PROJECT REPORT ON
SCADA CONTROLLING AUTOMATIC BOTTLE FILLING PLANT
PREPARED BY:
HARDIK GOHEL (04MC11) KAMIN PATEL (04MC37) KETAN PATEL (04MC39)
DEPARTMENT OF MECHATRONICS ENGINEERING U.V. PATEL COLLEGE OF ENGINEERING,
GANPAT UNIVERSITY, KHERVA - 382711.
CERTIFICATE SCADA CONTROLLING AUTOMATIC BOTTLE FILLING SYSTEM SUBMITTED BY:-
HARDIK GOHEL KAMIN PATEL KETAN PATEL
(04MC11) (04MC37) (04MC39)
Towards partial fulfillment of requirement for the award of Degree of Bachelor in MECHATRONICS ENGINEERING of GANPAT UNIVERSITY. This is the record of candidates own work carried out by them under our supervision & guidance. In our opinion the work submitted has reached a level required for being accepted for exam. The matter embodied in this project has not been submitted to any other university or institute.
GUIDE:
Mr. N. J. Thakkar, Lecturer, Mechatronics Department, U. V. Patel College of Engg. Mehsana.
COUNTERSIGNED:
Prof. S. M. Patel, Head of Department, Mechatronics & Mechanical Engg. U. V. Patel College of Engg. Mehsana.
Our hard work never shines if we do not convey our heart felt gratitude to those people from whom we have got considerable support and encouragement during this project. Many people have helped and provide direction, technical information and advice at all stages of our project and it’s our pleasure to say a vote of thanks to all of them Firstly we are thankful to our college to give us opportunity to represent our ability. We are deeply indebted to Mr. Nehul Thakkar, Prof. J.P.Patel & also Mechatronics staff for this motivation of support and provision of all necessary facilities of our project work. We will always remain grateful to those who has been a consistence source of our encouragement and whose constant care about as provided us a new direction to work.
HARDIK R. GOHEL KAMIN K. PATEL KETAN J. PATEL
(04MC11) (04MC37) (04MC39)
Automation, now a days have become in integral part of the industry, say any production as well as process industry, it is progressively increasing the productivity and the profitability of most large organization by rapidly becoming more efficient and competitive by their methods of production and management. Small industries with small exceptions, is not progressing to the same extended and their profitability is far too low for stability and growth. The efficiency of small industries is however, of vital importance to the economy of the country. They represent 90% of all industries, employ about half of those engaged in large industries and produce nearly half of the manufactured goods. For rapid industrial growth in developing countries like India which is basically a nucleus of small industries, it is of primary importance to put the wheels of efficiency of these small industries properly geared to accelerate productivity, to increase profitability and to achieve this goal at present juncture is Low Cost Automation as High cost Automation is not within the reach of developing countries. SCADA vendors release one major version and one to two additional minor versions
once per year. These systems evolve thus very rapidly so as to take advantage of new market opportunities, to meet new requirements of their customers and to take advantage of new technologies. As was already mentioned, most of the SCADA systems that were evaluated decompose the process in "atomic" parameters to which a Tag-name is associated. This is impractical in the case of very large processes when very large sets of Tags need to be configured. As the industrial applications are increasing in size, new SCADA versions are now being designed to handle devices and even entire systems as full entities (classes) that encapsulate all their specific attributes and functionality. In addition, they will also support multi-team development. As far as new technologies are concerned, the SCADA products are now adopting: Web technology, ActiveX, Java, etc. OPC as a means for communicating internally between the client and server modules. It should thus be possible to connect OPC compliant third party modules to that SCADA product. • •
If a laborer has to do a series of work for the completion of a certain job and it has to do the same job repeatedly for the whole day, his involvement into the job linearly decreases with time. The repeatability of the same type of work causes fatigue, stress, strain and negligence and eventually decreases the quality and quantity of production. So automating a part of his job, which involves tiring work, definitely increases quality of work as well as result in saving of time. In such circumstances, the person can even have the opportunity to attend other work. Implementation of automation plays a very important role in the output efficiency. In modern
times when there is paucity of time with one and all, the importance of Automation with easy Controlling system needs no explanation.
SR. NO.
TOPIC
PAGE NO.
1
PRINCIPLE OF PROJECT
01
2
ABOUT THE PROJECT
02
3
INTRODUCTION
03
4
CONCEPTUAL OVERVIEW
04
5
COMPONENTS o INPUT COMPONENTS o OUTPUT COMPONENTS
06
6
PLC PROGRAMMING o ELECTRICAL DIAGRAM o FLOW CHART o PHYSICAL LADDER DIAGRAM
07 08 10
INTERFACE TO SERVER o CONFIGURING I/O SERVER o CONFIGURING COMMUNICATION PORT o CONFIGURING TOPIC DEFINITION
11 12 13
8
DESIGNING
15
9
PROGRAMMING o TAGS o PROCEDURE DESCRIPTION
18 20
7
10
BIBLIOGRAPHY
24
SR. NO.
