Evolution of computer

application in the industry

By
V.S.Krushnasamy
Evolution of computer application in
the industry
Data logging
SCADA
DDC
PLC
DCS

Data logging
Data logger
Data logging
With the development of high speed digital
computers with mass storage,it became possible
to record such data continuously and
automatically,display the data on command,and
perform calculations on the data to reduce it to a
form suitable for evalution by appropriate
technical individuals.
The efficient operation of a manufacturing
process may involve the interplay of many factors
such as production rates,materials
cost,efficiences of control.
Data logging
When the process requires implementation of
many process-control loops,then the
interaction of one stage of the system with
another often can be analyzed interms of the
controlled variables of the loops.
Data logging divided in to two types
Fixed data loggers
Portable data loggers
Data logging
Fixed data loggers
The process is under the control of many analog
process control loops and there is provision for
analog process variable measurements to be
available as a commonly scaled voltage.
Thus some signal conditioning coverts all
measurements in to a given range,often a
specified voltage range as required by data
acquisition system.

Data logging
Computer
This is the central element of the system.
Through programming, the computer accepts
input data or state and perform the process or
evaluates the program through arithmetic and
logic operations.
It act as a discrete-state control or
programmable controller.

Data logging
DAS/DAQ
Data acquisition is the process of sampling signals that
measure real world physical conditions and converting
the resulting samples into digital numeric values that
can be manipulated by a computer. Data acquisition
systems (abbreviated with the acronym DAS or DAQ)
typically convert analog waveforms into digital values
for processing. The components of data acquisition
systems include:
Sensors that convert physical parameters to electrical
signals.
Signal conditioning circuitry to convert sensor signals
into a form that can be converted to digital values.
Analog-to-digital converters, which convert
conditioned sensor signals to digital values.

Data logging
Peripheral units
The PU are the support equipment to communicate
computer operations to outside world.
This unit consists of operator console where the
programs are entered and through which commands
can be given to initiate specfic actions, such as
calculations and data outputs by computer.
The console usually has a CRT/key board and a
typewriter unit for input and outputs mass storage
system such as magnetic tape,is used to store data
such as periodically sampled inputs from the process.
Data logging
Alarms
An important part of any data logging is an
alarm system.such an alarm system is usually
a computers or for help in a situation beyond
its direct control.
Types of alarms
Simple alarm
Multivariable alarms

Data logging
Simple alarm
One of the simplest digital application to process
control is the implementation of simple alarm
circuits.
These are very elementary binary processes
because we are only concerned about whether a
variable is above or below an alarm level.
Simple alarm constructed from a comparator
,where a voltage level indicates the alarm
condition.

Data logging
Multivariable alarms
If each of a variable expressed through two
states[logic1 and logic 0], then digital approaches
are ideally suited for a multivariable alarm.
The general procedure is to express the variables
as boolean parameters and to find the boolean
equation between the variables that gives an
alarm(0/1)
This equation then is implemented using logic
circuit elements.


Data logging
Portable data loggers
There are many cases when data needs to be logged
for a period of time from a loop and no fixed logger is
provided.
A portable logger can be temporarily connected to the
measurement output of the loop for this purpose.
The basic elements are DAS,computer/opertaor
console, alarm.
Some portable data loggers do not use a
computer.They are merely strip chart/magnetic tape
recorders.
Data logging
The computer based portable data loggers have some
mechanism for saving the logged for later analysis.
Recording mediums are
Printed output
Digitized strip-chart recording
Magnetic tape
Magnetic floppy disks
Networked data communications
In NDA the data logger may be connected to a LAN.
The data then can be transmitted over the network to
another, fixed computer installation.
The data can be stored on mass storage facilities that are
part of the network.


SCADA

SCADA

SCADA
SCADA: Supervisory Control And Data
Acquisition System
A Supervisory System
Encompasses all control ,indicating and
associated telemetry equipments at the
master station and all of the complimentary
devices in the remote stations

SCADA
SCADA stands for Supervisory Control And Data
Acquisition.
SCADA refers to a system that collects data
from various sensors at a factory, plant or in
other remote locations and then sends this
data to a central computer which then
manages and controls the data.

