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Implementation of an Intelligent System in Process Control

Conference Paper · October 2009

DOI: 10.13140/2.1.2414.4165

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National Conference on Trends in Instrumentation and Control Engineering (TICE 2009)

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Implementation of an Intelligent System in Process Control

Rajeev Kumar Chauhan*a, Kalpana Chauhana, Dr. M.L. Dewalb *a Lecturer, Deptt. Of Electrical & Electronics Engg. K.E.C. Ghaziabad, India

a Research Scholar, Indian Institute of Technology Roorkee, India bAssistant Professor, Electrical Department, Indian Institute of Technology Roorkee, India

*rajeevchr_nitj@yahoo.com; kal_2312@rediffmail.com

ABSTRACT

Supervisory control and data Acquisition (SCADA), or Distributed Control system (DCS) are controlling production plants such as power, Oil & Gas, water and waste management, etc. SCADA systems are also used by Process Industries including cement, paper and pulp, petrochemicals, fertilizers, steel industries, and aluminum plants. Supervisory control and data acquisition system is a system in which messages or commands are sent for the purposes of operation and control of processes. According to the three seasons viz. winter, summer, and autumn/fall the requirement of the process may changes appreciably. So there is a need to develop an intelligent system which can operate the number of units of the multiunit plant in accordance with the requirement of the season. This paper present SCADA system for the three unit plant. The output of the plant varies according to the respective season.

Keywords: SCADA, DCS, Process Control

1. INTRODUCTION

1.1 Background

SCADA is the main feature of any automation system. The ability to remotely monitor and control electric power system facilities found its first application within the power generation and transmission sectors of the electric utility industry. SCADA system is being used in industries for Control and Monitoring of a process. A SCADA system performs four functions:

1. Data acquisition

2. Networked data communication

3. Data presentation

4. Control

Primary components of SCADA system:

1. Sensors (either digital or analog) and control relays that directly interface with the managed system.

2. Remote telemetry units (RTUs). These are small computerized units deployed in the field at specific sites and locations. RTUs serve as local collection points for gathering reports from sensors and delivering commands to control relays.

3. SCADA master units. These are larger computer consoles that serve as the central processor for the SCADA system. Master units provide a human interface to the system and automatically regulate the managed system in response to sensor inputs.

4. The communications network that connects the SCADA master unit to the RTUs in the field.

Supervisory control and data acquisition (SCADA) allows a utility operator to monitor and control processes that are distributed among various remote sites. The goal of this paper is to develop a management that uses existing probabilistic control of production methodology to quantify the Number of panel of the plant to production utility SCADA systems. SCADA system owners bear the ultimate responsibility for protecting what they manage. They have participated in vulnerability assessments, have made improvements and continue to do so. Through vulnerability assessments and responding to research questions, they also provide the information that gives direction for other stakeholders.

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SCADA systems are used to automate complex industrial processes where human control is impractical — systems where there are more control factors, and more fast-moving control factors, than human beings can comfortably manage. SCADA systems control:

• Electric power generation, transmission and distribution: Electric utilities use SCADA systems for monitoring the current flow and line voltages, frequency fluctuations, to monitor the operation of relays and circuit breakers, and to take sections of the power grid online or offline etc.

• Water and sewage: State and municipal water utilities use SCADA to monitor and regulate water flow, reservoir levels, pipe pressure and other factors.

• Buildings, facilities and environments: Facility managers use SCADA to control HVAC, refrigeration units, lighting and entry systems etc.

• Manufacturing: SCADA systems manage parts inventories for just-in-time manufacturing, regulate industrial automation and robots, and monitor process and quality control etc.

• Mass transit: Transit authorities use SCADA to regulate electricity to subways, trams and trolley buses; to automate traffic signals for rail systems; to track and locate trains and buses; and to control railroad crossing gates.

• Traffic signals: SCADA regulates traffic lights, controls traffic flow and detects out-of-order signals.

Here are few of the things you can do with the information and control capabilities you get from a SCADA system:

• Access quantitative measurements of important processes, both immediately and over time

• Detect and correct problems as soon as they begin

• Measure trends over time

• Discover and eliminate bottlenecks and inefficiencies

• Control larger and more complex processes with a smaller, less specialized staff.