FIGURES
PAGE NO.
1
CONCEPTUAL OVERVIEW OF SCADA
04
2
ELECTRICAL DIAGRAM
07
3
FLOW CHART
08
4
PHYSICAL LADDER DIAGRAM
10
5
DESING OF INITIAL POSITION
16
6
HALF FILLED BOTTLE
22
7
FULLY FILLED BOTTLE
23
The main motive of project is to automatic filling of the liquid bottle from the tank with the help by controlling through the SCADA software. The main concentration of the whole system is on the SCADA.
SCADA It can control the overall action of the system in the field plant. It examines the status of the input and in responses control the overall process through the output. Combination of the input and output data are referred to as logic. Several logic combinations are usually required to carry out program. This program is stored in the memory and is periodically changed as per the requirements of the party by an order given to an operator, usually run the programs in predetermined order for SCADA. Hence, an industrial SCADA system will be used for the development of the controls of the four experimental terms. This describes the SCADA systems in terms of their architecture, their interface to the process hardware, the functionality and the application development facilities they provide. Some attention is also paid to the industrial standards to which they abide their planned evolution as well as the potential benefits of their use. Thus we get a perfect idea through its name itself as Supervisory
C ontrol And
Data Acquisition.
SCADA systems have made substantial progress over the recent years in terms of functionality, scalability, performance and openness such that they are an alternative to in house development even for very demanding and complex control systems.
The technology has been developing even since the Stone Age. The ancient man applied their minds towards the techniques to have comfort and betterment in their life. The same phenomenon is continuing even till today. Always there is tendency and thirsty with human beings to develop a better technique in any working process to attain or to provide less fatigue and mental stress and more comfort to the operators. There will be always a desire to-do things in a better way and speedy. The project “SCADA CONTROLLING AUTOMATIC BOTTLE FILLING PLANT” is also based on the above-mentioned as facts. The industries, which are having manual process of filling, can be automated using Automation & Controlling techniques. Application of Automation components as per requirement resulted the project of automatically filling and transporting. In this plant there are following major operations are performed. The first one is designing the whole plant as it is in the field and secondly filling of the bottle to the required level and then transporting it with help of conveyor. For this a programming is done in SCADA system accurately via I/O drivers of the specific types like ABKF2, SIEMENS2, etc... The Automation components used in the plants are conveyor system, sensors, and solenoid operated direction control valves and drain valves. After the end of a process, the filled bottle is collected and the bottle is now ready to be transported further for sealing and packing purpose. The manual error in filling operation, due to repeated similar operation, can be eliminated. The fatigue and mental stress of the operator is removed. The operation cycle is also increased considerably.
Acronym for Supervisory Control And Data Acquisition indicates a computer system for gathering & analyzing real time data. 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. The 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. SCADA systems are used not only in industrial processes: e.g. steel making, power generation (conventional and nuclear) and distribution, chemistry, but also in some experimental facilities such as nuclear fusion. The size of such plants range from a few 1000 to several 10 thousands input/output (I/O) channels. 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. The server I/O communication drives those are used for an application program that acts as a communication protocol server. It allows the application programs access to data in PLCs.
To get an overview of the SCADA system that how it can be processed by an operator as per the required application of the party or industrial plant; the conceptual overview of SCADA gives the basic idea of whole process expressed in Fig. 1.
Figure 1: Conceptual Overview of SCADA Hence for detailed process; it is discussed later on in the report. Here only the basic idea gets from Fig. 1 as predetermined above. SCADA systems used to run on DOS, VMS and UNIX; in recent years all SCADA vendors have moved to NT and some also to Linux based OS. AS shown in figure 1 the server communicates with Allen-Bradley either directly or indirectly using the Data Highway, Data Highway Plus, or DH485 with the appropriate AllenBradley communications interface. Therefore the communication interface is anyone from PLC2, PLC-3, PLC-5, and SLC-500 PLCs or the SIEMENS & ABB.
So to build up the whole design plant in the industry, several points should be taken into consideration are as follows: o o o o o o o o
Defining Components (I/O) PLC Programming Flow Chart PLC Ladder Diagram Interface to Server Initial Design of Layout Continue Process to the end At last achieve the required result….
The components which are on the field designed or planted, that type of designing layout must be done in SCADA. The input and output components are derived below with different symbols which are representing the PLC symbols, normally open or close.
