• Reduction of the specific consumption of electrical energy by the use of VFD and also,

improves motor safety.

• Supervising, control and invention stuff reduction

• It is easy to upgrade and maintain.

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