1.1 How SCADA works

Data Acquisition

First, the systems you need to monitor are much more complex than just one machine with one output. So a real-life SCADA system needs to monitor hundreds or thousands of sensors. Some sensors measure inputs into the system (for example, water flowing into a reservoir), and some sensors measure outputs

Data Communication

In a simple model of the widget fabricator, the “network” is just the wire leading from the switch to the panel light. In real life, one wants to be able to monitor multiple systems from a central location, and so he needs a communication network to transport all the data collected from the sensors. Early SCADA networks communicated over radio, modem and/or dedicated serial links.

Data Presentation

The only display elements; the light that turns on when the switch is activated does not obviously do on a large scale — one can’t track a light board of a thousand separate lights, and one does not want to pay someone simply to watch a light board, Hence, a real SCADA system that reports to human operators over a specialized computer that is variously called a master station, an HMI (Human-Machine Interface) or an HCI (Human- Computer Interface) is obviously desired.

An advanced SCADA master can add a great deal of intelligence and automation to a systems management procedure making the job much easier.

Control

National Conference on Trends in Instrumentation and Control Engineering (TICE 2009)

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Unfortunately, our miniature SCADA system monitoring the widget fabricator doesn’t include any control elements. So let’s add one. Let’s say the human operator also has a button on his control panel. When he presses the button, it activates a switch on the widget fabricator that brings more widget parts into the fabricator.

1.3 Purpose and goals of this Paper

In this Paper we Design a SCADA System which works according to the requirement hence shows an intelligent system. Here we design a SCADA System for industrial purpose for controlling and monitoring the process plant. In this paper we take a particular example for explaining this system however it can also be used or implemented to other different process plants.

2. BASIC LAYOUT

This SCADA system is implemented with the help of SCADA Software and hardware.The block diagram for SCADA implementation is shown in Fig1.

Fig. 1. Block Diagram for SCADA System applied to bottle filing plant

In case of bottling plant for filling cold Drink or water, the size of filling requirement is dependent on season. This paper presents a schematic which controls the production as per above said requirement. It also gives an additional feature for administrator that he may fix the no. of cycles and after completing those cycles the complete process stops automatically.

3. ALGORITHM AND WORKING

There are three units. These three units are controlled by SCADA according to the requirement. When there is fewer requirement such as in winters people purchase less water and cold drinks. So demand SCADA system sets the plant and only one unit is ON and other two are OFF. In this case 33.3% production takes place. Second case is when there is medium requirement and any two units are ON and third is OFF and a total of 66.7% production takes place. In the last case if requirement is full or high then all the units are ON and 100% production is achieved. The complete process is automatically shifted from one setting to another. There is an additional feature which we have presented is that administrator sets the no. of cycles and after completing those cycles the process will be automatically stopped. Table below shows the outputs according to operation of units.

National Conference on Trends in Instrumentation and Control Engineering (TICE 2009)

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Table 1. Outputs according to season

The ladder diagram shows the programming for this SCADA System

Fig 2. Ladder Diagram (PLC) for SCADA Operation

Season Unit1 Unit2 Unit3 Plant O/P

Winter ON OFF OFF 33.3%

Autumn ON ON OFF 66.7%

Summer ON ON ON 100%

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In the above ladder diagram we have done programming for operating units and its interactions with SCADA system for controlling the unit. Thick lines associated with this diagram show that the units related to these sections are activated i.e. they contribute in production. Here we have also shown blocks for timer and counter operation which handle the number of cycles of the production units.

4. DISSCUSIONS

This paper presents a SCADA system for those processes which depend upon seasonal demand. This paper also gives an automatic method of changing a production from one mode to another. There is no manual shifting required. This paper gives a way to get rid of excess production.

REFERENCES

[1] R. L. Alexander, "Intelligent electronic device (IED) technology SCADA and 3Ø metering," in Rural Electric Power Conference, 2002. 2002 IEEE, 2002, pp. C6-C6_3. [2] ---“Information Technology Progress Impact Task Force Report On Convergence,” President’s National Security Telecommunications Advisory Committee, Washington, DC, May 2000. [3] J. Marcuse, B. Menz, and J. R. Payne, "Servers in SCADA applications," Industry Applications, IEEE Transactions on, vol. 33, pp. 1295-1299, 1997.. [4] T. M. Walski, D. V. Chase, D. A. Savic, W. M. Grayman, S. Beckwith, and E. Koelle, Advanced water distribution modeling and management: Haestad press, 2003.

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