INTRODUCTION TO AUTOMATION

Automation is the use of control systems such as computers to

control industrial machinery and process, reducing the need for
human intervention. In the scope of industrialization, automation
is a step beyond mechanization. Whereas mechanization
provided human operators with machinery to assist them with
physical requirements of work, automation greatly reduces the
need for human sensory and mental requirements as well.
Processes and systems can also be automated.

Automation Impacts:

1. It increases productivity and reduce cost.

2. It gives emphasis on flexibility and convertibility of
manufacturing process. Hence gives manufacturers the ability
to easily switch from manufacturing products.
3. Automation is now often applied primarily to increase quality
in the manufacturing 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.
2. Performing tasks that are beyond human capabilities of size,
weight, endurance etc.
3. Economy improvement: Automation may improve in economy
of enterprises, society or most of humanity.

Disadvantages of Automation:
1. Technology limits: Current technology is unable to automate all
the desired 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.

Applications

 Automated video surveillance:

Automated video surveillance monitors people and vehicles
in real time within a busy environment. Existing automated
surveillance systems are based on the environment they are
primarily designed to observe, i.e., indoor, outdoor or
airborne, the amount of sensors that the automated system
can handle and the mobility of sensor, i.e., stationary camera
vs. mobile camera. The purpose of a surveillance system is to
record properties and trajectories of objects in a given area,
generate warnings or notify designated authority in case of
occurrence of particular events.

 Automated manufacturing:
Automated manufacturing refers to the application of
automation to produce things in the factory way. Most of the
advantages of the automation technology has its influence in
the manufacture processes.
The main advantages of automated manufacturing are
higher consistency and quality, reduced lead times,
simplified production, reduced handling, improved work
flow, and increased worker morale when a good
implementation of the automation is made.
  Home automation:
Home automation designates an emerging practice of
increased automation of household appliances and
features in residential dwellings, particularly through
electronic means that allow for things impracticable, overly
expensive or simply not possible recent past decades.
 Industrial automation:
Industrial automation deals with the optimization of energy-
efficient drive systems by precise measurement and control
technologies. Nowadays energy efficiency in industrial
processes are becoming more and more relevant.
Semiconductor companies like Infineon Technologies are
offering 8-bit microcontroller applications for example
found in motor controls, general purpose pumps, fans, and e-
bikes to reduce energy consumption and thus increase
efficiency.

Limitations to automation:
Current technology is unable to automate all the desired tasks.

As a process becomes increasingly automated, there is less and

less labour to be saved or quality improvement to be gained.
This is an example of both diminishing returns and the logistic
function.

Similar to the above, as more and more processes become

automated, there are fewer remaining non-automated
processes. This is an example of exhaustion of opportunities.
 SCADA
(SUPERVISORY CONTROL AND DATA ACQUISITION)

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 hardware to which it is
interfaced, in general via Programmable Logic Controllers (PLCs),
or other commercial hardware modules.
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.
These systems encompass the transfer of data between a SCADA
central host computer and a number of Remote Terminal Units
(RTUs) and/or Programmable Logic Controllers (PLCs), and the
central host and the operator terminals. A SCADA system gathers
information (such as where a leak on a pipeline has occurred),
transfers the information back to a central site, then alerts the
home station that a 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.
SCADA systems consist of:
1. One or more field data interface devices, usually RTUs, or PLCs,
which interface to field sensing devices and local control
switchboxes and valve actuators
2. A communications system used to transfer data between field
data interface devices and control units and the computers in
the SCADA central host. The system can be radio, telephone,
cable, satellite, etc., or any combination of these.
3. A central host computer server or servers (sometimes called a
SCADA Center, master station, or Master Terminal Unit (MTU)
4. A collection of standard and/or custom software [sometimes
called Human Machine Interface (HMI) software or Man
Machine Interface (MMI) software] systems used to provide
the SCADA central host and operator terminal application,
support the communications system, and monitor and control
remotely located field data interface devices.
Fig : Typical SCADA System
ARCHITECTURE:

Generally SCADA system is a centralized system which monitors

and controls entire area. It is purely software package that is
positioned on top of hardware. A supervisory system gathers data
on the process and sends the commands control to the process.
For example, in the thermal power plant the water flow can be set
to specific value or it can be changed according to the
requirement. The SCADA system allows operators to change the
set point for the flow, and enable alarm conditions incase of loss
of flow and high temperature and the condition is displayed and
recorded. The SCADA system monitors the overall performance of
the loop. The SCADA system is a centralized system to
communicate with both wire and wireless technology to Clint
devices. The SCADA system controls can run completely all kinds
of industrial process.
EX: If too much pressure in building up in a gas pipe line the
SCADA system can automatically open a release valve.