Sr. no
Inputs
Symbols
1
Start button
/
2
Stop button
/
3
Proximity sensor (bottle sense)
/
4
Proximity sensor (Liquid level sense)
/
Sr. no
Outputs
1
Solenoid valve 1 (Vin)
2
Solenoid valve 2 (Vout)
3
Conveyor motor
Symbols
The overall programming of model is done in Urologic PLC software for Allen Broadly. We can use the electrical diagram for basic plant layout and with the help of this electrical diagram as shown in Fig. 2 below.
Figure START 2: Electrical Diagram
FILL TANK
IS TANK
Figure 3: Flow Chart
The logic for simplifying the electrical diagram, the flow chart is used to show in which way the process is going and is likely to be the Fig. 3 as shown above. Once the electrical diagram and flow chart is completed then the remaining thing in PLC is the ladder diagram which is used for representing the symbolic programming of the process and will be further shown. Therefore the overall programming of model is done in Urologic PLC software for Allen Broadly. We can use the ladder diagram as programming language. During programming we can generate the symbolic ladder diagram and then giving address to the electrical diagram. This ladder diagram is shown in Fig. 4.
Figure 4: Physical Ladder Diagram
In this section the serial I/O server of the Allen – Bradley is interfaced with an appropriate drives to communicate different protocols. So, the server that will be accessing the data element. In this case, the data is out coming or going to ABPLC equipment via the server. The application portion of the server is known to be namely as ABKF2 for the specific ABPLC. Hence using this server an item can be trend, counter, level checked, register, etc…, in the SCADA.
Configuring I/O Server Once the server has been installed, a small amount of configuration is required. Configuring the server automatically creates a configuration file named, ABKF2.CGF. This will store the information for the communication ports.
To perform the required configurations, start up the server by double clicking on its icon and then to open the server’s window.
To access the option used for the various configurations, open the Configure menu as shown below.
Configuring Communication Port Use the Communication port settings option from the configure menu to configure communication ports that will be used to communication with AB device. When this option is selected the dialog box will appear as below:
So with the help of this and defining all necessary data as an appropriate baud rate or serial bit rate which is in bit per second and for SLC-500 it is 9600bps to communicating with port1. The default, Full Duplex is preferred setting. Then select the number of data bits that will match the configuration of AB device.
Configuring Topic Definition Use the topic definition option from the configure menu to create new, modify or delete topic definitions. Each topic definition must contain unique name for the PLC associated with it.
Enter a unique name up to 32 characters long with the first character being alphabetic. After giving the topic definition name, then new dialog box will appear for ABKF2 topic definition as below:
Select the connect type appropriate for the PLC network configuration.
After that the supporting Network addressing option will be activated for the selection and dialog box will appear as below:
The network addressing is a dynamic field. The applicable option appears according to the PLC family type and Connect type selected. In the example, network addressing is defined as follows:
The Host computer is directly connected to a 1770KF2 by a RS232 cable.
This network addressing shown
here is for the SLC-500 with a direct connects type. In this networking address is simple. The Host computer is directly connected to the SLC-500 by a RS232 cable.
The objects or a layout can be designed by using the tool box available in SCADA system window maker. We can choose the following toolbars as per our requirements. General Toolbar
The general toolbar is populated with toolbar buttons that execute most of the window commands located on the File menu and some of the object editing commands located on the Edit menu. Arrange Toolbar
The Arrange toolbar is populated with toolbar buttons that execute most of the object arranging commands located on the Arrange menu. Draw Object Toolbar
The Draw Object toolbar is populated with all the tools that you will use to draw both simple graphic objects or text objects and, complex objects such as alarm windows, real-time trends, historical trends, bitmap boxes and 3-dimensional buttons with labels in your windows. View Toolbar
The View toolbar is populated with toolbar buttons that execute most of the window commands located on the View menu. These commands are used to control the state of the Window Maker window.
For designing the objects click on the object and drag it on the screen. The links for showing the values memory/IO can be made by creating text "#. ##" and assigning display value properties to it. The level indication can be made by selecting the tanks wizard and assigning the % fill property to it. Similarly the indication of the pumps and other components can be done using the discrete colour property.
The components which are on the field designed or planted, that type of designing must be done via symbol factory mentioned in SCADA software. For this project we have note down the components or parts are as below: • • • • • • •
Push Buttons Conveyor Belt Bottles Tank Bottle Sensor Liquid Level Sensor 2 – Solenoid Valves
The initial design is made similarly as in the Fig. 5. It is defining the initialized position at the field location plant which is operated through PLC &is interfaced with the ABKF2 server in SCADA system.
