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Indo-Danish Tool Room, Jamshedpur

13

A PROJECT ON SCADAUsing Win CC v7.0

Under the Supervision of :

Mr. Neeraj Kumar

Submitted By :

Mr. Akash Kumar Karn

Haldia Institute of Technology


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BONAFIDE CERTIFICATE

This is to certify that MR.AKASH KUMAR KARN University Roll No :- 10300510009 ofHALDIA

INSTITUTE OF TECHNOLOGY, HALDIA has successfully completed his project on Supervisory

Control And Data Aquisition under my supervision from 18th

December 2012 to 17th

January

2013. He has completed all the aspects of this project successfully. I wish him all the best in his

near future.

MR.NEERAJ KUMAR

Faculty Member

PLC Department

IDTR,JAMSHEDPUR


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ACKNOWLEDGEMENT

I feel pride to express sincere gratitude and indebtedness to our guide MR.NEERAJ KUMAR,

Faculty member of PLC Department ,IDTR JAMSHEDPUR, for providing me the necessary

facilities and encouragement during the course of my project work.

I am thankful to him for all his suggestions and constant encouragement for making the

realm of dream into a success.

Last but not the least, I would like to thank Prof. D.D.G SIR, Head of department, AEIE Haldia

Institute of Technology, Haldia for providing me this golden opportunity to undergo traning in

such a prestigious institution of INDIA ,INDO DANISH TOOL ROOM JAMSHEDPUR.

Mr.Akash Kumar Karn

Haldia Institute of Technology


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Introduction and Brief History of SCADA

SCADA (Supervisory Control and Data Acquisition) has been around as long as

there have been control systems. The first SCADA systems utilized dataacquisition by means of panels of meters, lights and strip chart recorders.

Supervisory control was exercised by the operator manually operating various

control knobs. These devices were and still are used to do supervisory control anddata acquisition on plants, factories and power generating facilities.

Fundamental Principles of Modern

SCADA SystemsSCADA refers to the combination of telemetry and data acquisition. SCADA

encompasses the collecting of the information, transferring it back to the central

site, carrying out any necessary analysis and control and then displaying that

information on a number of operator screens or displays. The required control

actions are then conveyed back to the process.The PLC or Programmable Logic Controller is still one of the most widely used

control systems in industry. As needs grew to monitor and control more devices in

the plant, the PLCs were distributed and the systems became more intelligent and

smaller in size. PLCs and DCS or (Distributed Control Systems) are used asshown below.

The advantages of the PLC / DCS SCADA system are:

The computer can record and store a very large amount of data. The data can be displayed in any way the user requires.

Thousands of sensors over a wide area can be connected to the system. The operator can incorporate real data simulations into the system.

Many types of data can be collected from the RTUs.

The data can be viewed from anywhere, not just on site.


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The disadvantages are: The system is more complicated than the sensor to panel type.

Different operating skills are required, such as system analysts and

programmer. With thousands of sensors there is still a lot of wire to deal with. The operator can see only as far as the PLC.

SCADA Hardware

A SCADA System consists of a number of Remote Terminal Units (or RTUs)

collecting field data and sending that data back to a master station via a

communications system. The master station displays the acquired data and alsoallows the operator to perform remote control tasks.

On a more complex SCADA system there are essentially five levels or hierarchies: Field level instrumentation and control devices Marshalling terminals and RTUs

Communications system The master station(s)

The commercial data processing department computer system

SCADA Software

SCADA Software can be divided into two types, Proprietary or Open. Companies

develop proprietary software to communicate to their hardware. These systems aresold as turn key solutions. Open software systems have gained popularity

because of the Interoperability they bring to the system.Citect and WonderWare are just two of the open software packages whereas WinCC is a

proprietary software package available in the market for SCADA systems

SCADA and Local Area Networks

To enable all the nodes on the SCADA network to share information, they must be

connected by some transmission medium. The method of connection is known asthe network topology.

Nodes need to share this transmission medium in such a way as to allow all nodesaccess to the medium without disrupting an established sender.

Ethernet is the most widely used LAN today because it is cheap and easy to use.Connection of the SCADA network to the LAN allows anyone within thecompany, with the right software and permission, to access the system. Since the

data is held in a database the user can be limited to reading the information.