Hardware Architecture:
The generally SCADA system can be classified into two parts:
 Clint layer
 Data server layer
The Clint layer which caters for the man machine interaction. The
data server layer which handles most of the process data
activities. The SCADA station refers to the servers and it is
composed of a single PC. The data servers communicate with
devices in the field through process controllers like PLCs or RTUs.
The PLCs are connected to the data servers either directly or via
networks or buses. The SCADA system utilizes a WAN and LAN
networks, the WAN and LAN consists of internet protocols used
for communication between the master station and devices. The
physical equipments like sensors connected to the PLCs or RTUs.
The RTUs convert the sensor signals to digital data and sends
digital data to master unit.

Fig 5.5: Hardware Architecture

Software Architecture:
Most of the servers are used for multitasking and real time
database. The servers are responsible for data gathering and
handling. The SCADA system consists of a software program to
provide trending, diagnostic data, and manage information such
as scheduled maintenance procedure, logistic information,
detailed schematics for a particular sensor or machine and expert
system troubleshooting guides. This means the operator can sea a
schematic representation of the plant being controlled.
EX: alarm checking, calculations, logging and archiving; polling
controllers on a set of parameter, those are typically connected to
the server.

Human machine interface:

The SCADA system uses human machine interface. The
information is displayed and monitored to be processed by the
human. HMI provides the access of multiple control units which
can be PLCs and RTUs. The HMI provides the graphical
presentation of the system. For example, it provides the graphical
picture of the pump connected to the tank. The user can see the
flow of the water and pressure of the water. The important part of
the HMI is an alarm system which is activated according to the
predefined values.
 Fig : Human machine interface

For example: The tank water level alarm is set 60% and 70%
values. If the water level reaches above 60% the alarm gives
normal warning and if the water level reach above 70% the alarm
gives critical warning.

Monitoring/Control:
The SCADA system uses different switches to operate each device
and displays the status at
the control area. Any part of the process can be turned ON/OFF
from the control station using these switches. SCADA system is
implemented to work automatically without human intervention
but at critical situations it is handled by man power.
 DESIGN SCADA WITH INTOUCH WONDERWARE SOFTWARE
AND APPLICATION:
SCADA is main interface between your control system and
Operator. Maximum data and
features available on SCADA give you better control and clarity
about the system. SCADA
needs to read data from various devices like:-
 PLC/Controllers
 RTU
 Energy meters/Load managers/Data loggers
 Field instruments like Flow meters and positioners
Each of above data communicates with SCADA on various
protocols . SCADA reads or
writes the data in format of tags.

INTOUCH WONDERWARE SCADA SOFTWARE:

First we crate the animated object from “Wizard Selection” tool
than specify tag name as require. We can create almost any screen
animation effect imaginable. We can make objects
change colour, size, location, visibility, fill level, and so on.
Animation link selection dialog box are shown in fig
 Fig : Animation Link Selection Dialog Box
TOUCH LINK
A. User Input touch links:
Discrete: Used to control the value of a discrete tagname.
Analog: Used to input the value of an analog (integer or real)
tagname.
String: Used to create an object into which a string message may
be input.
B. Sliders touch links:
Vertical& Horizontal:
we can move the slider position horizontally or vertically.
C. Touch Pushbutton links:
Discrete Value:
Used to make any object or symbol into a pushbutton that
controls the state of a discrete tagname. Pushbutton actions can
be set, reset, toggle, momentary on (direct) and momentary off
(reverse) types.
Action:
Allows any object, symbol or button to have up to three different
action scripts linked to it; On Down, While Down and On Up.
Show Window:
Used to make an object or symbol into a button that opens one or
more windows when it is clicked or touched.
Hide Window:
Used to make an object or symbol into a button that closes one or
more windows when it is clicked or touched.