WHAT IS DATA ACQUISITION
Data acquisition is the process of retrieving
control information from the equipment
which is out of order or may lead to some
problem or when decisions are need to be
taken according to the situation in the
equipment. So this acquisition is done by
continuous monitoring of the equipment to
which it is employed. The data accessed are
then forwarded onto a telemetry system ready
for transfer to the different sites.
SCADA
SCADA
PURPOSE
To Provide the user with the capability to
exercise control over a specific device and
confirm its performance in accordance with
the directed action.
To process those data for use by operator
Operator control of remote devices

SCADA
FUNCTIONS OF SCADA
DATA ACQUISITION
INFORMATION DISPLAY
SUPERVISORY CONTROL
ALARM PROCESSING
INFORMATION STORAGE AND REPORTS
DATA CALCULATIONS

SCADA
DATA ACQUISITION
Periodic acquisition of data from RTUs
Data acquired on a polled basis
Two options available on how a RTU responds:
1. Send the actual value of points
2. Send only those points where change has
occurred
The latter option preferred and referred to as
Reporting By Exception
Its a collective process of several specialized
and highly related sub processes

SCADA
INFORMATION DISPLAY
This process consists of:
1. Retrieving both fixed and real time data from database
2. Combining them
3. Presenting them to the operator in the form of limited
graphics CRT color pages
This section is organized in a hierarchical tree structure
Display selection by dedicated function keys provides
very rapid access to frequently used displays

SCADA
SUPERVISORY CONTROL
Process of actuating equipment operation at
remote locations
This process includes:
1. Selection of station
2. Selection of the device to be controlled
3. Execution of desired commands such as TRIP or
close
Check-before-operate method is employed
for security of personnel and electric system

SCADA
ALARM PROCESSING
This process includes:
1. Alerting the operator to unscheduled events
2. Informing him the time of occurrence, the
station location, the device ID and the
nature of event
The most common output of the alarm are
CRT alarm lists, hardcopy printouts and
audible alarms

SCADA
INFORMATION STORAGE AND REPORTS
Accurate records are necessary to satisfy legal
and governmental requirements for
accounting, for support and forecasting future
system operations and for engineering
planning purposes
Pre-selected data sets are captured at periodic
intervals and saved in rotating file
Periodicity of storage frequently set at certain
time intervals called file time span

SCADA
DATA CALCULATIONS
Data calculations done with single variables are:
1. Determination of averages
2. Maximum or minimum values over given intervals
3. Integration with respect to time
Calculations done with multiple variables include
sums, differences, products, exponents, squares,
square roots, exponentiation and others
A practical application of such calculation is load
monitoring of large transformer banks

SCADA
FUNDAMENTALS OF OPERATION
POLLING SCHEMES
DATA INPUTS
CONTROL OUTPUTS
DATABASE
MAN MACHINE INTERFACE

SCADA POLLING SCHEMES

SCADA
In communications engineering this method is known
as time division multiple access (TDMA)
Master station controls and the RTUs respond to only
polling requests.
Following points are discussed through the diagram
given:
1. Multiple 2 or 4 wire telephone grade circuits
2. Polling command requests, and RTU responses are
time multiplexed
3. Automatic generation control (AGC)

SCADA
DATABASE
The newer database updates the real time part of the
user programs which retrieves data from the
database and save computed results back into the
database
They are not fixed in size but can easily be expanded
provided the physical memory is available
Information contained in SCADA database may be
categorized into:
1. Real time
2. Parametric
3. Calculated
4. Application

SCADA
MAN MACHINE INTERFACE
One of the greatest challenges in SCADA is to
provide efficient and user-friendly man machine
interface
It consists of the hardware as well as the program
function which makes it all work
Example of such a man machine interface : now
in SCADA systems the simple audible alarm has
been supplanted with a voice synthesizer which
actually verbalizes alarm messages

SCADA
APPLICATIONS
Industrial control
Oil & gas transmission, production and
distribution
Waste water utilities
Electric utility for remote control of
substations
Power distribution automation

SCADA
SCADA ADVANTAGES
CHEAPER
CONTINOUS
OPERATION
RELIABLE
IMPROVES MAINTAINANCE,
OPERATION,
CUSTOMER SERVICE
FEW OPERATORS CONTROL LARGE NO. OF
INDIVIDUAL ASSETS
PROVIDE RAPID RESPONSE TO EMERGENCIES
SCADA DISADVANTAGES
TROUBLED
ALARMS
LACK OF TRAINED
PERSONS

INITIAL CAPITAL INVESTMENT
SCADA MANUFACTURER AND NAME
OF THE SOFTWARE
WONDERWARE Intouch
ALLEN BRADLEY R.S View
SIEMENS Wincc
MODICON oriecon
G E FANUC implicity
INTELLUSION I Fix
KPIT Ashtra

BENEFITS OF SCADA
Long distance monitoring
Long distance training
Protection against terrorism/vandalism-alarm
Data management (engineering and
operations)
Automated operations with real time control