Figure 5: Design of Initial Position
After designing the initial position of the plant; next step is to make an appropriate interfacing with PLC via ABKF2 server to access the data. This data will be controlled or modified by doing changes directly in the main SCADA system. This is more beneficial point of view for achieving the higher accuracy & better output. So a programming part done in the memory discrete is referred in the next coming section.
Tags: A tag is a logical name for a variable in a device or local memory (ram). Tags that receive data from some external device such as programmable logic controllers or servers are referred to as I/O tags (input/ output). Tags that receive data internally from SCADA system is referred to as memory tags. Tags are stored in tag name directory and their names are then used in other parts of the program. The various tag types are described for the different data elements as specified on PLC, input/output drives related to its communicated ad dresses. Choose the types from below: •
Memory Discrete: Internal discrete tagname with a value of either 0
(False, off) or 1 (True, on). •
Memory Integer: A 32-bit signed integer value between -2,147,483,648
and 2,147,483,647. •
Memory Real: Floating (decimal) point memory tagname. The floating
point value may be between -3.4e38 and 3.4e38. All floating point calculations are performed with 64-bit resolution, but the result is stored in 32-bit. •
Memory Message: Text string tagname that can be up to 131 characters
long. If you do not assign the tag name to a specific Alarm Group, by default, InTouch will assign it to the root group, $System. Once you create a tag name and assign it to an Alarm Group, if you do not close the dialog box, all subsequent tag names that you define will be assigned to the same Alarm Group, unless you change it. For I/O type tag names, select Read Write to grant the tag name read and write capabilities in runtime.
If the tag you defined is I/O type then define access name and the item name for connecting the tag to the hardware. The procedure for access name is as follows:
• • •
•
•
•
•
Click Access Names, the Access Names dialog box appears. Click Add. The Add Access Name dialog box appears. In the Access Name box type the name you want InTouch to use to this Access Name. (For simplicity, use the same name that you will use for the topic name here.) InTouch uses Access Names to reference real- time I/O data. Each access Name equates to an I/O address, which contains a Node, Application, and Topic. In the Application Name box, type the actual program name for the I/O Server program from which the data value will be acquired. Do not enter the .exe extension portion of the program name. In the Topic Name box, type the topic name you want to access. The Topic Name is an application-specific sub-group of data elements. In the case of data coming from a Wonderware I/O Server program, the topic name is the exact same name configured for the topic in the I/O Server program. Select advice all items if you want the server program to poll for all data whether or not it is in visible windows, alarmed, logg ed, trended or used in a script. Selecting this option will impact performance, therefore its use is not recommended. Select Advise only active items if you want the server program to poll only points in visible windows and points that are alarmed, logged, trended or used in any script. Click OK to accept the new Access Name and close the dialog box. The Access Names dialog box will reappear displaying the new Access Name selected in the list.
At last give the item name i.e. address of the I/O. The item names will differ from server to server.
Procedure Description: First of all design the initial position then its time to do a program as it is as done in the memory discrete; shown below with defining various tags of the components. For the application of bottle filling plant as mentioned earlier that programming is done in the memory discrete; the program is done without confusion by using the window type script. At the primary stage W.S. has On Show & While Showing scripts are presented. Hence for that, all the different components should be specified by unique tag names. So first initialize the On Show by using different tag names as decided individually below: B1 = Push Button B2 = Conveyor Belt B3 = Filling Bottle B4 = Bottle Sensor B5 = Tank B6 = Lower Solenoid Valve B7 = Liquid Level Sensor B9 = Bottle Movement B10 = Upper Solenoid Valve B11 = No. of Bottles B12 = Initial Condition for next Bottle. After that the script While Showing has been made as shown below: IF b1==1 AND b12==0 AND b4==0 THEN b9=b9+5; ENDIF; IF b9==345 THEN b9=345; b4=1; ENDIF; IF b4==1 THEN b6=1; b5=b5 -1; b3=b3+1;
ENDIF;
IF b3==100 AND b1==1 THEN b9=b9+5; b2=b2+5; b6=0; b5=b5; b4=0; ENDIF; IF b9==710 THEN b11=b11+1; b2=0; b9=0; b3=0; ENDIF; IF b11==2 THEN b12=1; b9=0; b11=0; b10=1; ENDIF; IF b10==1 THEN b5=b5+1; ENDIF; IF b5==200 THEN b10=0; b12=0; ENDIF;
Thus the operator can derive the require output predetermined & get good results. The various images of the runtime and development time; it is taken in between the operations as shown in Fig. 6 & Fig. 7.
Figure 6: Half Filled Bottle
Figure 7: Fully Filled Bottle