Fig : push button dialog box

COLOR LINKS:
Discrete:
Used to control the fill, line and text colours attributes of an object
or symbol that is linked to the value of a discrete expression.
Analog:

Type your text

The line, fill, and text colour of an object or symbol can be linked
to the value of an analog tag name (integer or real) or an analog
expression. Five value ranges are defined by specifying four
breakpoints. Five different colours can be selected which will be
displayed as the value range changes.
Discrete Alarm:
The text, line, and fill colour of an object can all be linked to the
alarm state of a tag name, Alarm Group, or Group Variable. This
colour link allows a choice of two colours; one for the normal
state and one for the alarm state of the tag name. This link can be
used for both analog and discrete tag names. If it is used with an
analog tag name, it responds to any alarm condition of the tag
name
Analog Alarm:
The text, line, and fill colour of an object can all be linked to the
alarm state of an analog tag name, Alarm Group, or Group
Variable. Allows a specific colour to be set for the normal state as
well as a separate colour for each alarm condition defined for the
tag name.

Fig : Fill colour dialog box

OBJECT SIZE LINKS:
We use Object Size links to vary the height and/or width of an
object according to the value of an analog (integer or real) tag
name or analog expression. Size links provide the ability to
control the direction in which the object enlarges in height and/or
width by setting the "anchor" for the link. Both height and width
links can be attached to the same object.

Fig : object height dialog box

PERCENT FILL LINKS:

We use Percent Fill Links to provide the ability to vary the fill
level of a filled shape (or a symbol containing filled shapes)
according to the value of an analog tag name or an expression that
computes to an analog value. For example, this link may be used
to show the level of liquids in a vessel. An object or symbol may
have a horizontal fill link, a vertical fill link, or both.
 Fig : vertical fill dialog box
LOCATION LINKS:
We use Location Links to make an object automatically move
horizontally, vertically, or in both directions in response to
changes in the value of an analog tag name or expression

Fig : horizontal location dialog box

MISCELLANEOUS LINKS:
There are four type of miscellaneous links.
Visibility:
Use to control the visibility of an object based on the value of a
discrete tag name or expression.
Blink:
Used to make an object blink based on the value of a discrete tag
name or expression.
Orientation:
Used to make an object rotate based on the value of a tag name or
expression.
Disable:
Used to disable the touch functionality of objects based on the
value of a tag name or expression.
VALUE DISPLAY LINKS:
Value Display Links provide the ability to use a text object to
display the value of a discrete, analog, or string tag name. There
are three types:
Discrete :
Uses the value of a discrete expression to display an On or Off
user defined message in a text object.
Analog:
Displays the value of an analog expression in a text object.
String:
Displays the value of a string expression in a text object.

APPLICATIONS OF SCADA:

SCADA systems can be relatively simple, such as one that

monitors environmental conditions of a small office building, or
incredibly complex, such as a system that monitors all the activity
in a nuclear power plant or the activity of a municipal water
system.
SCADA monitors and controls industrial, infrastructure, or
facility-based processes, as described below:
.

 Infrastructure processes may be public or private, and include

water treatment and distribution, wastewater collection and
treatment, oil and gas pipelines, electrical power transmission
and distribution, wind farms, civil defence siren systems, and
large communication systems.
 Facility processes occur both in public facilities and private
ones, including buildings, airports, ships, and space stations.
They monitor and control HVAC, access, and energy
consumption.
Industries that are catered to are:
 Automotive
 Building Automation
 Cement & Glass
 Chemical
 Electronics
 Food and Beverage
 Machinery & Manufacturing
 Aerospace & Defence
 Metals & Mining
 Oil & Gas
 Pharmaceutical
 Power, Utilities & Generation
 Transportation
 Water & Wastewater

ADVANTAGES:
 The SCADA system provides on board mechanical and
graphical information
 The SCADA system is easily expandable. We can add set of
control units and sensors according to the requirement.
 The SCADA system ability to operate critical situations.
CONCLUSION:

With the speed of changing technology today it is easy to lose

sight or knowledge of the basic theory or operation of
programmable logic. Most people simply 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 ladder 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 specific
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.