CONCLUSION
SCADA is a control system with
More interfaces and efficient storage
More record or device oriented configuration
But system wide configuration tools are
needed
Are less expensive than DCS, but offer
different functionality than DCS
And finally various applications
DIRECT DIGITAL CONTROL (DDC)
DIRECT DIGITAL CONTROL (DDC)
DIRECT DIGITAL CONTROL (DDC)
DIRECT DIGITAL CONTROL (DDC)
BASIC DDC CONFIGURATION
OVERVIEW OF A DUAL COMPUTER
SYSTEM FOR DDC
DDC BACK-UP CONCEPT
DIRECT DIGITAL CONTROL (DDC)
In early systems a single mainframe computer
accomplished DAS,control.reporting to the operator,
and higher level computation.
In one of the first systems, the computer directly
controlled the process,without intervening controllers.
This architecture became known as DDC.
Only one computer was used in the first system
because of the high cost per processor and because of
the general absence of computer to computer
communications.
Later systems used an auxiliary computer.

DIRECT DIGITAL CONTROL (DDC)
The DDC technique essentially consists in replacing
number of analog controllers by single digital computer.A
single loop is replaced by a digital computer.
The process values measured by the sensors,are cyclically
sampled,and after the necessary ADC conversion
transferred to the control algorithm.
The output value a(k) is then calculated ,based on the
input deviation e(k) ,where e(k) is the difference between
set point value and the measured process value

DIRECT DIGITAL CONTROL (DDC)
Where T is the sampling period,K
p
,I
i
,T
D
the
relevent controller parameters.This is the first
digital algorithm ,practically applied in the
process control.
In the twin computer concept back-up
computer monitors the proper functioning of
the main computer and,in case of any
failure,takes over its functions

DIRECT DIGITAL CONTROL (DDC)
Computer mode also called DDC mode,in which the
computer performs control functions of the loop.
Automatic mode(A),or controller mode ,in which the
analog back-up controller controls the plant.
Manual mode (M),or open loop control mode,in which the
field operator directly acts on actuators.
In C ,the value of process variable,measured by the sensor,
is simultaneously transferred to the computer and the back
up computer.
For the given set point value,the DDC computes the
relevent output for actuator,which is latched for back-up
purpose(incase of computer or power fails).
For the same purpose, the computer also repeatedly
outputs the stotred set-point value to be latched.
DIRECT DIGITAL CONTROL (DDC)
In this way, the back-up controller,having both
the measured process value and the given
setpoint value can continuously compute the
corresponding actual value.
If computer fails
Sensor outpt to analog back up controller-set
point value from keypoard compare and
operates the actuator.
Manual s1- operates.
DIRECT DIGITAL CONTROL (DDC)
The DDC came into picture for thermal power plant
operation sidelining analog control system due to
following advantages.
Easy configuration,re-configuration and
parameterization of control loops.
Simple introduction of new control loops
Possibility of realization of advanced control algorithms
Model based optimization of optimal set point values
Comprehensive data acquisition and presentation
Easy self-tuning of controller parameters.

DIRECT DIGITAL CONTROL (DDC)
Disadvantage of DDC
Low fail safety of the system:the failure of the
computer caused the failure of all digital control
loops.
Higher investment,maintenance,and personnel
costs,including the programming costs.
Overloads of CPU and difficulties in programming
when process computer had to handle some
process automation functions in addition to DDC

DIRECT DIGITAL CONTROL (DDC)
Disadvantage of DDC
Though DDC take care of many things required for power
plant control,relization of logic and sequential control
functions were missing.
In case of boilers operations like startup and shutdown
traditionally done by relays which are separate from
control systems.
These systems executed both logic and sequential
control.hence overall system became expensive and the
reliability suffered.
To overcome these problems,PLC are introduced. They took
care in addition to logic and sequence control functions,the
function of timers,counters,registers,etc,besides diagnostic
features

PROGRAMMABLE LOGIC
CONTROLLER(PLC)
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Introduction
PLCs are specialized industrial devices for interfacing to and
controlling analog and digital devices.
They are designed with a small instruction set suitable for
industrial control applications.
They are usually programmed with ladder logic,which is
graphical method of laying out the connectivity and logic
between system inputs and outputs.
They are designed with industrial control and industrial
environments specifically in mind.
Therefore ,in addition to being flexible and easy to
program,they are robust and relatively immune to external
interference.
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
A programmable logic controller is a digital electronic
device that uses a programmable memory to store
instructions and to implement functions such as logic
sequencing, counting and arithmetic in order to control
machines and processes.
It has been specifically designed to make programming
easy.
Uses of PLCs
PLCs are widely used and extend from small contained
units with perhaps 20 digital inputs/outputs to modular
systems which can be used for large number of
inputs/outputs handle digital or analog
inputs/outputs,and also carry out PID control modes.
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Selection of a PLC
Types of inputs/outputs required such as
Isolation
Out-board power supply for inputs/outputs
Signal conditioning
Input/output capacity required
Size of the memory required. This is linked to the number
of inputs/outputs and the complexity of program used.
Speed and power required for CPU-This is linked to the
number of types of instructions that can be handled by a
PLC

PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Special features
The interfacing for inputs and outputs is inside
the controller
Easy programmable. They have an easily
understood programming language.
Programming is mainly concerned with logic
and switching operation.
Rugged and designed to withstand
vibrations,temperatures,humidity and noise.
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
PLC consists of the following main components
CPU[Central Processing Unit]
Memory
Input / Output circuitry

PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Main units of PLC
Power supply
Input/output (I/O) system
Real-time central processing unit
Memory unit
Programmer units
Peripheral devices
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
CPU[Central Processing Unit]
It controls and processes all the operations with
in the PLC.
It is provided with a clock with a frequency of
typically between 1 and 8 MHz.This frequency
determines the operating speed of PLC and
provides the timing and synchronisation for all
elements of the system.
A bus system carries information and data to and
from the CPU,memory and input/output units.
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
The various memory elements available in a PLC are
A system ROM to give permanent storage for operating system
and fixed data.
RAM for users program
Temporary buffer stores for input/output channels
The program in the RAM can be changed by the user.However
to prevent the loss of these programs when the supply is
switched off a battery is likely to be used in the PLC to maintain
the RAM contents for a period of time.
Specifications for small PLCs often specify the program memory
size in terms of the number of program step(A program step is
an instruction for some event to occur)that can be stored.
Typically the number of steps that can be handled by a small
PLC is the order of 300 to 1000,which is generally more than
adequate for most control situations.
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Input/output(I/O) circuitry
The I/O unit provides the interface between the system and
the outside world.
Programs are entered in to the I/O unit from a panel which
can vary from small keyboards with LCDs to those using
visual display unit with keyboard and screen display.
The programs,alternatively,can be enter in to the system by
means of a link to a personal computer which is loaded
with an appropriate software package.
The I/O channel provides signal conditioning and isolation
functions so that sensors and actuators can be generally
directly connected to them without the need for other
circuitry.

PROGRAMMABLE LOGIC
CONTROLLER(PLC)
The basic form of programming commonly
used with the PLCs is ladder programming.
This involves each program task being
specified as through a rung of a ladder.
Following methods can be used for I/O
processing
Continuous updating
Mass I/O copying

PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Timers
The timers are commonly regarded as relays with coils
which,when energized,result in the closing or opening
of input contacts after some preset time.
A timing circuit is specified by starting the interval to
be timed and the conditions or events that are to start
and /or stop the timer.
PLCs are generally provided with only delay-on timers
that is a timer which comes on after time delay.
Internal relays
These relays are often used when there are programs
with multiple input conditions.
The internal relays are also used for starting of multiple
outputs.

PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Counters
The use of counters is restored to when there is a need to
count a specified number of contact operations.
Counter circuits are supplied as an internal feature of PLCs.
Shift registers
Several internal relays can be grouped together to form a
register which can provide a storage area for a series
sequence of individual bits.
Thus a 4-bit and 8-bit registers would be formed by using
four and eight internal registers respectively.
The term shift register is used because the bits can be
shifted along by one bit when there is a suitable input to
the register.
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Advantages
Flexibility
Implementing changes and correcting errors
Large quantities of contacts
Pilot running
Visual observation
Speed of operation
Ladder programming method
Reliability and maintainability
Security
Fail-safe operation
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Low cost
Easy to install
Ensures increased productivity
Faster operation speed
Provides high reliability and easier maintenance
Can withstand harsh industrial environment/manufacturing
environment
Provides consistency in manufacturing
Can input/output both analog and digital signals
Reduced cost of scrap and rework(since the user/designer can change
the PLC program without changing any hardware or scraping the
present hardware).
Small size
PLC modules can be added, depending upon the input/output
requirements
Easier troubleshooting
PROGRAMMABLE LOGIC
CONTROLLER(PLC)
Disadvantages
Lacks the flexibility for expansion and
reconfiguration.
The operator interface in PLC systems is also
limited.
Implementing advanced control algorithms is
also limited.

DCS
DCS
DCS
DCS