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Modem Use in SCADA Systems

Modem Modem

PC

Figure : PC to RTU Using a Modem

Often in SCADA systems the RTU (Remote Terminal Unit (PLC, DCS or IED)) is

located at a remote location. This distance can vary from tens of meters tothousands of Kilometers. One of the most cost-effective ways of communicating

with the RTU over long distances can be by dialup telephone connection. Withthis system the devices needed are a PC, two dialup modems and the RTU(assuming that the RTU has a built in COM port). The modems are put in the autoanswer

mode and the RTU can dial into the PC or the PC can dial the RTU.

System Implementation

When first planning and designing a SCADA system, consideration should be

given to integrating new SCADA systems into existing communication networks

in order to avoid the substantial cost of setting up new infrastructure and

communications facilities. This may be carried out through existing LANs,

private telephone systems or existing radio systems used for mobile vehiclecommunications.

SCADA Systems Software

The typical components of a SCADA system, with emphasis on the SCADA software are

indicated in the following figure.

Figure: Components of a SCADA System


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SIMATIC HMI WINCC V7.0

WinCC is a powerful HMI system for use under Microsoft Windows XP, Windows Vista and

Microsoft Windows Server 2003. HMI stands for "Human Machine Interface", i.e. the interface

between the person and the machine. WinCC allows the operation and observance of the

processes that run in a machine. The communication between WinCC and the machine takes

place via an automation system

Steps of WinCC

Create a project

Configuring communication

Configuring the Process Screens

Archiving and displaying values

Outputting values from the process archive

Configuring messages

Outputting a message report


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Components of WinCC

Its basic components are the Configuration Software (CS) and Runtime Software (RT).

WinCC Explorer forms the core of the Configuration software. The entire project structure is

displayed in WinCC Explorer. The project is also administered here.

The most important partial systems of WinCC are:


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Tags of SCADA :

1) Internal SCADA Tag:

It corresponds to the internal process simulation with the help of which we can visualize a

process or a real world application.

2)External SCADATag:

External SCADA refers to the control and maintenance of a process or a machine which is

distant from the controllers location.

Configuring the Process Screens

Its provides information about the graphic system and a description of how to configure process

screens in WinCC Explorer.

The process screens are main elements of a project. They represent a process and allow the

operation and observation of this process.

The Graphics SystemThe graphic system is a partial system of WinCC. This partial system is used to configure

process screens.

It displays static and operator-controllable objects, such as texts, graphics or buttons.

It updates dynamic objects, e.g. modifies the length of a bar graph in relation to a process value.

It reacts to operator input, e.g. the clicking of a button, or the entry of a text in an input field.

The Components of the Graphics System

The Graphics System is made up of a configuration and a Runtime component:

The "Graphics Designer" editor is the configuration component of the Graphics System. In this

editor, you will create the process screens for your project.

Graphics Runtime is the runtime component of the Graphics System. Graphics Runtime displays

the screens in Runtime and administers all inputs and outputs.


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The Graphic System in Win CC using

process flow statement:


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Procedure


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Simulation Project On Internal SCADA:

Step 1> Creating a Tank filling process in Internal SCADA Tag and Starting

Simulation using Simatic Tag Simulator:


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Step 2> Creating a Bulb glowing process in Internal SCADA Tag:

i) When ON is pressed , Green Light glows instantly:

ii) When OFF is pressed , Red Light glows instantly:


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Step 3> When NEXT is pressed , the Tank Project Window appears in

Simulation Mode:

Step 4> When PREVIOUS is pressed , the Bulb Project Window appears

again in Simulation Mode:


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Conclusions & Discussions

SCADA is one of the most commonly used automation tool used nowadays for a

process/machine control by a controller who is working distant to the plant running under

PLC/DCS.

Generally an MPI protocol is used to establish communication between the PLC and the

SCADA operated PC to control a process.

In internal SCADA , we just used to simulate the output of a process in virtual mode.The

simulating program can show a tank filling up or draining solely under the desired

condition.The pipes or pumps in a simulation program merely exists for Graphics.

However in a real process under SCADA control , using external tagging , switch address

of the relay or contactor used in the PLC under the process is controlled using tag

assignment and ofcourse a simulation window can be obtained with respect to that.

New Technologies in SCADA Systems:A few of the new developments that are occurring in SCADA technology will be

briefly listed below. The rapid advances in communications technology are an

important driving force in the new SCADA system.

Rapid Improvement in LAN Technology for Master Stations

Man Machine Interface

Remote Terminal Units

Communications


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Bibliography:

INDO DANISH TOOLS ROOM MANUAL

INSTRUMENTATION ENGINEERS HANDBOOKA HANDBOOK ON INSTRUMENTATION BY PACONTROL

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